Paul and Sabrina's Cheap 3 Phase Inverter (AC Controller) with Field Oriented Control

[MPaulHolmes]

Oh good point. Yes, the same would be true for the DC controller (the big bertha DC controller with the ATTiny)

[ale0502]

hello,
almost already I have a pcb to test.
I need to know how the code "ACControlBoardDebugging" works.
It has functional UART?
It makes some feedback control, or just crank the motor?
What are the steps for starting up my board?

thanks to all

[MPaulHolmes]

Hello! I'm sorry, I've been away in Oregon at work. We just got back yesterday. All that debugging code does is set the PWMs of all 6 outputs to a fixed value, so you can measure the voltage from gate to emitter on each of the 6 PWMs. You can even just use a volt meter. That way, if all 6 of them are somewhere between -8.2 and +15 (far away from -8.2 and far from +15), you know the PWM is working, and that the hardware is good to go. Actually, make sure there is no motor and no batteries hooked up during that test. Leave the 3 phase cables unconnected. Also, if you just have the standalone board with no IGBTs, to avoid a false desat fault, you will have to temporarily have C1 connected to E1 connected to C2 connected to E2 connected to C3 connected to E3. You will also have to have a throttle plugged in, as well as the 3 current sensors. Only then will the PWMs make it all the way to the output.

[arber333]

Hi all

Ive been lurking some time now and reading this thread. Lots of info. I bought one PCB rev. 0 obviously and i built it to completion.

Like Paul said i will use 2x film caps 800V 100uF FFVE6B0107KJE. Irms is 90A and Ipeak 4500A.
http://eu.mouser.com/ProductDetail/A...252beq9Q%3D%3D

I tried to use as short rails as possible.
However a friend that is EE told me i have to use one or two elcaps too. So they will act as shock absorbers to cut resonance spikes.

Well i made this test on my old controler and replaced 2x 4700uf elcaps with 2x 100uF FFVE6B0107KJE. All was working well. The only noticable thing was inverter started to sing when pwm was active. I added two small elcaps in and singing was reduced noticably! So now i drive to work every day using old inverter with film caps. Obviously caps do their job! Irms is more than 300A and Idc is limited to cca 280A.

[ale0502]

Originally Posted by MPaulHolmes

Hello! I'm sorry, I've been away in Oregon at work. We just got back yesterday. All that debugging code does is set the PWMs of all 6 outputs to a fixed value, so you can measure the voltage from gate to emitter on each of the 6 PWMs. You can even just use a volt meter. That way, if all 6 of them are somewhere between -8.2 and +15 (far away from -8.2 and far from +15), you know the PWM is working, and that the hardware is good to go. Actually, make sure there is no motor and no batteries hooked up during that test. Leave the 3 phase cables unconnected. Also, if you just have the standalone board with no IGBTs, to avoid a false desat fault, you will have to temporarily have C1 connected to E1 connected to C2 connected to E2 connected to C3 connected to E3. You will also have to have a throttle plugged in, as well as the 3 current sensors. Only then will the PWMs make it all the way to the output.

Thanks Paul!
I can´t compile the "ACControlBoardDebugging".
I`m working on MPlab IDE V8.60 and i have the C30 compiler install. In fact, I can compile without problems the code "ACController".
I think this missing some file, I have the "ACController.h", "P30F4011.h", "uart.c" and "uart.h".

I copy down all warnings and errors:

