WaveSculptor 22 Motor Drive User`s Manual 18 April 2012
Contents
1. 15 3 ON ROAD TESTING After meeting all the relevant regulations in your country for vehicle registration and safety checks you should be ready to drive your car out in the real world We suggest gradually building up your confidence in the new drive system with a series of tests at increasing speeds and power levels 23 of 35 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 16 APPENDIX A RECOMMENDED COMPONENT SOURCES Part Description Manufacturer Manufacturer Part Number Suggested Supplier Supplier Part Number 16 1 CAN CABLING amp LOW VOLTAGE CONNECTORS DeviceNet Cable per metre Lapp Cable 2170343 Farnell 161 7915 6 way MicroFit connector housing CAN connectors Molex 43025 0600 Digikey WM1785 ND 14 way MicroFit connector housing Motor Sense connector Molex 43025 1400 Digikey WM2489 ND MicroFit crimps 20 24 AWG Molex 43030 0007 Digikey WM1837 ND 16 2 HIGH POWER CABLING amp CONNECTORS Motor Temperature Sensor 100k 25 C NTC thermistor BethTherm 10KD6A3721 Farnell 970 7298 High power 16mm M6 bolt lug connections Cabac CAA 16 6 Local electrical supplier High power cabling 16mm high temp orange Tycab Australia ZDFX151102 OR Local electrical supplier 17 17 1 17 2 5 USER S MANUAL TRITIUM WaveSculptor2. This applies to most motor controllers but with DC motor systems where efficiency is much more variable the effect is not usually as noticeable So when reading this document and the datasheet make sure to note if the specification is talking about motor current or battery current They are very different quantities MOUNTING CHOOSING A LOCATION Careful attention should be paid to positioning the WaveSculptor correctly to ensure optimum performance The main criteria for choosing a good mounting location are environment heatsinking and cable positioning The WaveSculptor may be mounted in any orientation including upside down Tool access 2mm hex key is required at both ends of the motor controller to be able to remove the lid and make the high power bolt connections ENVIRONMENTAL The WaveSculptor is not rated to withstand water spray or drips Mount it in a dry location A good location will probably also have some ambient airflow to help with heatsinking HEATSINKING The WaveSculptor22 does not contain any internal fans or active cooling components For most uses external cooling will have to be provided Refer to the Cooling chapter later in this document for details 6 of 35 5 4 6 2 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 CABLE POSITIONING The WaveSculptor has been designed with all cables and connections to the device at the front edge to allow
3. Conduction loss Power loss W i i i i i i i i i j 0 10 20 30 40 50 60 70 80 90 100 Motor Current Arms Predicting Loss To allow solar racing teams to predict the WaveSculptor power loss both for heatsink calculations and for race strategy algorithms the following estimate of controller losses can be used Pros Ro Lot OL B V suas S og Vous where I is the output current of the controller in Arms V s is the bus voltage battery voltage of the controller Ra is the equivalent resistance of the entire controller a isthe linear component of the switching loss per unit of bus voltage B is the constant component of the switching loss per unit of bus voltage Cf eq is the equivalent capacitance frequency product of the entire controller 9 of 35 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 The table below gives the constants for WaveSculptor22 Constant WaveSculptor22 MOSFETs Ro 1 0800E 2 e 3 3450E 3 B 1 8153E 2 7 1 5625E 4 7 3 HEATSINK REQUIREMENTS Once the total motor controller loss can be calculated an expected motor current and duty cycle is required to be able to calculate the heatsinking requirements of the controller This will depend on such things as the mass of the vehicle rolling and aero resistance and expected speeds and accelerations The more accurately this information is known the more optimal the heatsink c
4. 2 long or a hydraulic tool with an appropriate crimp die set Step 6 Crimp the barrel of the crimp For the tool used in these photos it can be crimped three times along the length of the barrel A hydraulic tool may be similar A high volume tool will probably only require a single action Step 7 Heatshrink both ends of the orange cable with red or black heatshrink to indicate DC polarity Red and Black cable should be reserved for low voltage 12V wiring in the car Use other colour heatshrink for the motor phases 27 of 35 18 18 1 18 1 1 18 1 2 18 1 3 18 1 4 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 APPENDIX C CAN COMMUNICATIONS PROTOCOL OVERVIEW Hardware The CAN hardware interface used is compatible with the CAN 2 0B standard The supported bit rates bits per second are 1 Mbps 500 kbps default 250 kbps 125 kbps 100 kbps and 50 kbps Software The CAN protocol uses data frames for most communication Remote frames are also enabled The identifier field uses the standard frame definition length of 11 bits with identifiers Ox7FO to Ox7FF reserved for use by the WaveSculptor bootloader The bootloader will send a message with identifier Ox7F1 at 500kbit after a system reset All measurement data is transmitted using IEEE single precision 32 bit format IEEE 754 with most significant byte MSB sent first Start Identifi
5. 22 Motor Drive TRI88 004 ver 2 18 April 2012 APPENDIX B GUIDE TO SUCCESSFUL CRIMPING MOLEX MICROFIT 3 0 At the bare minimum use a quality hand crimp tool such as Molex part number 0638111000 available at a reasonable price from Digikey part WM9999 ND The tool must be shaped to fold the crimp ears around and down through the centre of the wire conductor bundle crimping with pliers or an automotive barrel type crimp tool will not give a satisfactory result Refer to the Molex Quality Crimping Handbook http www molex com pdm_docs ats TM 638000029 pdf Note the pictures in the Troubleshooting section for the visual differences between a good and a bad crimp For higher volumes or critical applications such as racing the extra expense of a dedicated MicroFit hand tool such as Molex part number 63819 0000 may be appropriate This tool is available from Digikey part WM9022 ND Be aware that this tool does provide far superior results compared to the generic crimp tool HIGH POWER BOLT LUGS It is important to crimp the high power connections properly so that they remain reliable and low resistance for a long time High power connections should not be soldered for vehicle applications as the solder wicks up inside the copper strands and creates a stress point which can fatigue and break due to the vibration present in a vehicle Follow the steps below for a successful crimp Step 1 Cut the cable square and ne
6. also available requiring more integration with the vehicle An example would be an aluminium plate laminated into the skin of the vehicle such that the outside is flush with the rest of the skin to avoid turbulence and having the motor controller fastened to the inside surface A plate of at least 2mm thick means that standard hex drive countersunk M4 screws can be used to fasten to the WaveSculptor and remain flush with the outside surface The size of this plate can be chosen to give the required thermal resistance with heat rejected directly to ambient air outside flowing past at 10 of 35 7 3 2 7 4 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 vehicle speed A solution like this can provide a very low mass cooling method Note that the above calculations are the minimum requirement Allowance should be made for higher than expected ambient temperatures higher than expected power use and an amount of thermal headroom before the motor controller s thermal protection activates Short Term Peak Power Use As a further example say that your vehicle uses a 160V DC bus and requires 80A motor current for two minutes to do a fast qualifying time The graph above shows that the motor controller will be producing around 120W of loss at this power level Ambient temperature is high at 40 C and the maximum cold plate temperature specified in the datasheet is 70 C please check the data
