© 2020 EasyEDA Some rights reserved
Open source license: Public Domain
The Gate Drivers should power IGBT Half Bridge Drivers with gate drive up to around +15V/-8V at 10A so should work with most 3 phase BLDC and AC motors up to around 150KW eg a Nissan Leaf Motor at 400V would be fine. It should also work beyond this power level with better IGBTs or higher voltages though you may have to beef up the MOSFET Driver and Gate Power Supplies in some cases. Likewise the system board can also be used to control a lower voltage 72V-144V Forklift Series Wound DC Motor with just a single channel (for forward only) or 4 channels in 2 x half bridge configuration for forward/reverse control with just software changes and the components on extra channels can be left unpopulated (there are more elegant solutions than having a mostly unpopulated PCB but it will work fine) Due to the higher currents required for similar power at lower voltages the gate drive current of the IGBT may be a limiting factor and you would be better re-designing using parallel MOSFETs, again plenty of info out there if you google had enough.
Not shown are the Power Components, the 3 x Half Bridge IGBTs, Free-Wheeling Diodes, Fuses, Contactors, DC-Link Capacitors etc that control the high currents and so are better connected externally, these parts are well documented and the project builder is expected to know how they connect and the risks and safety requirements of working with very high voltages and currents.
Sensor inputs are provided for thermistors and current sense. Control inputs are provided for a 5K accellerator, 3 Switches and CAN Bus, 3 Open collector outputs are provided to drive relays such as the Main Contactor, Pre-Charge and another. The circuit is powered from the 12V Auxilliary battery, it is fused at a nominal 5A but a bit of experimentation may be required on this depending upon other chosen components.
Requires daughter MCU and resolver board fitted to operate (See seperate Project), the daughter board is seperate from motherboard to allow different MCU and Resolvers to be made if required as not everyone is familiar with the dsPIC and PGS411 resolver I use in my project.
The system design is based upon the Texas Instruments and ON Semiconductor Datasheets and Design References (TIDA-00917, AND9088) with input from a million other forums, all the questions you have can be answered from these and a bit of googling. I have tried to keep the parts as available as possible so generic substitutes can be made when the part enevitably goes out of stock. Most are from LCSC so a BOM and PCB can be built for under $100 from this EasyEDA link.
