Controller Finale

7/30/2019 Controller Finale

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BASICS OF

CONTROLLERSBY:

NIPUN VASHISHTH

VISHNU SINGH


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WHAT IS CONTROLLER??

NEED OF CONTROLLER.

TYPES OF CONTROLLER DC CONTROLLER

AC CONTROLLER CHOICE OF CONTROLLER

CONCLUSION


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A controller basically is the brain orcomputer of an electric car. It controls orgoverns the performance of the electricmotor of an electric vehicle.

The controller controls both manual orautomatic drive systems for starting and

stopping, going forward or backward,governing the speed, regulating orlimiting the torque, and protecting

against overloads and faults.


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The controller integrates the motor speedsand expected battery range/speed throughits energy density.

It controls the flow of power from thebattery to the motor, with various feedbacksensors to monitor the systems operation.

Coordinating between the controller andthe motor can help a car accelerate from 0 to60MPH in 6 to 7 seconds (or less), which candetermine the range of the car and the top

speed.


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SWITCH CONTROLLER

SOLID STATE CONTROLLER

ELECTRONIC CONTROLLER DC CONTROLLER

AC CONTROLLER


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Switch controllers are the oldest type.

Basically, they are a set of big switches thatconnect the batteries and motors in various

series/parallel combinations to get thespeeds.

In this four 12 volt batteries could be

connected for 12v, 24v, or 48v to provideslow, medium, and fast motor speeds


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Switch controllers are cheap, simple, andefficient.

Their main drawbacks are the stepwisespeed control.


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The DC brushed motor with solid-statecontroller is the most common type.

Basically, they use solid-state switches(transistor, MOSFET ,IGBT, etc.) to replace themechanical switches in a switch controller.

MOSFET SSC are more common among lowervoltage controllers since low voltage MOSFETs

tend to have very low on resistance and hencepower loss . MOSFET controllers are veryefficient at low power levels, since power lossin a MOSFET is proportional to the square of

the current.


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IGBT is somewhat like a hybrid betweenbipolar transistors and field effect transistors.IGBTs have a constant voltage drop which

makes them more efficient than MOSFETs athigh power levels, though often less efficientfor low power applications.

Disadvantage with IGBTs is that, like all

bipolar transistors, they are prone to thermalrunaway and imbalances when used inparallel.


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Electronic switches can be switched on/offmuch faster, and dont wear out. The controllerswitches them on/off so fast (thousands of

times per second) that the motor gets theaverage current rather than the peak or zero.

This is called Pulse Width Modulation (PWM).PWM controllers are modestly priced, readily

available in a wide variety of sizes, andprovide smooth stepless motor control.


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The easiest way to vary the DC voltage deliveredto a DC motor is to divide its steady, non varyingDC component into smaller pieces. The average ofthe number or size of these pieces will be a

resultant DC voltage that the motor thinks it isreceiving.

The controller takes power from the batteries anddelivers it to the motor. The accelerator pedal

hooks to a pair of potentiometer and thesepotentiometers provide the signal that tells thecontroller how much power it is supposed todeliver. The controller can deliver zero power, full

power , or any power level in between.


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This graph shows that the voltage delivered to themotor is proportional to the amount of time the pulseis on versus the total length of the period. As t off >>

ton in the left-hand graph, the average voltage (V) themotor receives is only equal to a small value. But in theright half of the graph, ton >> t off and Vm is a muchlarger valuenearly equal to Vbfor the batteryvoltage.


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The AC motor with solid-state inverter isthe most sophisticated type. They are usedin high-end EVs where meeting

performance objectives is more importantthan cost.

An AC induction motor or AC PM motor is

driven by an inverter that converts batteryDC voltage into variable voltage variablefrequency3-phase AC.


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New EV sports cars and the recent autocompany produced EVs all used AC drivesystems.

Like modern ICEs, these AC controllers arevery complex and expensive, but offer themost advanced features (like cruise control

and regenerative braking) and provide thebest overall range.


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An AC controller hooks to an AC motor. Using sixsets of power transistors, the controller takes in 300

volts DC and produces 240 volts AC, 3-phase.


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High reliability, high performance, and minimumcost are the key factor for EV controller choice.

Different types are:

High reliability, high performancemeans highcost(Cafe Electric Zilla controller, no know failures,300v 2000a, $3500)

High performance, minimum costmeans lowreliability(Logic systems rebuilt Curtis controller,

high failure rate, 156v 1000a, $1500)High reliability, low costmeans low

performance(used GE EV-1 SCR controller, 30years old and still working, 72v 400a, $1000)


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Its features include:

PWM-type controller.

MOSFET-based technology.

Runs at a constant switching frequency of 15 kHz. Automatic motor current limiting.

High pedal lockout.

Intermittent-duty plug braking. Overvoltage and under voltage protection.

User-accessible adjustments for motor current limit,plug braking current limit, and acceleration.

Comes in a waterproof heat sink case.


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The Zilla controller is one of the most popularand powerful motor controllers available forelectric vehicles. The Zilla has exceptionally

high power density. This controller can make your EV have the

most amazing pickup and torque like no otheron the market.


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It is impossible to imagine a ELECTRICVEHICLE without controllers.

Improvement of electric vehicles is directly

proportional to advancement of controllers. The controller is another pillar of every electric

vehicle. If one area could take credit forrenewed interest in EVs, the controller wouldbe it.


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THANK YOU

Controller Finale

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