7. of view Driver Controls Battery Management WaveSculptor CAN High Termination CAN Low Resistor The WaveSculptor motor controller uses the CAN bus to receive commands and transmit telemetry as well as to provide low voltage DC power to operate the controller electronics Therefore a basic system consists of three major components 1 WaveSculptor motor controller 2 Driver controls interface to pedals switches amp gauges 3 Power supply nominally 12V DC to operate the system Other components can also be added to the network Items typically found in a solar electric vehicle would include 4 LCD and other driver information displays 5 Battery management system 6 Multiple motor controllers 7 Datalogging and RF telemetry CAN WIRING The CAN data lines CAN H and CAN L must be implemented with twisted pair wire for proper data integrity The wire should have a characteristic impedance of 120 ohms Power should also be provided along the CAN cable ideally with another twisted pair to minimise noise pickup An overall shield can also be advantageous From a performance perspective the optimal choice of cable is 7mm Devicenet CANbus thin cable with 24AWG data 22AWG power twisted pairs and a braided shield Using this cable will result in a robust installation 12 of 35 8 3 8 4 8 5 8 6 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 A
8. 14 3 15 15 1 15 2 15 3 16 16 1 16 2 17 17 1 17 2 18 18 1 18 2 18 3 18 4 18 5 19 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 Connector PINOUti x hice de cae Aik shi ave wee ech eens eee 16 Motor Position Sense vaio entidad o E a ons dali alent latas 17 Motor Temperature SeSe siui ueraia nese nese ANA ENAN E eai Aa CEEA rare arenas 17 High Power ConNectiONS omcconoccnnoconncconnccnnncranornnnornnncrnnnnnoranannannnrnnnss 17 Cali AA A A dasetav dee 18 Motor Inductance miii ielvel ves ddes cee sey E Tiia eevee 18 High Power COnnections cccccececceeeenee eee ee een eeeae eee aa essa a eeeaaaeesaa ease esaeeseeeaeeaeeaae 18 TOSTADO eo asa webb E eae 19 Precharge stance A AAA 19 FUSIL dioss 19 VISO cra ii cae AA pol eae ean ee ETa 19 Motor Setup amp TestiNQ occcoocccnnnconnnconncnnnnconancnnanenannrnncrnancrrnannnnnrananos 20 Low Power Seti A A 20 PhasorSense BLDC MOTOTS ariran aans enia Ee aE Eae aa E ai ENEE ENAT AEA 20 Low Power Testing PC ConNtrOl occoonccconcnnoncnnoncnnnnnconononnnnnnnnnarononnnronranennrnnnnraraninns 20 Low Power Testing Driver Controls Hard WarFe oooonccccncccnncccnnncncnncncnnncncnnricnninnnnns 21 High Power TestiNQ coococonccconoccnnnconnnronncrnnncrnnnconnnrannnrnnncrnnanrnanrrnnaranos 21 COMENSAL encased 21 PC Software Control peiura a ia ia bas 22 Drivel CONTO Sai Ii 22 DiViNo IRSA E 22 WARNINGS 25 ai IT E
9. 8 April 2012 19 REVISION RECORD REV DATE CHANGE 1 2 December 2010 Document creation JMK 2 18 April 2012 Clarified broadcast and reset messages Clarified error descriptions AKR 35 of 35
10. AA AE O ia 22 o A E E net wun cenaend TA EET 22 ON ROA ESOO ii A deed sed agen td eance ade teeta dente 23 Appendix A Recommended Component SOurces cccssssseeceeeeeeeeeeeenaas 24 CAN cabling amp Low Voltage CONN Ctors cece cee eee eect eee eee eee eee ane ne tenet need 24 High power cabling amp CONNECtoOFS ccooccccnccccnncnnoncncnnccnnnncnnnnrnnnnnnnnnnrnonnraconaninannncnns 24 Appendix B Guide to Successful Crimping cceeseeeeeeeeeeeeeeeeeeeeeeeaae 25 Molex MICrOFIt Dia A cadets doe NENEA EAA EAEE A a A 25 High Power Bolt LUQS iciiiinci dd dana 25 Appendix C CAN Communications Protocol ccomocccccccnonnnnncnnannnnnnanans 28 OU orde 28 Drive Command Sian anona de Aa ees 29 Drive Command EXAM E S e A A Eaa A a N E Da A EE E AA EEN 30 Motor Controller Broadcast MessagesS ooocccoccccnncncnncnnnnonnnnncnnnnrncnnannnnnrannncnnnnannnons 30 Configuration COMMANOS ccocccconcccnnccnnnocnnnncnnnnonnnnonnnnnrncnnrnrnnrnrnnnnrnnronrrnnrrnrenannnes 34 Revision RecOrd oconccconccconnccnnncnnnnrnnncrnancrnnnrnnnnrnnnnnnrrnnnnnnnrranannaneranannss 35 3 of 35 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 1 INTRODUCTION This document describes the operation connections mounting communications cooling and how to get started with and use the Tritium WaveSculptor 22 Motor Controller This product processes and uses potentially lethal voltages and currents Do not p
11. Motor Controller Base Address 11 Interval 1 second Variable Bits Type Description IPM Heat sink Temp 63 32 C Internal temperature of Heat sink in main IPM Motor Temp 31 0 C Internal temperature of the motor IPM DSP Board Temperature Measurement ID Motor Controller Base Address 12 Interval 1 second Variable Bits Type Description Reserved 63 32 DSP Board Temp 31 0 C Temperature of the DSP board IPM RESERVED ID Motor Controller Base Address 13 Interval 1 second Variable Bits Type Description Reserved 63 32 Reserved 31 0 Odometer amp Bus AmpHours Measurement ID Motor Controller Base Address 14 Interval 1 second Variable Bits Type Description DC Bus AmpHours 63 32 Ah Charge flow into the controller DC bus from the time of reset Odometer 31 0 m Distance the vehicle has travelled since reset Slip Speed Measurement ID Motor Controller Base Address 23 Interval 200 ms Variable Bits Type Description Slip Speed 63 32 Hz Slip speed when driving an induction motor Reserved 31 0 C CONFIGURATION COMMANDS Commands to configure and calibrate the motor controller are also present Contact Tritium for a full specification if necessary 34 of 35 USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 5 TRITIUM 1
12. USER S MANUAL TRI88 004 ver 2 18 April 2012 WaveSculptor 22 Motor Drive User s Manual 18 April 2012 2012 Tritium Pty Ltd Brisbane Australia http www tritium com au 1 of 35 Bb Y N Pp 4 1 5 1 5 2 5 3 5 4 6 1 6 2 7 1 7 2 7 3 7 4 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 8 10 9 1 9 2 9 3 10 11 11 1 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 TABLE OF CONTENTS INTTOAUCtION ccconnoconnnconnncnnncrnnnrnnnnrnnnnrnnnnrnnncnnnnrnnnnrnnnnrnnncnnnnrananennacananss 4 Getting Started comocnonoccnnnnonnnconncnnnncnnnnrnnnnrnnnnrnnnrnnnnrnnnnrnnnnrnancnnnnnnnanna 5 Unpacking amp PreparatiON omooconcononncconnconnnconnnranncrnnncnnnnrannnrannnranannnannasa 5 Controller FUNCtiON ccconocconcccnnnconnccnnnccnnncrnnorannnnrrnnnnnnnrranannnnrrnnanannnenna 6 OVA oan tied nau cod A aed ae 6 A Note on Motor and Battery CuUrTenNtS ooocccoccccnccccnncnnonoconnncnnnnrnnnncnnnnnnnnnnronnananenns 6 MOUNtINQ ccconncconnnconnccnnnncnnncnnnnrannnrnnncrnnnrrnnnrnnnnrnnncrnnnrannrrnnnrnnannrannananss 6 Choosing A LocatioN ecrane ae iina aaa a aina AET EAA aa Ataa 6 ENVIO Metu A aa eae eae 6 HeatSiNki otr id ada od ld 6 Cable POSITIONING 3 A a 7 Accessing the Controller ooocconcccnncconnnconnoranononanrannnrnnnornnorananranncrananaanes 7 Sis 218 O TOO O 7 INSPECTION COVER arco a a EA A ena seme cea 7 COOliNGQ ccocconnccnnnconnncnnncnnnncnnnncnnnnrn
13. an be Two scenarios are outlined below the continuous use case and the short term peak power case 7 3 1 Continuous Use Say your vehicle uses a 160V DC bus and requires 30A motor current continuously to maintain cruising speed on the highway The ambient temperature is high at 40 C and the maximum cold plate temperature specified in the datasheet is 70 C please check the datasheet for the correct value The graph above shows that at this voltage and current the motor controller will be producing around 35W of loss To maintain the cold plate of the motor controller at or below the specified temperature a cooling solution with a total thermal resistance to ambient of at least 70 40 35W 0 85 C W is required Assuming 0 05 C W for thermal grease between the cold plate and heatsink this means that a heatsink with a thermal resistance of at least 0 80 C W is required This could be provided using an off the shelf comb section extruded aluminium heatsink with base dimensions approximately the same as the cold plate and a 40mm fin depth weighing around 1 5kg using convection airflow only However significant weight savings are possible by using a smaller fin depth and force cooling with a fan Careful placement of the motor controller in the vehicle so that there is ambient airflow could mean that the fan is not required to run continuously therefore saving considerable power Further improved alternatives are