Usual disclaimer. This is public domain and while every effort has been made to ensure the circuit is accurate, it is experimental and mistakes may occur in design or build so it is up to the system builder to ensure it works.
Boz. July 2019
ID | Name | Designator | Footprint | Quantity | BOM_Supplier | BOM_Supplier Part |
---|---|---|---|---|---|---|
1 | 2N7002 | Q4,Q7,Q5,Q6,Q12,Q13,Q11,Q14,Q18,Q19,Q1 | WSOT-23 | 11 | LCSC | C65189 |
2 | 1N4148W | D15,D16,D17,D18,D31,D27 | SOD123 | 6 | LCSC | C2099 |
3 | INTERFACE | U1 | 5569-2X12 PCB MOUNT | 1 | Digi-Key | WM1362-ND |
4 | Wsense | CN3 | 22035045 | 1 | LCSC | C37815 |
5 | Vsense | CN4 | 22035045 | 1 | LCSC | C37815 |
6 | HVsense | CN5 | 22035045 | 1 | LCSC | C37815 |
7 | 10 | R18,R19,R20,R44,R45,R43 | 2512 | 6 | LCSC | C47019 |
8 | 4.7K | R61,R67,R69,R63,R65,R62,R72 | 0805 | 7 | LCSC | C26022 |
9 | LM5030SD | U4 | SDC10A | 1 | Digi-Key | LM5030SD/NOPBCT-ND |
10 | EL357N(B)(TA)-G | U15 | SOP-4_P2.54 | 1 | LCSC | C6649 |
11 | 78M05 | U2 | TO-252-2 | 1 | LCSC | C111265 |
12 | MCU-A | P9 | HDR-TH_40PIN-V-ROW2-COL20-FEMALE-PITCH2.54 | 1 | LCSC | C50982 |
13 | MCU-B | P10 | HDR-TH_40PIN-V-ROW2-COL20-FEMALE-PITCH2.54 | 1 | LCSC | C50982 |
14 | 1K | R7,R22,R23,R24,R47,R48,R46 | 0805 | 7 | LCSC | C17513 |
15 | 26.1K | R2 | 0805 | 1 | LCSC | C104160 |
16 | FOD8316R2 | U7,U8,U9,U12,U13,U11 | SOIC-16_300MIL | 6 | LCSC | C80622 |
17 | 120Ω | R81 | R0805 | 1 | LCSC | C25280 |
18 | 2.4 | R28,R29,R30,R53,R54,R52 | 2512 | 6 | LCSC | C25481 |
19 | MAIN-FUSE 5A | F1 | FUSE_1812 | 1 | LCSC | C381482 |
20 | B1100B13F | D8,D3,D26,D22,D21,D4,D5,D6,D7,D9,D10,D11,D19,D20,D23,D24,D25 | SMB(DO-214AA)-F | 17 | LCSC | C124202 |
21 | B1100B13F | D2 | SMB(DO-214AA)-F | 1 | LCSC | C124202 |
22 | LP5907QMFX-3.3Q1 | U14 | SOT-23-5 | 1 | LCSC | C130005 |
23 | 2.7K | R9,R26,R25,R21,R4,R68,R70,R64,R66,R71,R73,R74,R75 | 0805 | 13 | LCSC | C17530 |
24 | FAULT | LED1 | LED-1206 | 1 | LCSC | C84270 |
25 | WB- | LED15 | LED-1206 | 1 | LCSC | C84270 |
26 | WT- | LED17 | LED-1206 | 1 | LCSC | C84270 |
27 | VB- | LED11 | LED-1206 | 1 | LCSC | C84270 |
28 | VT- | LED13 | LED-1206 | 1 | LCSC | C84270 |
29 | UB- | LED18 | LED-1206 | 1 | LCSC | C84270 |
30 | UT- | LED20 | LED-1206 | 1 | LCSC | C84270 |
31 | HEF4046BT,653 | U5 | SOIC-16_150MIL | 1 | LCSC | C90682 |
32 | 10KΩ | R31,R32,R40 | R0805 | 3 | LCSC | C140868 |
33 | 750342312 | T1,T2,T3 | WURTH 750342312 500KHZ SMP TRANSFORMER | 3 | Digi-Key | 1297-1223-ND |
34 | 1K | R49,R3,R56,R57,R5 | 0805 | 5 | LCSC | C115302 |
35 | AMS1117-3.3_C165482 | U3 | SOT-223 | 1 | LCSC | C165482 |
36 | 100pF | C59,C60,C62,C100,C101,C99 | 0805 | 6 | LCSC | C152851 |
37 | 25.5K | R51,R55,R59,R60,R58,R86 | 2512 | 6 | LCSC | C175356 |
38 | CON-HV+ | P2 | VH3.96-2A | 1 | LCSC | C16728 |
39 | IGBT-UT | P3 | VH3.96-2A | 1 | LCSC | C16728 |
