Hybrid Motor Controller Developer Kit?
Hybrid Motor Controller Developer Kit?
(OP)
I'm not sure where to ask this question, here in the hybrid section or in the electrical motor control section. I'll try here first because I think the expertise needed is more from the hybrid side.
I am beginning development of a system which would consist of a battery array, a motor controller (the subject of this post), an electric motor (BLDC , approximately 30 kw), and a single wheel which would be coupled directly to the motor. The system would be mounted to existing vehicles (Truck, car, boat) although its only interaction with the vehicle would be to draw makeup power from the vehicle electrical system (limited to 12v 100A, hopefully much less). A typical operation cycle would have the wheel driven by a constant torque (external to the vehicle) for approximately ten minutes (backdriving the motor and putting electrical energy into the battery array in the device), followed by the motor driving the wheel for a similar length of time against a resistive torque of similar magnitude (energy out of battery array). A key function of the motor controller would be to maintain a constant motor torque throughout the cycle despite the change in direction of power, and despite the resulting speed and direction changes (including brief periods while stationary). The motor and controller will need to have cutting edge levels of efficiency so that the net energy expenditure for a cycle is small enough to be replenished by the vehicle electrical system. The motor will be of the "LRK Torquemax" aka "brushless outrunner" type and will be fabricated for this application. This type of motor has been developed in the last few years primarily by the model airplane community where it is valued for its extremely high torque output at low speeds and its high efficiency. Given the available information and work that I've previously done in solenoid design I think that I will be able to develop a suitable motor. The controller however is a mystery to me. Is there such a thing as a motor driver developers kit out there which I could buy and program to develop the concept and to learn from? Or maybe a few key components that could be pieced together to make a controller suitable for this use? Whatever I work with needs to have the capability of operating bidirectionally & regeneratively. My initial development could be done on a smaller scale using off the shelf model motors, if that works out as the best way to go. The market for this device is relatively small (dozens per year at best), so it would be nice if the "developer's kit" electronics package could also be related to the production electronics package. I would appreciate any help in locating and / or developing the required motor controller, and / or pointing me toward applicable texts. I may also consider paying for external development, although that would be from a modest personal budget.
Thanks,
Mark
I am beginning development of a system which would consist of a battery array, a motor controller (the subject of this post), an electric motor (BLDC , approximately 30 kw), and a single wheel which would be coupled directly to the motor. The system would be mounted to existing vehicles (Truck, car, boat) although its only interaction with the vehicle would be to draw makeup power from the vehicle electrical system (limited to 12v 100A, hopefully much less). A typical operation cycle would have the wheel driven by a constant torque (external to the vehicle) for approximately ten minutes (backdriving the motor and putting electrical energy into the battery array in the device), followed by the motor driving the wheel for a similar length of time against a resistive torque of similar magnitude (energy out of battery array). A key function of the motor controller would be to maintain a constant motor torque throughout the cycle despite the change in direction of power, and despite the resulting speed and direction changes (including brief periods while stationary). The motor and controller will need to have cutting edge levels of efficiency so that the net energy expenditure for a cycle is small enough to be replenished by the vehicle electrical system. The motor will be of the "LRK Torquemax" aka "brushless outrunner" type and will be fabricated for this application. This type of motor has been developed in the last few years primarily by the model airplane community where it is valued for its extremely high torque output at low speeds and its high efficiency. Given the available information and work that I've previously done in solenoid design I think that I will be able to develop a suitable motor. The controller however is a mystery to me. Is there such a thing as a motor driver developers kit out there which I could buy and program to develop the concept and to learn from? Or maybe a few key components that could be pieced together to make a controller suitable for this use? Whatever I work with needs to have the capability of operating bidirectionally & regeneratively. My initial development could be done on a smaller scale using off the shelf model motors, if that works out as the best way to go. The market for this device is relatively small (dozens per year at best), so it would be nice if the "developer's kit" electronics package could also be related to the production electronics package. I would appreciate any help in locating and / or developing the required motor controller, and / or pointing me toward applicable texts. I may also consider paying for external development, although that would be from a modest personal budget.
Thanks,
Mark





RE: Hybrid Motor Controller Developer Kit?
Anyway, is this motor a chopped DC motor (ie an electrically commutated 3 phase DC motor)? If so that's what we use on solar cars, and these guys will know what to do.
http://www.tritium.com.au/legacy/legacy.html
We used the "Gold" in a couple of events recently and it is quite programmable.
This looks more like what you want
http://www.tritium.com.au/project/project.html
They are a small and helpful company.
An even smaller, and longer established company is AERL, the brains there is called Stuart Watkinson and he may have a motor controller available. Last address I have for him is
AUSTRALIAN ENERGY RESEARCH LABS P/L
2 ROSLYN COURT
NORTH TAMBORINE 4272
QUEENSLAND, AUSTRALIA
Phone: Int.+ 61 7 5545 0177
Fax: Int.+ 61 7 5545 0866
You might want to look at wind turbines.
Cheers
Greg Locock
Please see FAQ731-376: Eng-Tips.com Forum Policies for tips on how to make the best use of Eng-Tips.
RE: Hybrid Motor Controller Developer Kit?
Mark
RE: Hybrid Motor Controller Developer Kit?
Here's another contact who is a fount of all wisdom: Paul Lillington, Lillington Motors, Sydney. He built a custom motor controller for us once. Haven't spoken to him for 10 years tho. This may be his address http://oceania.manta.com/coms2/dnbcompany_5kjgkx
Cheers
Greg Locock
Please see FAQ731-376: Eng-Tips.com Forum Policies for tips on how to make the best use of Eng-Tips.
RE: Hybrid Motor Controller Developer Kit?
Ed Danzer
www.danzcoinc.com
www.dehyds.com
RE: Hybrid Motor Controller Developer Kit?
Wouldn't it work to have a DC-DC voltage converter between the mosfets (or whatever the drivers are) and the batteries? Thanks for the Matlab suggestion, I'll look at it.
Mark
RE: Hybrid Motor Controller Developer Kit?
Remember the battery voltage will be increasing as the regeneration voltage is dropping.
I’m not an electronics/electrical guy but have studied the concepts and how they compare to fluid power. Either system has problems with storing braking energy when charging to a single storage vessel.
Ed Danzer
www.danzcoinc.com
www.dehyds.com
RE: Hybrid Motor Controller Developer Kit?
RE: Hybrid Motor Controller Developer Kit?
I did find BLDC motor developers kits on digikey.com and I've bought two. I'm struggling about with one of them (Silicon labs) and if I can't make reasonable headway in the next few days I think I'll offer a few $$ to a college kid to work with me on this.
Keep the thoughts and suggestions flowing!
Thanks,
Mark
RE: Hybrid Motor Controller Developer Kit?
The "kt" in "device (up to 30kt minus inefficiencies into the battery bank). " was a typo. I was trying for "kw" (or should I say "kW). I was not referring to knots ot kilotons.