We’re an upstart electric vehicle company, hoping to have an initial offering by the end of September. We need a centralized control unit with a 3 phase AC VFD, DC/DC converter, and a buck/boost charger; details below. We want everything integrated to one PCB, no larger than 11x14 inches, smaller if possible, and controlled by a single microprocessor with native USB support (preferred over USB adapter circuitry). The battery pack will be offered between 96 and 360 VDC nominal, so the system must support the full range.
DC/DC converter:
Probably a full bridge topology, but willing to hear other (isolated) ideas (PWM from the MCU)
Must take full pack voltage and reduce/regulate to 13.8VDC +/- 3%
Must supply up to 100A.
Charger:
120/240VAC 50-60Hz input
Buck/Boost to match battery potential (PWM also from the MCU)
Power factor correction (active or passive)
Programmable current limit from 0-50A
Programmable charge profile (CC/CV limits)
Motor Controller:
400A peak IGBT
3 phase AC output (variable frequency up to 400Hz)
Hall Effect and optical encoder support
0-5k potentiometer speed/torque control
Regenerative braking (programmable aggressiveness)
Programmable control profile (max RPM, PID acceleration/deceleration profile, motor parameters, etc.)
By our estimation the only hardware that should require any significant design should be the gate drivers for the IGBT and the regeneration circuit. The charger and the converter should be fairly trivial (for an electrical or electronics engineer) since they are directly controlled by the MCU
It seems you need a lot of thing, we are in motion control for a very long time and we have developed uc controlled BLDC,DC and AC motors, high efficient chargers,converters. We would like to know details specification of each modules. And what axactly you need from us,we provide schematic (simulation) BOM, testing methodology the software and PCB layout, in case you need a hardware prototype the cost of all the hardware plus sending it to your place and also to consstruct the test jig will be required.
Hello,
Looking at your requirements, I feel it would not be of great benefit to provide a hard quote on this. Parts alone for a prototype and a revision or two may eat up the intended $700 budget. While I can certainly understand why you may want to minimize the cost, I would suggest we discuss further an arrangement where an hourly rate is set on the project, plus the cost of supplies, routed through the getafreelancer's escrow service. I have worked extensively with startup groups before, and I am sensitive to potential budget constraints you may have an open to further discussion pertaining to this bid process.
I HAVE STARTED MY PROFFESSION SIXTEEN YEARS BEFORE AS AN AC,DC DRIVES SERVICE ENGINEER. I AM DOING FOR THE LAST SIX YEARS AC, DC DRIVES DESIGN AS PER THE CUSTOMER REQUIREMENT
Dear sir,
I'd like to contribute in your electric car control project. I am an electrical engineer, specializing in industrial automation.
Instead of integrating everything on a single PCB, I would suggest to have a control cabinet consisting of VFD, battery charger and main controller. Handling hundreds of amps on a PCB that houses your main controller is not a good idea.
In my opinion, regenerative breaking is not applicable in this "all-DC" system.
Have you decided about the battery? will these be regular car battery (12v)?
What type of motor are you planing to use here? You mentioned "upto 400-Hz".
Will this vehicle move on railway-type tracks, or on roads?
Looking forward to working with you. Best regards.
Yeasir Rahul