Users Manual
Contents
1. ssssm meme 12 5 1 3 Excessive Acceleration or Faulty Motor ssssssssssse me eene 12 5 2 Hall EtFOES c S eo nde ED ORAE SEA OA UR AE ERIS ROC RA EHE 12 6 ParamExtract ssssssssesseeeneenns sua uuu AR RRRGRRRRRRRRRRRRRRRRRRRRRRRRRRRSESSSHSHHHHHRHHHHSR 12 6 1 Voltage Current Plot cr i ete Eee a Pe oe EH P ex Ere Pea 13 6 2 Current Decay Plot geo e a epe e Lane eed ee eee ea 13 6 3 Final Output aded nee erp eie EE FR ERE EE RHET D ERE Fere beet 13 7 DataLogging ussesssseeasseeassnuahnmuaaniuu as paa iaraa dau a aaa d uuu a anu un n 13 8 Error Log e eessssssssssenunennn ssa EEPE UNER KORRAS VEENEV AANEEN ERNAS E AEEA 14 9 Revision History sssesssseessssuannnuanumuaussuu us iaa usua Naaa kaia auda uu nn 15 USERS MANUAL TRI50 026 ver 1 TRITIUM mene 1 28 February 2007 PC INTERFACE FUNCTIONALITY The WaveSculptor interface software is provided to allow WaveSculptor owners to configure and test their motor controller s OBSERVATION This main screen shows the status and measurements from the WaveSculptor On start the software is not connected to the CANUSB adapter The CAN baud rate should be selected from drop down box a of Figure 1 prior to clicking the connect button Once the software opens a port to the CANUSB adapter the text box ah of Figure 1 changes from red Disconnected to green Connected Text box ai of Figure 1 is a count2. q 200ms Aligned with the motor flux current in this compo nent will weaken or strengthen the motor flux lout Q r 200ms This component of current produces motor torque and does work 15V Rail s 1s The voltage of the 15V rail used to power the low voltage sections of the WaveSculptor 1 65V Reference t 1s Used to generate the centre voltages of the current measurement circuits 1 2V Rail u 1s The voltage of the 1 2V rail used to power the core of the FPGA 2 5V Rail v 1s The voltage of the 2 5V rail used to power the core of the FPGA Fan PWM w 1s The Pulse Width Modulation used to control the fan speed A value here and no fan speed would indi cate a fan fault Fan Speed X 1s The fan speed in RPM Motor Temp y 1s The temperature of the connected motor in degrees Celsius 3 of 15 USERS MANUAL TRITIUM mede TRI50 026 ver 1 28 February 2007 Table 1 WaveSculptor Measurements Measurement Figure d update Description ref Interval Heatsink Temp z 1s The temperature of the controller s internal heat sink in degrees Celsius DSP Temp aa 5s The temperature on the surface of the DSP FPGA control board within the controller Air in Temp ab 5s The temperature of the intake air flow May read higher than ambient air when fan speed is zero Air out Temp ac 5s The temperature of the air at the controller s air outlet NOT USED IN THE 20kVA VERSION Cap Te
3. 2 6 TRITIUM USERS MANUAL WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 Table 3 General Configuration values Figure 3 Value Ref Units Description Min bus voltage f V The controller will attempt to limit drive current if the bus voltage falls below this setpoint Hardcurrent limit g A The setpoint for the hardware based current compa rators This is not adjustable and may not read cor rectly for a second or two after reset Serial Number h Uniquely identifies the controller Set during manu facture Should match the serial number on the case Firmware Version i Version of firmware running on the DSP in the con troller Hardware Veri j Version of DSP FPGA control board in the WaveS son culptor Base Address k The CAN identifier that the WaveSculptor will send all its CAN packets relative to The edit box will force the address to a multiple of 32 Driver Controls l The CAN identifier that the WaveSculptor will Base Address expect to receive CAN packet relative to Again the edit box will force the address to a multiple of 32 CAN baud rate m The CAN baud rate the WaveSculptor will use Vehicle Mass n kg The total mass of the vehicle Directly affects the velocity control loop Vehicle amp Rotating Mass are used to calculate the P and I terms in the velocity loop Rotating Mass 0 kg The sum all rotating mass This term is more impor