14. atly with no loose strands The best tool to use is a parrot beak cable cutter available at electricians supply stores 25 of 35 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 Step 2 Strip the insulation to the correct distance for the crimp you are using When inserted into the crimp the insulation should touch the barrel of the crimp with no large gaps and you should be able to see the ends of the copper strands through the inspection hole next to the lug of the crimp Step 3 Put a small blob 6mm or 1 4 diameter of electrical jointing compound into the barrel of the crimp This compound prevents oxygen and moisture from getting into the crimp later on and keeps it in good condition for a long time Step 4 Insert the wire into the crimp Hold your finger over the inspection hole to stop the jointing compound coming out therefore forcing it up between the wire strands Push the wire all the way into the crimp barrel so that the wire insulation touches the end of the barrel with no large gaps 26 of 35 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 Step 5 Set your hex crimp tool to the same size as the crimp lug In the example photos here we have used 35mm cable lugs and crimp tool To crimp with the proper force you will need either a bolt cutter type crimp tool as shown in the photo above with handles around 600mm
15. ction happens when brake pedal is pushed Selecting Neutral on the driver controls makes the car coast to a stop Turning off the key makes the car coast to a stop 14 HIGH POWER TESTING 14 1 CONNECTIONS Make sure your precharge circuit contactors and fusing are in place Check the 21 of 35 14 2 14 3 15 15 1 15 2 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 polarity of the supply cables to the WaveSculptor Take all appropriate safety precautions when working on the HV circuitry Depending on the legislation in your country you may require a licensed electrician to work on the high voltage parts of the system Making sure that all contactors are off in the safe state make the bolt connections to the DC POS and DC NEG terminals of the WaveSculptor PC SOFTWARE CONTROL Move the CAN cable and termination resistor from the hardware driver controls and reconnect it to the CAN Ethernet bridge Run the PC software Run through the same checks as outlined in the previous 24V low voltage testing section DRIVER CONTROLS Reconnect the CAN cable and termination resistor to the hardware driver controls Run through the same checks as listed above in the 24V driver controls hardware testing Test at least the following functionality Driving forwards Car coasts to a stop when accelerator pedal is lifted Driving in reverse Car coasts to a stop when acce
16. cts a DC supply on the CAN bus connection of between 9 and 15V 13 8V from a small lead acid battery charged by your vehicle s DC DC converter is ideal Refer to each device s datasheet for CAN bus current consumption values and make sure that the total is less than the rating on your chosen cable Tritium s EV Driver Controls product provides a means to connect power from the battery into the CAN bus to power other devices on the network It can switch power to the CAN bus based on the state of the ignition key DRIVER CONTROLS Tritium can provide a CAN bus driver controls device This interfaces to pedals and switches and provides the messages required to operate a WaveSculptor controller The firmware for this device is open source allowing it to be easily customized to suit your vehicle As the communications specification is open the WaveSculptor can also be operated from custom driver controls hardware specific to your vehicle or from a Windows PC running either the provided Tritium software or custom software of your choice Please refer to the driver controls datasheet and user s manual on our website for further details SYSTEM EXPANSION Tritium can provide a CAN bus LCD display capable of showing up to four different telemetry values one at a time on a 3 5 digit sunlight readable screen Multiple displays can be used if desired MULTIPLE MOTORS Multiple motors controllers are accommodated easily with the CAN bus sys
17. dge to power up both the Ethernet Bridge and the WaveSculptor control electronics If everything is connected correctly you should see telemetry values appearing and updating several times per second in the PC software window DRIVER CONTROLS Wire and install the hardware driver controls as described in the Driver Controls User s Manual Test the driver controls as described in the User s Manual 15 of 35 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 11 MOTOR SENSE CONNECTIONS 11 1 OVERVIEW The WaveSculptor22 requires a position sensor to be able to control the motor It can also measure the temperature of the motor and gradually reduce the motor current if this temperature rises towards a user programmable threshold Since there are a large variety of possible combinations of position and temperature sensors Tritium has implemented the interface on the motor controller in a generic manner Small adapter circuit boards suitable for mounting directly inside the motor terminal box are used to adapt the sensors in that motor to the interface required by the WaveSculptor22 This also provides a robust signalling mechanism isolated differential for the longest length of cable possible The WaveSculptor provides isolated regulated 5V and 12V DC to power the external adapter Refer to the datasheet for specifications on these supplies The WaveSculptor provides four isolated differ
18. e both drive and regenerative braking to do so Use this mode to regeneratively brake to a halt by setting current to your desired braking force and setting velocity to zero MOTOR CONTROLLER BROADCAST MESSAGES Data frames containing telemetry values are periodically broadcast onto the bus by the WaveSculptor Broadcast of these values can be individually enabled and disabled via the Windows configuration software Any of these telemetry values can be requested at any time no matter if enabled or disabled by sending the appropriate RTR packet on the CAN bus For example with a WaveSculptor22 configured at base address 0x400 your device should send an empty packet onto the CAN bus with an ID of 0x402 and the RTR bit set The WaveSculptor22 will reply immediately with a packet from ID 0x402 containing the latest bus voltage and current readings 30 of 35 18 4 1 18 4 2 5 TRITIUM Identification Information USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 ID Motor Controller Base Address 0 Interval 1 second Variable Bits Type Description Serial Number 63 32 Uint32 Device serial number allocated at manufacture Tritium ID 31 0 char 4 T088 stored as a string msg 0 T msg 1 0 The periodic broadcast of this message cannot be disabled It is needed to find the motor controller on the network if the base address is lost or mis configured Sta
