New Energy Vehicle Motor Controller (MCU)

火辣西米秀

New Energy Vehicle Motor Controller (MCU) [Copy link]

The motor controller, as one of the core components of electric vehicles, is a decisive factor in the vehicle's power performance. It obtains the vehicle's requirements from the vehicle controller, obtains power from the power battery pack, and modulates its own inverter to obtain the current and voltage required to control the motor, which is then supplied to the motor so that the motor's speed and torque meet the vehicle's requirements.

The motor controller is the nerve center connecting the motor and the battery, and is used to adjust the performance of the vehicle. Sufficiently intelligent electronic control can not only ensure the basic safety and precise control of the vehicle, but also enable the battery and motor to fully exert their strength.

1. Composition

The motor controller is divided into two parts: low voltage and high voltage. The low voltage part includes input/output interface circuit, control main board, arithmetic unit, memory, sensor, etc. The high voltage part includes IGBT module, drive main board, super capacitor, discharge resistor, DC high voltage connector, UVW connector, etc.

There is a water channel inside the motor controller housing, and there are water inlet and outlet pipe joints outside the housing. The outlet pipe below the radiator is connected to the water pump, which sends the coolant into the motor controller to cool the IGBT components, then flows into the motor, and then flows back to the return pipe above the radiator.

Upper components

Lower level components

2. The role of each component

(1) Input/output interface circuit, responsible for the external input signal and the control mainboard conversion connection, responsible for the control mainboard output signal and the external conversion connection

(2) Control the main board, communicate with the VCU, power the resolver sensor, analyze the resolver signal, control the IGBT, monitor the high-voltage DC bus current, monitor the IGBT module temperature, and monitor the high-voltage plug connection status

(3) Drive the main board, receive instructions from the control main board, and control each IGBT to turn on or off

(4) IGBT (Insulated Gate Bipolar Transistor), which converts DC power into three-phase AC power and changes the frequency, controls the motor speed and direction of rotation, recovers energy when the vehicle decelerates, converts three-phase AC power into high-voltage DC power, and charges the power battery

(5) Supercapacitor: The supercapacitor is connected in parallel with the high-voltage DC bus to keep the voltage stable when the motor starts.

3. Principle

The inverter bridge modulates the output sine wave to drive the motor. The all-in-one controller includes a power distribution circuit. It provides power distribution for various parts of the integrated controller, such as TM (power transformer) contactor, fuse, electric air conditioning circuit power supply, electric defrosting circuit power supply, etc.

IGBT drive circuit: receives control signals, drives IGBT and feedbacks status, provides voltage isolation and protection

Auxiliary power supply: Provide power for the control circuit and isolated power for the drive circuit

DSP circuit: receives vehicle control instructions, provides feedback information, detects motor system sensor information, and transmits motor control signals according to instructions

Structure and cooling system: Provide heat dissipation for the motor controller, provide controller installation support, and provide controller safety protection

4. Function

(1) Control the motor forward and reverse. The vehicle moves forward when the motor rotates forward and reverses when the motor rotates reversely.

(2) Control speed and execute acceleration, constant speed, deceleration, etc. according to the driver's instructions

(3) Control the crawling, put the vehicle in D or R gear, lift the brake pedal, do not step on the accelerator pedal, and drive the vehicle slowly

(4) Energy recovery, also known as kinetic energy feedback, in which the motor is transformed into a generator

(5) Communication function, communicating with other control units and gateways via CAN bus

(6) Fault diagnosis: when self-diagnosis is abnormal, the fault code is stored and sent to the VCU

(7) Protection function: protect the motor controller, drive motor, and power battery from exceeding the operating temperature limit

(8) Driving safety: during driving, the anti-shake function can be added according to customer needs to ensure driving comfort.

beyond_笑谈

The same is true for high-power water-cooled drives, but waterproofing must be done well, otherwise if the water cooling box leaks, it will be over.

晒太阳的老男孩

The motor controller, as one of the core components of electric vehicles, is a decisive factor in the vehicle's power performance. It obtains the vehicle's requirements from the vehicle controller, obtains power from the power battery pack, and modulates its own inverter to obtain the current and voltage required to control the motor, which is then supplied to the motor so that the motor's speed and torque meet the vehicle's requirements.

通途科技

Like it, the pictures and text are very good, thanks for sharing, keep it up! ! ! !