4. Telem Send Measurements Velocity control loop constants p d TE U ee Vehicle Mass kg Iv Velocity v Currents iv DO Volt iv DO Curr v BEMF Reset Config V Fan Speeds IV Heatsink Motor temp IV Airln CPU temp v AirOut Cap temp V Odometer BusAh Rotating Mass kg Close Figure 3 General Controller information tab on the Configuration dialog box Table 3 gives a description of the different configuration values and the impact they have on the WaveSculptor operation Table 3 General Configuration values Value Figure 3 Ref Units Description Current Limit a Arms Represents the 10096 motor current setpoint Also used to calculate the software over current trip point ref Section 2 2 Values higher than 100Arms can be stored in the configuration file but the WaveSculptor20 has a saturation point on this value of 100Arms S Speed Limit m s The maximum speed setpoint Idc Limit eo Represents the 10096 bus current setpoint 2 Heatsink Limit C The motor current will be reduced if the heatsink temperature nears this setpoint Values higher than 90 C can be stored in the configuration file but the WaveSculptor20 has a saturation point on this value of 90 C Max bus voltage e The controller will attempt to limit regeneration cur rent if this setpoint is exceeded 6 of 15 4
5. of 15 4 3 1 r USERS MANUAL TR ITIUM WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 Table 4 Motor Configuration Values Figure 4 Ref Units Description Value Phase Resistance i mOhms The resistance of the controller half bridge induct ance amp motor winding resistance Obtained with ParamExtract is a read only value in the release version of the software Phase Induct j uH The inductance between the controller phase termi ance nal and the motor neutral point Obtained with Para mExtract is a read only value in the release version of the software Speed Constant k Vrms s rad The RMS voltage induced between phase and neu tral at a motor frequency of one radian per second Is used to start the BEMF estimate however once in neutral the speed constant is re evaluated Phase Sequence I Ticked if phase C leads phase B while the motor is Reverse rolling forward Used in the control system Set by PhasorSense and is read only in the release version of the interface software Hall Transition m The first six entries represent actual transitions the Table last two entries are the unused hall combinations The transition angle is in degrees and the hall tran sition is in last hall gt new hall format Set by PhasorSense Motor Temperature scale and offset The motor temperature output voltage is isolated with a single digital optocouple
6. vehicle and if the slide is pulled above the actual vehicle speed the controller will drive with more current in an 4 of 15 USERS MANUAL TR ITIUM WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 attempt to increase vehicle speed The rate at which the vehicle will slow or speed up will be limited by the motor current or other setpoints which set point is limiting is displayed in text box e of Figure 1 Do NOT regen when operating from a power supply instead of batteries this may damage the supply Slider e of Figure 2 controls the bus current setpoint it ranges from 0 to 100 of the maximum current setpoint in the configuration file Text box f of Figure 2 displays exact current setpoint The controls dialog box provides a keyboard interface for fine movements of the sliders Table 2 shows the keyboard functions Table 2 Control dialog box keyboard functions Key Function Description Up Arrow Increases motor current setpoint by 0 196 Down Arrow Decrease motor current setpoint by 0 196 Space Bar gt Zeros motor current setpoint Right Arrow Increase vehicle velocity setpoint by 0 196 Left Arrow Decrease vehicle velocity setpoint by 0 196 Enter Zeros the vehicle velocity setpoint will regen at the current setpoint a Increase bus current setpoint by 0 196 z Decrease bus current setpoint by 0 196 4 CONFIGURATION The configuration dialog box prov