19. e software in the WaveSculptor DRIVE COMMAND EXAMPLES Ignoring the added complexity of bus and thermal limiting the WaveSculptor operates such that it will use the maximum available current torque to try and achieve the desired velocity This is true for both accelerating and decelerating operation i e the WaveSculptor will automatically regneratively brake if a setpoint velocity is provided that is slower than the current speed Two main drive modes will be used in a normal vehicle setup torque control and velocity cruise control A conventional vehicle runs in torque control mode where the position of the accelerator gas pedal controls the amount of torque produced by the engine In an electric system the motor current is proportional to torque and can be easily regulated as can the velocity To run the motor in torque control mode set the velocity to an unobtainable value such as 20000rpm Set the current to a value that is proportional to your accelerator pedal position If you wish to drive in reverse set the velocity to 20000rpm The motor will operate the same as a normal car and will coast down to a stop if the driver removes their foot from the pedal To run the motor in velocity cruise control mode set the current to your maximum desired acceleration force usually 100 and set the velocity to the desired speed The WaveSculptor will use the setpoint current to keep the vehicle at the setpoint speed and will us
20. e stud e Use a torque wrench to tighten the nut to 10Nm 7 5 ft lbs CABLE The cable used to connect to the high power terminals must be rated for the full DC battery voltage as a minimum The current rating of the cable will depend on your expected load and duty cycle for your driving habits in your vehicle The WaveSculptor bolt terminal area is designed to accept up to 16mm cable with an outside diameter of up to 10mm Tritium suggests the use of at least 110 C rated PVC cable note that standard PVC is 90 C rated to allow a longer duration of peak power output without exceeding the cable temperature rating this may allow the use of a smaller cross section cable saving some weight The cable should have orange coloured insulation This is required by the NCOP14 standard for EV conversions in Australia but is a good idea in any case This is what is used in the Prius and other hybrid vehicles and emergency response personnel are trained to not cut through orange cables Use a short piece of red or black insulation at the ends of the orange cable to indicate polarity Use of flexible cable with a high number of fine strands is advised to help with cable routing and reduce strain and fatigue on the terminations Tritium recommends using ZDFX double insulated 0 6 1kV 110 C rated cable from Tycab Australia which is made with a high number of 0 2mm strands resulting in a flexible cable It is available in orange insulation Sim
21. ential inputs for information from the motor Three of these are routed to timer capture peripherals in the main processor and are normally used for three Hall effect position sensors The fourth channel is routed to a UART serial receiver and expects digital data Depending on the adapter board this data may contain temperature position velocity or a combination of all three A brief datasheet for each adapter option is available on the Tritium website If your motor requires an adapter that is not yet available please contact Tritium to enquire about development as new adapters are simple and low cost to design 11 2 CONNECTOR PINOUT The connector used on the WaveSculptor22 for motor sense signals is a 14 way 3mm pitch Molex MicroFit connector The pinout is shown below as viewed from the wire side as you would look at it while inserting crimps Please refer to Appendix B for an overview of correct crimping technique as poor crimps will cause unreliable operation H1 A H2 B SERIAL SHIELD CON KCIRTOICINID RX RX RX H3 1 RX BROWN GREEN WHITE RED YELLOW The wiring for this connector should be implemented with twisted pairs as the signal inputs are differential Tritium recommends using Belden 9506 type cable shielded 6 pair for this connection with suggested cable colours shown above 16 of 35 11 3 11 4 12 5 TRITIUM USER S MANUAL WaveSculptor 22 Moto
22. er Control Data Field CRC Ack End Figure 1 CAN data frame Identifier The identifier field has been split into two sections for Tritium devices Bits 10 5 contain the device identifier and bits 4 0 contains the message identifier associated with that device as shown in Figure 2 This means that there is a maximum of 63 Tritium device that can be on the CAN bus at any one time The 64th location is reserved for the bootloader Each Tritium device can have 31 different types of messages The first message identifier is used by the device identification message Two device slots could be used if more messages per device were required however this has not been required yet The term Base Address is used instead of Device Identifier in the Windows configuration program Base Address is simply the Device Identifier multiplied by 32 Using this term makes it more obvious what range of CAN identifiers have been used As an example there may be a Tritium driver controls at base address 0x400 a left wheel WaveSculptor motor controller at 0x420 and a right wheel WaveSculptor motor controller at 0x440 So address range 0x400 0x45F would be used by this Tritium system 10 54 0 DEVICE IDENTIFIER MESSAGE IDENTIFIER Figure 2 CAN device identifier address format Data Field The data field in all frames is fixed at 8 bytes 64 bits which allows space for two IEEE 754 32 bit floating point variables as shown in Figure 3 The data fie
23. ero the motor current then zero the velocity If using batteries now test regen braking Set velocity to 100 Gradually increase motor current Now with the motor spinning set motor current to around 10 Zero the velocity The motor will regen brake to a halt Since it does not have the mass of a vehicle to damp the system it may then oscillate slightly forwards and backwards this should be relatively minimal if the vehicle mass was set to 30kg as outlined in the previous section Zero the motor current when near zero speed to stop this happening 13 4 LOW POWER TESTING DRIVER CONTROLS HARDWARE Remove the CAN cable and termination resistor from the CAN Ethernet bridge and connect them both to the EV Driver Controls hardware Provide 12V power to the driver controls Go through the startup sequence as described in the Driver Controls User s Manual Depending on the exact firmware you have this will usually involve turning the key to the start position and selecting forward gear in the driver controls Use the accelerator gas pedal to run the motor Complete the following checks Driving forwards Car coasts to a stop when accelerator pedal is lifted Driving in reverse Car coasts to a stop when accelerator pedal is lifted If your driver controls is configured to use regen it works correctly in forwards If your driver controls is configured to use regen it works correctly in reverse Appropriate a
24. everything in the system is working corrrectly A suitable low voltage supply is a pair of 12V batteries in series Make sure to fuse them correctly and use your precharge circuit A power supply with current limiting is the best option if one is available Run the PC software and provide 12V along the CAN cable to power up the motor controller electronics You should see telemetry values updating on the PC Connect the 24V to the high power section of the motor controller You should see the reported battery voltage on the PC show the correct value PHASORSENSE BLDC MOTORS If you are using a BLDC or other permanent magnet motor refer to the software user s manual for the procedure to run PhasorSense This routine identifies the relationship between motor phases and hall position sensors Next run the parameter extraction routine which calculates motor parameters Save the results into one of the ten available motor configuration slots In the general configuration screen set this motor slot as the Active Motor For bench testing with an unloaded motor set the vehicle mass in the config screen to 30kg Using the actual vehicle mass when running with an unloaded motor will cause the velocity control loop to overshoot and oscillate around the setpoint LOW POWER TESTING PC CONTROL This test will check that the motor spins and is configured correctly Open the controls screen in the PC software View Controls There a