ACControlBoardDebugging.c:20: warning: missing braces around initializer
ACControlBoardDebugging.c:20: warning: (near initialization for 'savedValuesDefault.spares')
ACControlBoardDebugging.c:24: warning: missing braces around initializer
ACControlBoardDebugging.c:24: warning: (near initialization for 'savedValues.spares')
ACControlBoardDebugging.c:28: warning: braces around scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:28: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:28: warning: (near initialization for 'savedValuesDefault2.throttleType')
ACControlBoardDebugging.c:31: warning: braces around scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:31: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:31: warning: (near initialization for 'savedValues2.throttleType')
ACControlBoardDebugging.c:118: error: syntax error before 'RTData'
ACControlBoardDebugging.c:118: warning: type defaults to 'int' in declaration of 'RTData'
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: excess elements in scalar initializer
ACControlBoardDebugging.c:118: warning: (near initialization for 'RTData')
ACControlBoardDebugging.c:118: warning: data definition has no type or storage class
ACControlBoardDebugging.c: In function '_ADCInterrupt':
ACControlBoardDebugging.c:398: error: 'THROTTLE_FAULT_COUNTS' undeclared (first use in this function)
ACControlBoardDebugging.c:398: error: (Each undeclared identifier is reported only once
ACControlBoardDebugging.c:398: error: for each function it appears in.)
ACControlBoardDebugging.c:503: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:504: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:505: error: 'piType' has no member named 'errorSum'
ACControlBoardDebugging.c:505: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:506: error: 'piType' has no member named 'errorSum'
ACControlBoardDebugging.c:506: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:509: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:510: error: 'piType' has no member named 'errorSum'
ACControlBoardDebugging.c:511: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:515: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:515: error: 'piType' has no member named 'P'
ACControlBoardDebugging.c:515: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:515: error: 'piType' has no member named 'I'
ACControlBoardDebugging.c:515: error: 'piType' has no member named 'errorSum'
ACControlBoardDebugging.c:518: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:519: error: 'piType' has no member named 'errorSum'
ACControlBoardDebugging.c:520: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:524: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:524: error: 'piType' has no member named 'P'
ACControlBoardDebugging.c:524: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:524: error: 'piType' has no member named 'I'
ACControlBoardDebugging.c:524: error: 'piType' has no member named 'errorSum'
ACControlBoardDebugging.c:527: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:528: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:531: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:532: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:535: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:536: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:539: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:540: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:544: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:545: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c: In function 'InitPIStruct':
ACControlBoardDebugging.c:627: error: 'piType' has no member named 'P'
ACControlBoardDebugging.c:627: error: 'SavedValuesStruct' has no member named 'Kp_Id'
ACControlBoardDebugging.c:628: error: 'piType' has no member named 'I'
ACControlBoardDebugging.c:628: error: 'SavedValuesStruct' has no member named 'Ki_Id'
ACControlBoardDebugging.c:629: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:630: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:631: error: 'piType' has no member named 'errorSum'
ACControlBoardDebugging.c:633: error: 'piType' has no member named 'P'
ACControlBoardDebugging.c:633: error: 'SavedValuesStruct' has no member named 'Kp_Iq'
ACControlBoardDebugging.c:634: error: 'piType' has no member named 'I'
ACControlBoardDebugging.c:634: error: 'SavedValuesStruct' has no member named 'Ki_Iq'
ACControlBoardDebugging.c:635: error: 'piType' has no member named 'error'
ACControlBoardDebugging.c:636: error: 'piType' has no member named 'pwm'
ACControlBoardDebugging.c:637: error: 'piType' has no member named 'errorSum'
ACControlBoardDebugging.c: In function 'ComputeRotorFluxAngle':
ACControlBoardDebugging.c:750: error: 'MAX_RPS_TIMES16' undeclared (first use in this function)
ACControlBoardDebugging.c:751: error: 'RPS_FAULT' undeclared (first use in this function)
ACControlBoardDebugging.c: In function 'FetchRTData':
ACControlBoardDebugging.c:1323: error: request for member 'throttle' in something not a structure or union
ACControlBoardDebugging.c:1324: error: request for member 'temperatureBasePlate' in something not a structure or union
ACControlBoardDebugging.c:1326: error: request for member 'IdRef' in something not a structure or union
ACControlBoardDebugging.c:1327: error: request for member 'Id' in something not a structure or union
ACControlBoardDebugging.c:1328: error: request for member 'IqRef' in something not a structure or union
ACControlBoardDebugging.c:1329: error: request for member 'Iq' in something not a structure or union
ACControlBoardDebugging.c:1330: error: request for member 'pdc1' in something not a structure or union
ACControlBoardDebugging.c:1331: error: request for member 'pdc2' in something not a structure or union
ACControlBoardDebugging.c:1332: error: request for member 'pdc3' in something not a structure or union
ACControlBoardDebugging.c:1333: error: request for member 'RPS_times16' in something not a structure or union
ACControlBoardDebugging.c:1334: error: request for member 'batteryCurrentNormalized' in something not a structure or union
ACControlBoardDebugging.c:1335: error: request for member 'faultBits' in something not a structure or union
ACControlBoardDebugging.c: In function 'EESaveValues':
ACControlBoardDebugging.c:1340: error: 'SavedValuesStruct' has no member named 'Kp_Id'
ACControlBoardDebugging.c:1341: error: 'SavedValuesStruct' has no member named 'Ki_Id'
ACControlBoardDebugging.c:1342: error: 'SavedValuesStruct' has no member named 'Kp_Iq'
ACControlBoardDebugging.c:1343: error: 'SavedValuesStruct' has no member named 'Ki_Iq'
ACControlBoardDebugging.c: In function 'MoveDataFromEEPromToRAM':
ACControlBoardDebugging.c:1425: error: 'SavedValuesStruct' has no member named 'Kp_Id'
ACControlBoardDebugging.c:1426: error: 'SavedValuesStruct' has no member named 'Ki_Id'
ACControlBoardDebugging.c:1427: error: 'SavedValuesStruct' has no member named 'Kp_Iq'
ACControlBoardDebugging.c:1428: error: 'SavedValuesStruct' has no member named 'Ki_Iq'
ACControlBoardDebugging.c:1443: error: 'SavedValuesStruct' has no member named 'Kp_Id'
ACControlBoardDebugging.c:1444: error: 'SavedValuesStruct' has no member named 'Ki_Id'
ACControlBoardDebugging.c:1445: error: 'SavedValuesStruct' has no member named 'Kp_Iq'
ACControlBoardDebugging.c:1446: error: 'SavedValuesStruct' has no member named 'Ki_Iq'
ACControlBoardDebugging.c:1462: error: 'SavedValuesStruct' has no member named 'Kp_Id'
ACControlBoardDebugging.c:1463: error: 'SavedValuesStruct' has no member named 'Ki_Id'
ACControlBoardDebugging.c:1464: error: 'SavedValuesStruct' has no member named 'Kp_Iq'
ACControlBoardDebugging.c:1465: error: 'SavedValuesStruct' has no member named 'Ki_Iq'

