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As electric vehicles (EVs) become more prevalent on our roads, the need for efficient and reliable dual power control systems is becoming increasingly important. These systems play a crucial role in managing the power output of the electric motor and the internal combustion engine in hybrid vehicles, ensuring optimal performance and fuel efficiency. In this blog post, we will provide you with four essential pieces of advice to consider when choosing a dual power control system for electric vehiclesdual power control system for electric vehicles.
1. Consider the Vehicle's Power Requirements.
The first step in selecting a dual power control system for an electric vehicle is to consider the power requirements of the vehicle. This includes the power output of both the electric motor and the internal combustion engine, as well as any other auxiliary systems that may need to be powered. By understanding the vehicle's power requirements, you can ensure that the dual power control system you choose is capable of meeting those needs efficiently and effectively.
In addition to power requirements, it is also important to consider the overall power distribution within the vehicle. This includes how power is distributed between the electric motor and the internal combustion engine, as well as any battery storage systems that may be in place. A dual power control system that is able to effectively manage power distribution can help maximize the performance and efficiency of the vehicle, leading to a smoother and more enjoyable driving experience.
2. Look for Advanced Control Algorithms.
When selecting a dual power control system for an electric vehicle, it is important to look for systems that are equipped with advanced control algorithms. These algorithms play a crucial role in managing the power output of the electric motor and the internal combustion engine, ensuring that both systems work together seamlessly to provide optimal performance and efficiency.
Advanced control algorithms can also help improve the responsiveness and agility of the vehicle, as well as enhance overall driving dynamics. By choosing a dual power control system with advanced control algorithms, you can ensure that your electric vehicle performs at its best in a wide range of driving conditions, from city streets to highway cruising.
3. Consider the System's Reliability and Durability.
One of the most important factors to consider when choosing a dual power control system for an electric vehicle is the system's reliability and durability. Electric vehicles are complex machines that rely on a variety of systems working together seamlessly to provide reliable performance. By selecting a dual power control system that is known for its reliability and durability, you can ensure that your electric vehicle will continue to perform at its best for years to come.
In addition to reliability and durability, it is also important to consider the system's ease of maintenance and repair. A dual power control system that is easy to service and repair can help minimize downtime and keep your electric vehicle running smoothly. By choosing a system that is reliable, durable, and easy to maintain, you can ensure that your electric vehicle remains a reliable mode of transportation for years to come.
4. Seek Out a Trusted and Experienced Manufacturer.
When choosing a dual power control system for an electric vehicle, it is important to seek out a trusted and experienced manufacturer. A manufacturer with a proven track record of producing high-quality dual power control systems can provide you with the assurance that you are purchasing a reliable and efficient product. By choosing a manufacturer with experience in the electric vehicle industry, you can ensure that your dual power control system is designed and built to meet the unique needs of electric vehicles.
In addition to experience, it is also important to consider the manufacturer's reputation for customer service and support. A manufacturer that is known for providing excellent customer service can help guide you through the selection process and provide ongoing support for your dual power control system. By choosing a manufacturer that is trusted and experienced in the industry, you can ensure that your electric vehicle is equipped with a high-quality dual power control system that will meet your needs for years to come.
In conclusion, selecting a dual power control system for an electric vehicle is an important decision that should not be taken lightly. By considering the vehicle's power requirements, looking for advanced control algorithms, prioritizing reliability and durability, and seeking out a trusted and experienced manufacturer, you can ensure that your electric vehicle is equipped with a dual power control system that will provide optimal performance and efficiency. By following these four essential pieces of advice, you can make an informed decision and choose a dual power control system that will help you get the most out of your electric vehicle driving experience.
The push towards electric vehicles is not limited to cars and 2 wheelers only. To ease the load on Diesel driven public transport vehicles, E-Autos, E-Rikshaws and other such vehicles are being promoted. However, there are certain roadblocks that need to be overcome, w.r.t the application of electric motors in EV.
While Brushless DC and PMSM motors have been the preferred electric motors for electric vehicles, their power requirements vary for different types of EVs.
For better clarity, let’s take an example of an OEM who is working on different segments of Electric Vehicles (like 2-wheelers, three-wheelers, 4-wheelers and even electric commercial vehicles).
Each vehicle will require an Electric Motor of different power ratings and hence a separate motor control solution needs to be developed for each of them. Increased time-to-market and inflated cost are two of the adverse effects that this OEM will need to overcome.