25. guration utility Motor Drive Command ID Driver Controls Base Address 1 Variable Bits Units Description Motor Current 63 32 Desired motor current set point as a percentage of maximum current setting Motor Velocity 31 0 rpm Desired motor velocity set point in rom The WaveSculptor motor controller must receive a Motor Drive Command frame at least once every 250ms If this does not occur the controller will assume that communications have failed and will halt all motor control functions placing the system into neutral and coasting until another valid command is received Motor Power Command ID Driver Controls Base Address 2 Variable Bits Units Description Bus Current 63 32 Desired set point of current drawn from the bus by the controller as a percentage of absolute bus current limit Reserved 31 0 29 of 35 18 2 3 18 3 18 4 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 Reset Command ID Driver Controls Base Address 3 LEGACY Variable Bits Units Description Unused 63 32 Unused 31 0 Legacy reset method Avoid in new implementations ID Motor Controller Base Address 25 Variable Bits Units Description 0x00535754 63 32 Chars TWS 0x45534552 31 0 Chars RESE Send a command from this address to reset th
26. hicle performance HV ISOLATION The WaveSculptor has an isolation barrier rated to 1kV continuously between the CAN bus the DC bus and the Motor position connection This helps minimise damage in the event of a fault and also allows safe connection of the high voltage battery pack Tritium recommends that the CAN bus be operated at the system ground potential with CAN Ground connected to the vehicle chassis at some point in your system The battery ground high voltage DC connections and motor phases should be isolated from the vehicle chassis This is so that a single fault anywhere in the high voltage system will not result in a high voltage potential being present between any wiring and the chassis of the vehicle Please refer to any relevant regulations governing this type of connection 19 of 35 13 13 1 13 2 13 3 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 MOTOR SETUP amp TESTING LOW POWER SETUP At this stage put the car on a vehicle lift or use a secure method to lift the drive wheels from the ground A low voltage supply should be connected to perform the next stage of testing Note that if it is necessary to run these tests again later they may be run from the high voltage pack it is not necessary to disconnect everything and use a low voltage setup At this point however the low voltage supply should be used as a safer option until it is known that
27. ilar cable will be available from alternative suppliers in other countries MOTOR INDUCTANCE The WaveSculptor requires a minimum of 50uH inductance phase neutral per phase to operate correctly Please ensure that sufficient external inductance has been added if your motor does not have at least this amount of inductance already External inductors will most likely only be required on ultra high efficiency ironless BLDC type motors These external inductors must be rated to the full motor current and have windings insulated to the full DC bus voltage HIGH POWER CONNECTIONS The positions of the various connections are shown on the front panel of the controller and also labelled next to the bolt terminal on the PCB Make certain that the DC and DC connections are the correct polarity 18 of 35 12 4 12 5 12 6 12 7 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 TESTING At this point do not connect the other end of the high power DC NEG and DC POS cables to your precharge circuit or batteries You will need to connect them to a low voltage supply of power for initial testing which is detailed in the Motor Setup amp Testing section of this document PRECHARGE The WaveSculptor22 has 270uF of extremely low impedance capacitance across the DC bus input connections An external precharge circuit is mandatory When not driving a motor the WaveSculptor draws minimal p
28. is summary considers the four major switching loss types off switching on switching reverse recovery and capacitive switching loss All of these losses have a very strong relationship to input voltage and output current and only a weak relationship via ripple current to output voltage This is an extremely useful observation for those wanting to produce a simple model of the losses in a MOSFET based motor controller Test Methodology To produce the efficiency curves in the datasheet and the modelling information in this document the switching losses in the WaveSculptor were measured directly by analysing the current and voltage switching waveforms Conduction losses were simply derived from the measured phase to phase resistance of the WaveSculptor A high bandwidth system was used to acquire the switching waveforms and data showing switching loss versus load current was then extracted Semiconductor parameters were then calculated from this data producing best fit curves and hence functions that can be used to create an efficiency map over the entire operating area of the controller 8 of 35 7 2 3 7 2 4 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 Power Loss The power loss of the WaveScuptor22 operating with 160V DC bus voltage is shown in the diagram below 180 por es Measured loss Capacitive switching loss 160 Switching loss inc RR
29. lable on the WaveSculptor22 page on the Tritium website for dimensions and details Use a thin layer of thermal grease or conformable thermal gap filler pad to fill any air gaps between the WaveSculptor22 cold plate and your heatsink and provide the best thermal path between the two This material is not required to be electrically insulating Attach the heatsink to the cold plate using eight M4 screws threading into the tapped inserts in the motor controller base making certain to note the maximum screw depth specified in the datasheet Exceeding this depth will force the screw into internal components of the motor controller almost certainly damaging it 11 of 35 8 2 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 CAN BUS AND LOW VOLTAGE CAN NETWORK TOPOLOGY The CAN bus is structured as a linear network with short stubs branching from T connectors on the main bus backbone to each device The CAN bus data lines must be terminated at each end of the main bus with 120 ohm resistors between the CAN H and CAN L signals In the range of Tritium EV products including the WaveSculptor 22 EV Driver Controls and BMS Pack Master the CAN connections are implemented with an in and an out connector therefore placing the T on the device resulting in a very short fixed length stub on the circuit board of each device This is ideal from a signal integrity and network performance point
30. ld is sent and expected to be received least significant byte first This allows a direct overlay of a float 2 array and char 8 array on a little endian processor such as an Intel x86 the TI DSP in the WaveSculptor or the MSP430 micro in the driver controls product 28 of 35 18 1 5 18 2 18 2 1 18 2 2 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 High float Low float s eeeeeeee mmmmmmmmmmmmmmmmmmmmmm s eeeeeeee mmmmmmmmmmmmmmmmmmmmmm 63 62 55 54 32 31 30 23 22 0 Figure 3 Format of the data field in a data frame Units Please note that variables described in the following packets with units of percent should be sent with a minimum floating point value of 0 0 and a maximum value of 1 0 Do not send 100 0 as the maximum value DRIVE COMMANDS These are data frames broadcast from the driver controls to any listening motor controller These commands contain desired set points for the control software to operate the controller The commands are sent as required however there is a maximum permissible delay between consecutive Motor Drive commands The identifier of a received command will contain the base address of the device from which the message was sent and a message identifier offset The base address of the sending device is a preset value stored in internal memory which can be set during initial configuration of the motor controller using the confi
