Lebowski
🏍️ Giga poster
Code:
config __FBORPOR, PWRT_64 & PBOR_ON & BORV42 & MCLR_EN & RST_PWMPIN & PWMxL_ACT_HI & PWMxH_ACT_HIlooks like brownout is at 4.2 V ....
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Lebowski's motor controller IC, schematic & setup, new v2.A1
- Thread starter Lebowski
- Start date
looks like brownout is at 4.2 V ....
Tomdb
🔋 Established
If that is true, then even bigger reason to doubt it being the 5v rail.
Biggest pointer to that is, at 100v it works fine even at 20 and 30 amps for the FOC test current, it does not generate and overflow error and then runs the motor just fine.
Once I get some aluminium tape I will start on my EMC shielding.
Thank you very much guys for the advice, I will just keep plugging away at it.
Biggest pointer to that is, at 100v it works fine even at 20 and 30 amps for the FOC test current, it does not generate and overflow error and then runs the motor just fine.
Once I get some aluminium tape I will start on my EMC shielding.
Thank you very much guys for the advice, I will just keep plugging away at it.
Volttan
🧲 New user
Tomdb
I found on another forum your document with Honda controller.
I think the lower and upper gate marked vice versa
I found on another forum your document with Honda controller.
I think the lower and upper gate marked vice versa
Tomdb
🔋 Established
Not really, because currently for me If I go up in pwm duty cycle i get an higher voltage on the output, plus I checked it with a scope when went through it. But if you have some nice scope traces to prove it no problem.
Quick way to check, 5 volt on the pin, what does the phase output do.
Quick way to check, 5 volt on the pin, what does the phase output do.
I got mine running again with the 2.91 code.
I still can't honk the horn it makes the controller brownout.
I have added caps the horn and tried the diode in series with the brain then removed the diode and run a isolaed supply and it still does it but I had to add a ground to an arduino that is shared with the brain for desat. I will isolated the arduino next and try that.
2.91 seems best so far. It is super smooth. I have some little things to tweak and report back.
Currently set at 600 phase amps 300 battery (will up to 750) and 100 amps feild weakening (will up to 500 amps)
Its useless in the rain. Spins the tires at 1/2 throttle at 100km/h...... Will report back when its dry. M&H Drag tires are almost here
I still can't honk the horn it makes the controller brownout.
I have added caps the horn and tried the diode in series with the brain then removed the diode and run a isolaed supply and it still does it but I had to add a ground to an arduino that is shared with the brain for desat. I will isolated the arduino next and try that.
2.91 seems best so far. It is super smooth. I have some little things to tweak and report back.
Currently set at 600 phase amps 300 battery (will up to 750) and 100 amps feild weakening (will up to 500 amps)
Its useless in the rain. Spins the tires at 1/2 throttle at 100km/h...... Will report back when its dry. M&H Drag tires are almost here
Lebowski
🏍️ Giga poster
Maybe it is worthwhile you guys try out de 'buffered' approach I use on my own PCB. you may already have this, maybe not.
Basically what it does is from the high voltage it has a DCDC to 15V, and then from 15V it has a second DCDC going to 5V .
This makes that the 5V hardly sees any spikes from the high voltage, as the 15V is kind of an extra buffer in-between.
In my case the 15V is the gate drive supply...
Basically what it does is from the high voltage it has a DCDC to 15V, and then from 15V it has a second DCDC going to 5V .
This makes that the 5V hardly sees any spikes from the high voltage, as the 15V is kind of an extra buffer in-between.
In my case the 15V is the gate drive supply...
Futterama
⚡ Regular
You could also try using two separate LiPo batteries as low voltage supplies, like a 4S with a linear regulator for 15V and 2S with a linear regulator for 5V. This way you can determine if the noise/voltage drop is actually from the main supply or some inductive noise.
When I did my initial tests a long time ago, I used batteries for the 15V and 5V supplies, mostly because I didn't have isolated supplies at the time, but it can come in handy while doing extensive testing too.
When I did my initial tests a long time ago, I used batteries for the 15V and 5V supplies, mostly because I didn't have isolated supplies at the time, but it can come in handy while doing extensive testing too.
Lebowski
🏍️ Giga poster
Tomdb said:
Maybe the controller IC gets some sort of spike via the battery voltage measurement pin ?
Tomdb
🔋 Established
No battery measurement voltage. It is just, throttles current transformers and stages. But looks like I will have plenty of time tomorrow to do more testing.
Lebowski
🏍️ Giga poster
Maybe ask Arlo1 for tips about how he has set up the 5V supply, he's succesfully running over 140kW with a 470V battery...