thanks

[MPaulHolmes]

OK I've changed the code so there's no need for a separate debugging program. Now you just type
debug 1
and that turns on debug mode. To turn it off, you type
debug 0
Make sure no motor is attached when you do that. Then you can measure the voltages from each gate to source.

I tried to make a new github thing for it, and I can't friggen figure out how to add files to it. I don't know if they changed how it's done, but I don't know how now.

This code is tested with the Leaf motor and an induction motor. I hate github. there, I said it. haha.

edit: Well, I tried to make a new somethingOrOther, and that failed, but I was able to edit the other files in the existing "somethingOrOther", so now they have updated code.

[ale0502]

Thank you very much Paul!!

only a humble comment, I think in the uart.c file on github it´s the uart.h header code, so i replace this with n old that i have save on my pc.
Now almost compiling, just throw me two errors in uart.c:

UART.c: In function 'ProcessCommand':
UART.c:138: error: 'PERMANENT_MAGNET_AC_MOTOR_WITH_ENCODER' undeclared (first use in this function)
UART.c:138: error: (Each undeclared identifier is reported only once
UART.c:138: error: for each function it appears in.)
UART.c:143: error: 'PERMANENT_MAGNET_AC_MOTOR_WITH_RESOLVER' undeclared (first use in this function)

[MPaulHolmes]

Oh dang it. OK I fixed github. Now try it. I think yesterday I pasted into uart.c twice. Once for uart.c, and then once for uart.h.

[arber333]

Hi

Does anyone have bare resolver to encoder PCB that they can take a photo of?
I have completed mine, but in the end last three contacts have developed short. I tried to clean this but in the end only a glob of molten solder and vacuum tool cleared it. Well to my dismay i saw that vacuum sucked not only excess solder but also a tab under AD2S pin 47 REFOUT. I am not sure how to proceed, since i dont have either schematic or PCB to see where those connections go. I would either need .sch file or a good picture of tracks of unpopulated PCB.

https://leafdriveblog.files.wordpres...-10-31-762.jpg

TNX

[ale0502]

Hi arber333,
I don´t have that board, but on AD2S1210 datasheet say that pin 47 is "Voltage Reference Output" and on the analog devices evaluation board "EVAL-AD2S1210SDZ" is not connected, only goes to a testpoint.
Paul surely going to help you.

Now I have a question for Paul and another forum members, I have my hardware controller finish and my dspic communication works good, there any way to disable failures? Because, I don´t have the desat fail conected and another thinks, and my controller protect the hardware triggering the alarm and dosent works.

thanks