Andy LianGabriel MirandaChris McManusDrew PearsonAndrew Perez

Design motor control system for the Solar Jackets solar racing vehicle

Continuing work from previous group Fall 2010

System responsibilities: Electric motor operation Central communication between vehicle

subsystems

Test bench construction Safety systems

designed and installed Functioning motor

control using serial and analog signals

Effective cruise control Switch between serial and analog control

Air gap adjustment and controlEffective load testing

Dynamic control of motor air gapFunctional cruise control using SBCRegenerative brakingLoad testingCommunication with vehicle

subsystems

Air gap between rotor and stator Adjustable while motor in use

▪ Increase air gap –> Increase top speed/Decrease torque

▪ Decrease air gap –> Decrease top speed/Increase torque

Need highest torque when gap is minimized▪ 35-40 in-lb (640 oz-in)

Stepper Motor Planetary Gear

Set Specs

▪ ~120 oz-in▪ 4.5” L x 3.2” H x

2.2” W▪ 12 VDC▪ SBC Control

Pricing▪ Motor: $227-$336▪ Gearbox: $452-

$589

Window Lift Motor

▪ FIRST Robotics Specs

▪ 82 in-lb▪ 12 VDC

Pricing▪ $60-$80

Pros Cons

Option 1 (Stepper Motor)

-SBC Control-Precise Control

-Price-Size-Need gearbox

Option 2 (Window Lift Motor)

-Compact Size-Price

-Hard to find info-Need encoder

Brake Lights

Reverse Lights

All I/O except serial interface lines

Serial used to check status of controller

Brake Lights

Reverse Lights

Configures controller

Provides all inputs Checks controller

status

Controller prevents change from serial to discrete or vice-versa while coasting

Proposed solution: Keep controller in serial mode Run inputs to SBC

IFM

SBC

Inputs

Responsibilities Automated

motor control Vehicle

subsystem communication

RS-485 Battery Management Maximum Power Point Tracking

USB Human-Machine Interface

RS-485 Battery Management Maximum Power Point Tracking

USB Human-Machine Interface

RS-485 Battery Management Maximum Power Point Tracking

USB Human-Machine Interface

Speed control mode Speed is represented by throttle pot voltage

▪ Full voltage represents full speed Braking is represented by regen pot voltage

Torque control mode Difference in pot voltages determines motor

phase current Motor phase current is proportional to

torque

Values exist in registers on motor controller

SBC routines include Cruise control Regenerative braking control Report motor condition to other

subsystems Respond to condition of other

subsystems

• Use motor-generator setup • Will provide

• Verification of motor and cruise control functionality

• Variable loading of motor

Previous test setup

Generator Added for load

testing Connected via

shaft

Variable load Mimic drive

cycles

With permission from Professor Habetler or Harley, we will conduct load testing in Van Leer Room W 139. We will receive help from Stefan Grubic

Successful operation of Fall 2010 motor setup

SBC code restructuring and cleaningPreliminary load test strategyPreliminary air gap control system

specs

Successful compilation of SBC codeSelect air gap adjustment motorSerial control of motorWrite cruise control algorithmLoad and test motorRegenerative braking

algorithm/setupCommunicate with other subsystems