Futterama
⚡ Regular
The ACPL-C87 is kinda expensive.Arlo1 said:
Lebowski, would it be possible for the controller IC to accept a digital reading from a small PIC on the HV side through a digital isolation barrier to the controller IC?
Futterama
⚡ Regular
$0 as I have hundreds laying around from other projects :wink:Arlo1 said:
marcexec
⚡ Regular
Futterama said:
The amount of lovingly crazy guys on this forum is amazing
Animalector
🚴♂️ Mega poster
If you have hundreds of them, just use one for a/d then transmission through an Opto, and then another one to read and do the d/a conversion back to analogue.
Solvef
Solvef
Tomdb
🔋 Established
It is definitely noise
This is just scope ground and floating probe. So there is quite some noise.
What my setup looks like now. Only difference is that I made an aluminium tape covered enclosure out of cardboard that I am grounding, next to try is a 5v dc/dc on the board.
This is just scope ground and floating probe. So there is quite some noise.
What my setup looks like now. Only difference is that I made an aluminium tape covered enclosure out of cardboard that I am grounding, next to try is a 5v dc/dc on the board.
Lebowski
🏍️ Giga poster
Arlo1 said:
Youth of nowadays using processors for everything :?
The analog way would be to build an opamp based oscillator with the output duty cycle dependent on the to measure voltage. Pass the PWM signal through an optocoupler and low pass filter on the receiving end...Tomdb
🔋 Established
Done more testing, measuring the current sensors during the FOC measurement and looking at the traces there are no wierd anomalies. Also looked at a few of the phase drive signals also look fine, except the small emc ripple.
Going to try a few more setups to minimize the emc noise. Has anyone beside Arlo built a Lebowski powered HV (100+ volts) setup? Arlo has the big benefit of having tiny phase leads and nice grounding case.
Going to try a few more setups to minimize the emc noise. Has anyone beside Arlo built a Lebowski powered HV (100+ volts) setup? Arlo has the big benefit of having tiny phase leads and nice grounding case.
Lebowski
🏍️ Giga poster
I think somehow it has to do with how the measurement ends. The chip does the measurement and then shuts down PWM, all FETs off. Current still flowing in the motor will take the path of the diodes and be dumped in the battery. Resulting spikes etc can affect the 5V and reset the controller IC if the system somehow is not build robust enough.
More current would mean bigger dump in battery, so it would be interesting to try the measurement with lower current.
Also, I could ramp down nicely after the measurement and prevent the big dump. BUT I also see this as a kind of litmus test, basically if the system fails the FOC measurement it doesn't deserve to live, I.e. it is likely it will have problems during normal use...
More current would mean bigger dump in battery, so it would be interesting to try the measurement with lower current.
Also, I could ramp down nicely after the measurement and prevent the big dump. BUT I also see this as a kind of litmus test, basically if the system fails the FOC measurement it doesn't deserve to live, I.e. it is likely it will have problems during normal use...
Tomdb
🔋 Established
Okay just because I am trying to snub out all posisble issues. Noise is now down alot, v2.9 does complete the foc calc however it give the overflow error.
So I swapped out the v2.9 chip with all the extra caps out for a v2.51 the original one. And to my big disbelief it completes FOC calc and gives me a measurement result.
However it still manages to crash alot during measurements.
HEX from the v2.51
So I swapped out the v2.9 chip with all the extra caps out for a v2.51 the original one. And to my big disbelief it completes FOC calc and gives me a measurement result.
However it still manages to crash alot during measurements.
HEX from the v2.51
Code:
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0x0962 *Tomdb
🔋 Established
Varying the FOC measurement erpm: 7.99 k-erpm it is possible to go to frequency that will allow the v2.51 to complete the measurements without a problem.
Will now test this step on the v2.9 chip
V2.51 running for at 8k e-rpm
Will now test this step on the v2.9 chip
V2.51 running for at 8k e-rpm
Code:
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0x0962 *Tomdb
🔋 Established
okay for the v2.9 chip this works too. Now to try it when i change to just the IC with out the caps on the dip legs and some other mods one by one.
Bare IC works too. Finally some progress, now lets take this one more step further and see what happens when it gets put back into the inverter housing.
Inside the inverter It does not work, Not really a problem. Will add a enclosure on the top, the inverter will only be used for testing.
Code of the v2.9 foc working at 160v at 8k e-rpm.
Bare IC v2.9
Bare IC works too.
Finally some progress, now lets take this one more step further and see what happens when it gets put back into the inverter housing.Inside the inverter It does not work, Not really a problem. Will add a enclosure on the top, the inverter will only be used for testing.
Code of the v2.9 foc working at 160v at 8k e-rpm.
Code:
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0x0820 *Bare IC v2.9
Code:
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0x0820 *Similar threads