40 | IGBT-UB | P4 | VH3.96-2A | 1 | LCSC | C16728 |
41 | IGBT-VT | P5 | VH3.96-2A | 1 | LCSC | C16728 |
42 | IGBT-VB | P6 | VH3.96-2A | 1 | LCSC | C16728 |
43 | IGBT-WT | P7 | VH3.96-2A | 1 | LCSC | C16728 |
44 | IGBT-WB | P8 | VH3.96-2A | 1 | LCSC | C16728 |
45 | US1M | D12,D13,D14,D29,D30,D28 | SMA(DO-214AC) | 6 | LCSC | C5441 |
46 | THERMISTER-IGBT3 | CN1 | XH-2AW | 1 | LCSC | C33132 |
47 | THERMISTER-4-MOTOR | CN2 | XH-2AW | 1 | LCSC | C33132 |
48 | ACCELERATOR-5K | CN6 | XH-2AW | 1 | LCSC | C33132 |
49 | THERMISTER-IGBT1 | CN7 | XH-2AW | 1 | LCSC | C33132 |
50 | THERMISTER-IGBT2 | CN8 | XH-2AW | 1 | LCSC | C33132 |
51 | 49.9K | R8,R87 | 0805 | 2 | LCSC | C17719 |
52 | - | L1 | SMD-13.45X12.6-1365 | 1 | LCSC | C242230 |
53 | PWR-12V | LED3 | LED-1206 | 1 | LCSC | C99881 |
54 | PWR-3V3 | LED4 | LED-1206 | 1 | LCSC | C99881 |
55 | ACTIVITY | LED5 | LED-1206 | 1 | LCSC | C99881 |
56 | READY | LED6 | LED-1206 | 1 | LCSC | C99881 |
57 | PWR-5V | LED2 | LED-1206 | 1 | LCSC | C99881 |
58 | HV Active | LED7 | LED-1206 | 1 | LCSC | C99881 |
59 | PWR-24V | LED8 | LED-1206 | 1 | LCSC | C99881 |
60 | WB+ | LED14 | LED-1206 | 1 | LCSC | C99881 |
61 | WT+ | LED16 | LED-1206 | 1 | LCSC | C99881 |
62 | VB+ | LED10 | LED-1206 | 1 | LCSC | C99881 |
63 | VT+ | LED12 | LED-1206 | 1 | LCSC | C99881 |
64 | UB+ | LED9 | LED-1206 | 1 | LCSC | C99881 |
65 | UT+ | LED19 | LED-1206 | 1 | LCSC | C99881 |
66 | RESOLVER | P1 | HDR-IDC-2.54-2X4P | 1 | LCSC | C9135 |
67 | BSC070N10NS3GATMA1 | Q20,Q21 | PG-TDSON-8 | 2 | LCSC | C148247 |
68 | 100nF | C16,C18,C23,C21,C10,C15,C17,C25,C12,C50,C105,C106,C107,C108,C110,C111,C112,C35,C94,C96,C98,C102,C104,C114,C115,C116,C117,C118,C119,C120,C121,C14,C19,C22,C122,C123,C124,C125,C126 | 0805 | 39 | LCSC | C1711 |
69 | XL6019E1 | U6 | TO-263-5 | 1 | LCSC | C73018 |
70 | 100K | R1 | 0805 | 1 | LCSC | C319972 |
71 | 10K | R13,R10,R17,R16,R14,R11,R15,R12,R38,R35,R39,R36,R37,R34,R33,R42,R27,R50,R76,R77,R78,R79,R80,R82,R83,R84,R85 | 0805 | 27 | LCSC | C17414 |
72 | 10uF | C29,C26,C32,C40,C46,C53,C38,C7,C2,C44,C51,C57,C63,C3,C8,C70,C67,C73,C76,C82,C88,C79,C85,C91,C97,C103,C113,C109,C27,C28,C30,C31,C33,C34,C36,C37,C39,C41,C42,C43,C45,C47,C48,C49,C52,C54,C55,C56,C58,C61,C64,C65,C66,C68,C69,C71,C72,C74,C75,C77,C78,C80,C81,C83,C84,C86,C87,C89,C90,C92,C93,C95 | 1210 | 72 | LCSC | C13585 |
73 | 470pF | C20 | 0805 | 1 | LCSC | C61096 |
74 | SB10100L | D1 | TO-277 | 1 | LCSC | C113946 |
75 | 1000uF | C4,C5,C11 | CAP-13*20 | 3 | LCSC | C88743 |
76 | 150uF | C6,C9 | CAP-D8.0XF3.5 | 2 | LCSC | C270008 |
77 | DMC4029SK4-13 | Q8,Q9,Q10,Q16,Q17,Q15 | TO-252-4 | 6 | LCSC | C260864 |
78 | 22nF | C1 | 0805 | 1 | LCSC | C326967 |
79 | 0.22 | R6 | 2010 | 1 | LCSC | C146381 |
Unfold