P16261: EV Team 3-Phase AC Motor Controller A/public/
Customer Handoff & Final Project Documentation
Table of Contents
Team Vision for Final Demo and Handoff
- We planned to:
- PCBs (Inverter and Interface) and software functional.
- CAN communication functional
- New enclosure complete
- Demonstration prepared for Imagine.
- We managed to:
- Successfully demo a working prototype at ImagineRIT.
- Flash the LaunchPad for standalone mode
- Completed the Interface board.
- Create a new minimalist Inverter board for testing purposes.
- CAN is mostly functional
- Complete the community presentation.
- Complete the Technical Paper.
- Complete the Team Poster.
- All connectors to EVT specifications.
Test Results Summary
- Many of the tests could not be completed for the projects original target: the E-bike motor controller. This is due to the fact that the motor driver stage had issues. That troubleshooting is ongoing but our hypothesis is that the gate signals to the N-MOSFETs are being corrupted by noise generated on the board. To fix this use a coaxial cable to isolate these signals from noise. An alternative is suggested in future recommendations which is to move the noise generating components to the opposite side of the board as the DRV8301. This is problematic as some noise will be generated from the power traces which are inherently near the gates.
- Nearly all of the tests can be marked complete if the scope is modified to that of the prototype board which controls the small test motor via a throttle. This setup was demonstrated at ImagineRIT 2016 and functioned without flaw for all of the event.
- The tests that cannot be marked complete are:
- S7 - Not high priority since the motor is being properly controlled
- S8 - 98% complete
- S10 - Completed by specifying a fuse with a smaller current rating. Holder is ready to be installed
- S11 - Has been removed as a requirement after agreement with customer.
- The remaining tests meet all of the customers requirements for the prototype board. If it can be checked off with the prototype board it is highly likely that the same could be done with a completed and working e-bike motor controller.
- Motor control software is 100% functional.
Risk and Problem Tracking
- Some risk still remains these were not able to be tested/could not be prevented. If it were able to be mounted, the PCB would be too large for the enclosure we purchased and designed. Another would be required. Power consumption for the e-bike controller was not completed since the board never finished preliminary troubleshooting and testing.
- Many problems from earlier have been solved. There are two large issues still remaining to be solved: CAN, which is near completion and inverter/interface boards failure to spin motor, which is still being tested.
Final Project Documentation
- P16261 Technical Paper
- P16261 Poster
- P16261 Final BOM
- P16261 Future Recommendations
- P16261 Board Designs (KiCAD)
- P16261 Firmware/Software Code Base
- Note: Firmware/Software archived at https://bitbucket.org/evt/motorcontroller
- P16261 CAD Files for Enclosure and Connectors
Functional Demo Materials
- Test Results:
Plans for Wrap-up
- We need to:
- Write-up Software Guide
- Write-up Hardware Design Guide