31. lerator pedal is lifted Appropriate action happens when brake pedal is pushed If your driver controls is configured to use regen it works correctly in forwards If your driver controls is configured to use regen it works correctly in reverse Selecting Neutral on the driver controls makes the car coast to a stop Turning off the key makes the car coast to a stop DRIVING WARNINGS Perform the following tests in a location off public roads in an area free of obstructions Take all appropriate safety precautions when performing this testing Using the Windows configuration software set the vehicle mass to the actual mass of the vehicle so that the velocity control loop will be tuned optimally PROCEDURE Perform the same checks that were performed with the vehicle off the ground Driving forwards Car coasts to a stop when accelerator pedal is lifted Driving in reverse Car coasts to a stop when accelerator pedal is lifted 22 of 35 USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 5 TRITIUM Appropriate action happens when brake pedal is pushed If your driver controls is configured to use regen it works correctly in forwards If your driver controls is configured to use regen it works correctly in reverse Selecting Neutral on the driver controls makes the car coast to a stop Turning off the key makes the car coast to a stop
32. nnnrnnnrrnnnrnnnnrnnnrnnnrnnnnrnnnnrnnncananannnrnnnss 8 OVA da A te eect sede ida ne eee 8 EMIGIONGY iii font aod teh niet ea biota ie es 8 Heatsink Requirements ita DA etc 10 Mechanical interface aseran enna inni nTa aAA EAA aE AKEE EEEE i 11 CAN Bus and LOW Voltage ococonooconcccnnnconanconnnrnnncnnnnnnnrrnnnnnncrnnnannannnss 12 CAN Network TopolOgQy ccooccccoccccnncccnncnconaccnnncnnnncncnnonnnnnnnnnncnnnnrnnonnnrnnnrnnnnrncnnrncnnes 12 CAN Wii naaa 12 CAN Connector ad dla 13 CAN SH A ia 13 CAN Terminator de A iia 13 COMMUNICATIONS aci AA 13 Power SUP DPI Vicios ada ie o idad da ca tb 14 Driver CONTO Sutra a le a 14 System EXPANSION viscose wats ts A At eevee tae 14 Multiple Motorsy icciceiciseiiicg chien na n dese aa 14 PC SOftWaFe oomccconnncononcnnncnnnocannnrnnnnrnnnnrnnnrnnnnrnnnnrnnncrnnnrnnnrnnnnanerannanass 15 Ethernet Bridge Installation cceceeeeceee eee nets etree eee ede eee eee ee anes eee eee een eeaee 15 PE SOTMWa neice A AA 15 Low Voltage CAN BUS TesStiNQ ooccccoccccoccccnncccnncnnnnacnnnncnconannnnrnncnnncnncnnnrcnranncnnnnns 15 Driver CONtrOlS conccconccconnccnnnconnoronnnrnnncrnnnrnnnnrnnnnrnnncrnnsrrnnnrnanaranneranass 15 Motor Sense CONNectiONS omcoconocconocnnnnconancnnnnconnnanancrrnnnnnnnrrnnnnannnrnnnss 16 OVGIVIGW iA esses A eee ats Betts Ret erie eae 16 2 of 35 11 2 11 3 11 4 12 12 1 12 2 12 3 12 4 12 5 12 6 12 7 13 13 1 13 2 13 3 13 4 14 14 1 14 2
33. ontroller Velocity Measurement ID Motor Controller Base Address 3 Interval 200 ms Variable Bits Units Description Vehicle Velocity 63 32 m s Vehicle velocity in metres second Motor Velocity 31 0 rem Motor angular frequency in revolutions per minute Phase Current Measurement ID Motor Controller Base Address 4 Interval 200 ms Variable Bits Units Description Phase C Current 63 32 Arms RMS current in motor Phase C Phase B Current 31 0 Arms RMS current in motor Phase B While the motor is rotating at speed these two currents should be equal At extremely low commutation speeds these two currents will only match in one third of the motor position the other two thirds will involve current also flowing in Phase A Motor Voltage Vector Measurement ID Motor Controller Base Address 5 Interval 200 ms Variable Bits Units Description Vd 63 32 V Real component of the applied non rotating voltage vector to the motor Vq 31 0 V Imaginary component of the applied non rotating voltage vector to the motor 32 of 35 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 18 4 7 Motor Current Vector Measurement ID Motor Controller Base Address 6 Interval 200 ms Variable Bits Type Description ld 63 32 A Real component of the applied non rotating current vector to the motor This vector rep
34. ower from the DC bus with only a high value discharge resistor to bleed charge Therefore careful attention should be given when working on the controller to ensure that the capacitors have been discharged first Note that these capacitors hold around 3 Joules of energy and take around one minute to discharge to safe levels Tritium can provide a circuit to implement the precharge function as part of our Pack Master BMS system Please refer to the product webpage for more information There are a variety of other ways to implement precharge but many do not automatically check for faults and may overheat themselves in the event of a problem FUSING At least one appropriately rated fuse must be installed in the high voltage DC circuit This fuse must be rated to the highest expected DC voltage AC rated fuses are not appropriate unless they have a DC rating as well Choosing the current rating of the fuse depends on your expected load the maximum fault current in the battery system duration of loads cable sizes and several other factors It is beyond the scope of this document to detail fuse selection for your vehicle Note that the WaveSculptor can be programmed to limit the current it draws from the DC bus connection which may simplify fuse contactor and wiring selection However this will also have the effect of limiting total system power throughput so be aware that when setting it to less than 100 that you may compromise your ve
35. pril 2012 CAN CONNECTOR The connector used on the WaveSculptor22 and other Tritium devices is a 6 way 3mm pitch Molex MicroFit connector The pinout is shown below as viewed from the wire side as you would look at it while inserting crimps The colours shown match those in the standard DeviceNet CAN cabling pairs Please refer to Appendix B for an overview of correct crimping technique as poor crimps will cause unreliable operation BARE BLUE WHITE SHIELD GROUND CAN L CAN H SHIELD GROUND 12V BARE BLACK RED CAN SHIELDING If the recommended braided shield is used in the cable then terminate it to the SHIELD pin lower left corner on the connector on both CAN IN and CAN OUT connectors on each device On one device only in the network instead of using the SHIELD pin terminate the shield to the SHIELD GROUND pin upper left corner on the connector on both CAN IN and CAN OUT connectors to ground the shield for the entire network at this single point The usual place to do this is where power is fed into the network typically at Tritium s EV Driver Controls product CAN TERMINATION To implement the required 120 Ohm termination resistor at each end of the CAN bus plug a connector into the unused CAN connector on the last device at each end of the network with a resistor crimped into the appropriate locations Leave the power ground and shield pins unconnec
