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

[MPaulHolmes]

I found a significant error for the PI loop, but it only showed its ugly head in the PMSM case. The Leaf motor works SOOOO much better now.

[thingstodo]

Originally Posted by e*clipse

Paul, thingstodo -

Is the net current between the AC motor and the battery pack flowing into the battery at all times during regen? If not, it's more of "reverse torque" than pure regen - does it switch modes?

If so, (if it does reverse) what happens with the current near 0 rpm?

E*clipse

The data shows approximately where the energy that the AC controller is regenerating from the AC motor is not enough to run the AC controller, and the High voltage pack begins to use power again. Between 1100 and 1200 rpm. Below 1100 rpm the motor takes power.

First test

https://youtu.be/GWUgdRVXpCs

Second test

https://youtu.be/PQRFHKEAPIU

Log files 18 5, 18 6 plus spreadsheets .. all attached .. as a 2 zip files .. because they are too frigging big.

[thingstodo]

Update for Jan 18, Check AC voltage output from AC Controller

https://youtu.be/ShSbnuXRANk

Update for Jan 18, Max out Regen current

https://youtu.be/vNbh6GT2Jsw

[thingstodo]

Jan 31 update

I tried again to get over 360 AC Amps, with a freshly-charged Lead-acid pack.

Log file and spreadsheet attached.

https://youtu.be/GR2rcev1Mlo

[MPaulHolmes]

Is it just me, or was that freaking awesome? I'm surprised that there are no occasional overcurrent trips. Things seem to be pretty under control. Oh that just makes me so happy!

[WindyDrew]

I can't wait to get my leaf motor up and running. I'm excited. Seems like everything is going good on the test end.

[Astro]

Same here, except with a rewound industrial motor.
It is all sounding very positive.
My build is still a work in progress so i am in no hurry for Paul to ship my controller.
It is much more useful where it is letting Paul and thingstodo squash software bugs.
It also shows how solid the hardware design is that it has survived all the testing without failure.
Well done.

[mitsui]

Hello guys, I'm trying to build this board (thank you so much for making this open source Mr. Holmes, such kindness) but I have a couple of questions worrying me:
1.I have Lem La 100-p current sensors at hand and these things require +-15V supply voltage.If I connected these to the circuit with 5v and ground would they work like yours?(like 2.5V at 0A and ~5V at max current)
If not is it possible to make an external circuit that will make the sensor reading the same format with it?

2.Is it possible to replace 5x22uF MLCC ripple smoothing capacitors feeding bjts with single 100 uF electrolytic aluminum-tantalum ones with the polarity in mind or would reverse transients blow up these ones? If it is possible what were the reasons for choosing 60 pieces of relatively expensive capacitors?

and finally
3.If I supplied the dc bus voltage from a rectified high power 3 phase transformer with no ground connection and 24V from AC-DC converter fed with same grid would it cause a isolation & short circuit fault?

Would you enlighten about these issues? Sorry for being a pain in the neck

[WindyDrew]

Received my controller today from Paul. Plan on writing a instruction guide with pics as I put my race car together. Thanks

[thingstodo]

Originally Posted by WindyDrew

Received my controller today from Paul. Plan on writing a instruction guide with pics as I put my race car together. Thanks

AWESOME! If you would like someone to critique/comment on the instructions - I am available!

Paul - what do you say to an official release version number? Change the firmware from 1.00 to .. 1.1? 2.0? Make no other changes and post the source and executable, schematic files, etc on your web site?

Do you have a revision number for the instructions? Maybe 2.0?