This challenge (related to Motors of different Power Ratings) can be overcome with our EV Motor Controller Unit. Its two-tier technology architecture is designed to separately manage the Power Control and drive algorithms (that drive the motor). Simply put, the microcontroller driving the motor will remain unchanged for every motor (BLDC or PMSM).
Only a separate hardware chip, called the daughter board will need to be customized based on the electric motor’s power rating.
Need more clarity? The layered Software and Hardware architecture will help you develop a better understanding!
Before we look at the architecture of the EV Motor Controller, let’s explore the components of the Control unit.
Now let’s understand the software architecture of our EV Motor Control System.
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Interface Layer: The role of the IF layer is to act as an interface or a bridge between the application layer and the other layers of the motor controller platform. The Application Layer (not part of our platform) will host all the OEM-specific applications.
Service, Safety and Utility Layers: These are the most important layers in terms of functionality. The coveted Field-Oriented Control algorithm is part of these layers, along with other safety, in-vehicle networking and vehicle diagnostics stacks.
Now let’s have a more detailed overview of the software architecture:
Other modules like LINTP, XCP, FCM, Stack Test, CPU Load etc. are also included for safety, in-vehicle communication and fault handling.
Hardware Abstraction Layer: HAL comprises of the routines and functions that lets the upper layers interact with the ECU hardware. As seen in the diagram, CAN Network Management, CAN Interface, LIN Network Management, ADC etc. are some of the protocols for which HAL has been included.
The Hardware Abstraction Layer in this motor control system comes in handy when the algorithms need to be migrated to a different MCU family.
Low-Level Drivers: LLD is the basic microcontroller peripheral. It has no idea about the nature of the value that it is receiving from the microcontroller. Its job is to pass on the value to the HAL where the value will be converted to a physical value.
For example, the LLD measures a current value which is 0-5 V. When this value is received by Hardware Abstraction Layer, it is converted to a physical value of 0-30 A. LLDs for PWM, ADC, LIN, CAN and MCU are included in the bottom-most layer of our EV motor control system.
The hardware platform that supports our FOC algorithm and other software stacks is also a very crucial part of the EV motor control unit. Let’s have a quick overview of the underlying hardware.
Our EV Motor Control Unit has been designed on an Automotive-grade, Dual Core Microcontroller platform– 32 Bit TI Delfino.
The Control Board (Microcontroller) receives inputs from:
This EV System overview will give a better understanding.
Based on these inputs, the Field-Oriented Control algorithm directs the MCU to generate PWM signals. These signals are sent to the Daughter Board (Power Board).
Daughter Board, as explained earlier, is the power management system of our EV Motor Controller unit. Also called as the power board, it is responsible for generating the current supplied to the electric motors. As mentioned earlier, it consists of varying number of MOSFETS for this purpose.
The addition of the Daughter Board has made our motor controller platform a highly flexible and a universal solution for Electric Vehicle Applications. Whether you need to drive a smaller BLDC or PMSM motor or a bigger one, the MCU remains the same. All one needs to customize is the small daughter board
The customizations for different use-cases essentially boil down to
Higher the power rating of the motor, larger the number and rating of the MOSFETs. For instance, our prototype motor control system designed for a 5 KW BLDC motor has 6 MOSFETs in parallel on each side of the board.
Now to drive a smaller EV, say an electric 2-Wheeler that requires a 1 Kw motor, the daughter board will require only 2 smaller MOSFETs. Other supporting hardware components will also be based on the electric motor’s power rating.
The motor control system being a vital component in various mechanical and electrical applications, offers precise regulation and management of motor functions. Those can be other appliances like industrial machines, ventilators etc. Whether in industrial machinery, robotics, or automotive systems, the motor control system plays a pivotal role in ensuring optimal performance, efficiency, and safety.
By interfacing with sensors and feedback mechanisms, it orchestrates the speed, direction, and torque of motors, adapting seamlessly to diverse operational requirements. From simple on-off control to sophisticated closed-loop systems, the versatility of motor control systems caters to a wide spectrum of needs, empowering automation and enhancing productivity across industries.
A couple of areas where motor control systems are advancing and likely to continue evolving:
As is quite evident from its design, our EV motor control system ECU is designed to cater to the changing needs of the Electric Vehicle industry. The segregation of motor drive logic (FOC algorithm) and power management aids in faster turn-around time for EVs programs.
For a Demo of our Motor Control system for Electric Vehicles, please contact us at sales[at]embitel[dot]com.