36. r Drive TRI88 004 ver 2 18 April 2012 MOTOR POSITION SENSE For operating Brushless DC BLDC and Permanent Magnet Synchronous PMSM type motors the WaveSculptor requires three motor position sensing inputs commonly provided using Hall effect switches embedded in the motor Please note that the relation between each Hall effect input and a motor output phase as well as the polarity of the Hall effect input signal does not matter The WaveSculptor will detect these relationships when running its initial setup and configuration routine PhasorSense The only requirement for these signals is that they have a fixed alignment ideally a 0 offset with the zero crossing point of the back EMF waveform of the motor and that the signals are offset from each other by 120 This is where most motors will be configured by default Use an oscilloscope to check that this angle is close to 0 for your motor MOTOR TEMPERATURE SENSE Tritium s motor adapters are currently available for use with NTC thermistor and Pt100 temperature sensor elements Variations are possible to accommodate thermocouple and LM35 type semiconductor sensors also HIGH POWER CONNECTIONS It is important to correctly terminate the high power wiring for successful long term operation of the controller DC battery and AC motor phase connections should be crimped to bolt lug crimp terminals The bolts in the WaveSculptor22 have a metric M6 thread so use a lug designed for
37. re three sliders setting Motor Current Motor Velocity and Bus battery current respectively The motor controller will use up to whatever motor current you have set to try and achieve the requested velocity The motor current will be limited if the battery current reaches the bus current setpoint If using batteries as the power source regenerative braking regen can also be tested Do NOT test regen braking if using a power supply for the 24V source as you will force current back into the supply and damage it The motor controller will regen if the velocity is set to a lower speed than the motor is actually moving and motor current is above zero To stop without regen braking 1 Zero the motor current then 2 Zero the velocity 20 of 35 USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 5 TRITIUM To stop with regen braking 1 Set motor current to your desired regen current then 2 Zero the velocity Now that the motor is configured correctly set the Bus Current to 100 if it is not already Change the Velocity slider to around 10 Now gradually increase the Motor Current slider and the motor should smoothly accelerate to a moderate speed Zero the motor current then zero the velocity and the motor should smoothly coast to a stop Now set the velocity slider to 100 Once again gradually increase the motor current The motor should smoothly accelerate to a faster speed than before Z
38. resents the field current of the motor Iq 31 0 A Imaginary component of the applied non rotating current vector to the motor This current produces torque in the motor and should be in phase with the back EMF of the motor 18 4 8 Motor BackEMF Measurement Prediction ID Motor Controller Base Address 7 Interval 200 ms Variable Bits Type Description BEMFd 63 32 V By definition this value is always OV BEMFq 31 0 V The peak of the phase to neutral motor voltage 18 4 9 15V Voltage Rail Measurement ID Motor Controller Base Address 8 Interval 1 second Variable Bits Type Description 15V supply 63 32 V Actual voltage level of the 15V power rail Reserved 31 0 18 4 10 3 3V amp 1 9V Voltage Rail Measurement ID Motor Controller Base Address 9 Interval 1 second Variable Bits Type Description 3 3V supply 63 32 V Actual voltage level of the 3 3V power rail 1 9V supply 31 0 V Actual voltage level of the 1 9V DSP power rail 18 4 11 Reserved ID Motor Controller Base Address 10 Interval Variable Bits Type Description Reserved 63 32 Reserved 31 0 33 of 35 18 4 12 18 4 13 18 4 14 18 4 15 18 4 16 18 5 USER S MANUAL TRITIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 IPM Heat sink Motor Temperature Measurement ID
39. rovide power or operate with the cover removed To be opened and connected to by authorised personnel only 4 of 35 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 GETTING STARTED Work through this manual in sequence using this checklist as you go Items arrived in good condition Read and understood the datasheet Read and understood this document A good mounting location chosen Cooling system designed Controller mounted into place CAN Bus 12V supply wiring installed PC software installed 12V supply and CAN communications functioning Motor sense connections completed Precharge system working HV DC cables connected PhasorSense routines run and saved Motor test at low voltage wheels off ground using PC software Motor test at low voltage wheels off ground using driver controls hardware Motor test at high voltage wheels off ground using PC software Motor test at high voltage wheels off ground using driver controls hardware Private road test Motor phase cables connected On road vehicle test UNPACKING PREPARATION Check that all items on the packing list are in the box and undamaged Contact the shipping company and Tritium if there is obvious outer box damage during transport Contact Tritium immediately if there is a discrepancy with
40. rt and tighten all four screws 7 of 35 7 2 7 2 1 7 2 2 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 COOLING OVERVIEW The WaveSculptor22 will usually require some form of external heatsinking The extent of this will depend on the ambient operating temperature the motor current and duty cycle and operating voltage Once these are known the heat that is required to be removed from the controller can be calculated from its efficiency There will be a wide variety of possible cooling solutions which is why the WaveSculptor22 has been designed for technically qualified users to choose their own optimal solution for their exact vehicle and use scenario The aim of the cooling solution provided by the end user is to keep the WaveSculptor cold plate temperature below the limit specified in the datasheet Above this point the motor controller will automatically reduce the motor output current to protect itself resulting in reduced performance for your vehicle EFFICIENCY Background The power electronic switching devices in the WaveSculptor22 are MOSFETs and the majority of loss in the motor controller comes from these devices Losses in a MOSFET are split into conduction and switching loss Conduction loss is easy to characterise and model but there are many MOSFET switching mechanisms that create loss To simplify analysis and covering the bulk of the loss in any case th
41. sheet for the correct value Assume that the vehicle begins the qualifying lap with a heatsink at ambient temperature Heat from the controller in this type of scenario could possibly be stored rather than immediately rejected to ambient In the situation above the total energy required to be adsorbed by the heatsink is 120W 120 seconds 14 4kJ Using an aluminium block specific heat 0 897J g C and a 30 C temperature rise would require a mass of m Q AT c 14 4kJ 30 C 0 897 535g Using a thin aluminium case containing water specific heat 4 186J g C almost 5x better than aluminium would reduce this mass to 115g Combining this type of heat storage device with the continuous use heatsink to ambient air will result in a cooling solution suitable both for constant lower power operation and with the heat capacity to absorb peaks of high current operation A combined system could be made with an all aluminium system with a 535g block mounted into the skin of the vehicle This provides a low risk option Alternatively other types of system such as one using a small volume of circulating water are possible with the water providing both heat transport from the motor controller to an ambient cooling plate in the skin of the car and also thermal mass to absorb short term high power use MECHANICAL INTERFACE The WaveSculptor22 provides a large flat surface to attach to your cooling solution Refer to the mechanical drawing avai
42. simplified positioning in your vehicle The DC bus and motor phase cables can be quite stiff make sure to allow enough room in front of the controller so that they can bend at greater than minimum radius ACCESSING THE CONTROLLER SAFETY Opening the cover on the WaveSculptor will expose the high power terminals for battery and motor phase connections High voltages may be present inside this cover Before opening make sure that the battery contactors are dis engaged so that high voltage is not present at the motor controller Allow one minute for the internal capacitors to discharge before working on the controller INSPECTION COVER The lid of the controller is held closed against the base with stainless steel M3 button hex head screws two at each end of the controller Use a 2mm allen hex key to loosen and remove all four screws Lift off the lid and set it aside Use a multimeter to check across the battery connection terminals for high voltage If more than a few volts are present wait additional time for the capacitors to discharge to a safe level To avoid damage due to static discharge touch the controller body before working inside the controller and touching any internal circuit boards Be extremely careful to not drop loose fasteners into the motor controller as they may move around while driving and short out the battery or motor phase connections When finished working inside the WaveSculptor replace the lid and inse
43. ted COMMUNICATIONS The CAN standard does not specify high level message protocols Tritium devices use a custom protocol outlined in the communication specification document for each device 13 of 35 8 7 8 8 8 9 8 10 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 By default each device operates at 500 kbits second one step below the maximum possible data rate of 1 Mbit second and comes programmed from the factory with a CAN base address that will allow it to work without problems with other Tritium devices Using the Windows PC interface program and the Tritium CAN Ethernet bridge both the data rate and the base address can be programmed to suit your network WaveSculptor controllers also have a second programmable base address that they watch for command messages This should be set to whatever base address is used by the driver controls node on the network The WaveSculptor motor controller expects regular messages from the driver controls device If a message is not received within a set timeout period refer to the communications specification in Appendix A for the exact value then the controller will change to a safe mode and will stop driving the motor until a valid message is received again This protects against faults where either a connector is loose or broken the cable has been damaged or the driver controls have failed POWER SUPPLY Each Tritium device expe
44. tem All that is required is for each WaveSculptor controller to be programmed to receive messages from the same driver controls base address and then to run 14 of 35 9 2 9 3 10 6 USER S MANUAL TRI TIUM WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 the vehicle in current control mode the default setup Each motor will now operate at the same current thus giving automatic wheel speed differences for cornering with the system acting as an electronic differential The base address of each WaveSculptor controller should be programmed to a different value This allows viewing of separate telemetry data from each controller on the LCD displays or other telemetry systems in the vehicle PC SOFTWARE ETHERNET BRIDGE INSTALLATION Refer to the CAN Ethernet bridge User s Manual for installation and setup of this piece of hardware Connect the Ethernet bridge via a CAN bus cable to the WaveSculptor Use 120 ohm termination resistors between the CAN H and CAN L lines at both items 12V Power Y CAN Ethernet Bridge WaveSculptor Termination tesistor Termination Resistor PC SOFTWARE Refer to the Software Download section on the WaveSculptor 22 product page for the Configuration Setup software tool download Refer to the Software User s Manual for installation and usage instructions LOW VOLTAGE amp CAN BUS TESTING Provide 12V DC to the CAN bus adapter at the CAN Ethernet Bri
45. the items or other damage You will require the following specialised tools for installing the WaveSculptor motor controller Allen hex keys Molex MicroFit crimp tool Cable cutters Hex lug or hydraulic crimp tool Various electronics hand tools for low power cable cutting amp stripping 5 of 35 4 2 5 2 5 3 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 CONTROLLER FUNCTION OVERVIEW As a high level description the WaveSculptor takes high voltage DC from a battery pack and converts it to a lower voltage 3 phase AC to drive a motor Power flow is bi directional so it can also perform regenerative braking regen where power flows from the motor back into the batteries It is a four quadrant device which means that it can drive or regen in both forwards and reverse directions Ignoring the losses in the system refer to the datasheet for efficiency curves for the WaveSculptor total power through the motor controller is conserved It does not create energy it just converts it from one form DC to another AC A NOTE ON MOTOR AND BATTERY CURRENTS Motor current is proportional to torque whereas battery current is proportional to power Power Torque x speed The effect of this is that battery current will only approach motor current as the motor speed approaches 100 At low motor speeds the battery current will also be low regardless of what the motor current is
46. this size bolt with a 6 5mm hole High power connections should not be soldered for vehicle applications as the solder wicks up inside the copper strands and creates a stress point which can fatigue and break due to the vibration present in a vehicle For a guide to good quality crimping of the high power connections please read Appendix B of this document Copper oxidation is a threat to the long term reliability of both the crimp and the bolted joint to the controller Use a thin smear of anti oxidation electrical jointing compound on the contact surface of the crimp lug when bolting the cable to the controller as shown in the diagram below Crimp Lug M6 brass bolt captive Cable M6 nut full depth Se he M6 spring washer M6 flat washer ise PCB The bolts are permanently assembled into the motor controller and are 17 of 35 12 1 12 2 12 3 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 prevented from rotating by a nylon holder To assemble the bolted joint follow these steps e Route the cable in through the rubber grommet and locate the crimp lug down over the stud It is easiest to push the cable through with the lug vertical and rotate it down over the top of the bolt e Place a plain washer on top of the lug e Place a spring washer on top of the lug e Thread a nut over th
47. tus Information ID Motor Controller Base Address 1 Interval 200 ms Variable Bits Type Description Receive error count 63 56 Uint8 The DSP CAN receive error counter CAN 2 0 Transmit error count 55 48 Uint8 The DSP CAN transmission error counter CAN 2 0 Active Motor 47 32 Uintl6 The index of the active motor currently being used Error Flags 31 16 Uint16 Flags indicate errors Bits Parameter 15 8 Reserved 7 Desaturation fault MOSFET driver UVLO 6 15V rail under voltage lock out UVLO 5 Config read error some values may be reset to defaults 4 Watchdog caused last reset 3 Bad motor position hall sequence 2 DC Bus over voltage 1 Software over current 0 Hardware over current Limit Flags 15 0 Uint16 Flags indicate which control loop is limiting the output current of the motor controller Bits 15 7 O e N UAU OD Parameter Reserved IPM Temperature or Motor Temperature Bus Voltage Lower Limit Bus Voltage Upper Limit Bus Current Velocity Motor Current Output Voltage PWM 31 of 35 18 4 3 18 4 4 18 4 5 18 4 6 5 TRITIUM USER S MANUAL WaveSculptor 22 Motor Drive TRI88 004 ver 2 18 April 2012 Bus Measurement ID Motor Controller Base Address 2 Interval 200 ms Variable Bits Units Description Bus Current 63 32 A Current drawn from the DC bus by the controller Bus Voltage 31 0 V DC bus voltage at the c
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