7. 0 845 845 121 13 912 3241 102 Figure 8 An error log listing oooonond 3 6 3 0 0 3 3 394 394 3 3 OK There are several different types of errors can be presented in the one log Table 7 shows all the existing error logs that the WaveSculptor can make Table 7 Types of error logs and their parameters Error Log Type Time Param1 Param2 Param3 Param4 Over Current Seconds since Bus voltage Bus current Phase A Cur Phase B Cur Over Voltage reset 1 5V 3A rent rent Hall Sequence 3A 3A 14 of 15 6 TRITIUM USERS MANUAL WaveSculptor PC Interface Table 7 Types of error logs and their parameters TRI50 026 ver 1 28 February 2007 Error Log Type Time Param1 Param2 Param3 Param4 Hall Sequence Seconds since Expected Last Expected Last Last Halls New Halls reset reset Halls rev Halls fwd Config Struct Seconds since Expected Actual Struc Size Mismatch reset Structure Size ture Size Motor Config Seconds since Index to the Checksum error reset structure Config missing Seconds since Checksum error reset Watchdog Reset default Seconds since 32 bit param Under the ELog menu item there is also an Erase command This is greyed out on the released version of the software There is no need to erase the error log the WaveSculptor can store upto 16896 errors before looping ar
8. 00000e 000 1 02000 00000e 000 PhaseC Voltage aie 1 51500 00000e 000 Phased Voltage PhaseB Voltage ARCP rail 02000 00000e 000 02000 00000e 000 411 motor dependant currents are relative to base current Bus Current B 03125 0 00000e 000 03125 0 00000e 000 Phased Current PhaseB Current 1 i PhaseC Current 1 1 87500 5 50000e 001 Over Current Set Point 62500 0 00000e 000 03125 0O 00000e 000 Reset Config Figure 4 Calibration Controller information tab on the Configuration dialog box MOTOR CONFIGURATION Configuration values for upto 10 different motors can be configured in this dialog box This allows complete testing and setup for all motor that you expect to use in the car while still in the workshop You should not need to use the PC interface software once 8 of 15 USERS MANUAL TRITIUM ma TRI50 026 ver 1 28 February 2007 out on the road as the active motor can be set via a CAN bus message allowing you to activate an already configured motor x File Transfer General Calibration Motor a ____Active Motor_ 0 Tyre Diameter m 05 b r Phasor Sense Param Extract obtained Motor Constants Descripti CSIRO surface c RESP EE Line Resistance mR 240 8405 i N d _____NrofPolePairs 4 Line Inductance uH 248 5722 7 m Motor Cut out T CC 490 e E EN Ea eee Speed Constant V s rad 0 39 k Motor T
9. PhasorSense Acquisition press button f of Figure 6 You then have 10seconds to spin the motor with an electrical motor frequency of more than 12Hz Even on a fairly low pole count motor of 4 pole pairs this is only 180RPM which is achievable by hand The WaveSculptor uses hall edges to decide if the speed is sufficient so if the halls are not connected to the controller a Failed to obtain sufficient speed message will be given It should be noted that PhasorSense needs to have a 1Mb s CAN connection to the controller If any other CAN baud rate is selected PhasorSense will not be a selectable option It may also be required to have only the WaveSculptor on the CAN bus with other items disconnected and or not generating traffic PHASE VOLTAGE ERRORS The phase voltage are all measured separately relative to ground the phase to phase voltages displayed in graph a of Figure 6 are produced by subtracting one from the other This is important to know when trying to identify which actual motor phase is not connected or not working One Motor Phase Missing The phase to phase voltage that does not rely upon the missing phase will be the only one that looks correct like a sinewave For example if phase A was not connected phase to phase voltage Vab and Vca would not work however Vbc would still work as it does not rely phase A 11 of 15 USERS MANUAL TRI50 026 ver 1 TRITIUM mede 5 1 2 5 1 3 5 2 28 February 2007 Tw
10. USERS MANUAL O TRITIUM MR TRI50 026 ver 1 28 February 2007 Users Manual PC interface to the Tritium WaveSculptor 28 February 2007 2007 Tritium Pty Ltd Brisbane Australia http www tritium com au USERS MANUAL TR ITIUM WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 6 TABLE OF CONTENTS 1 PC Interface functionality ccccsceeesseeeeeee esse ee eeee esses eeseeeeaeeesaeeeeeeeeeaeneeannes 1 2 Observation sescentae eens eee essen eee eee ae eee a aA aa Ea aaa Kaaa 1 2 1 uinum 2 2 2 egg avs 2 2 3 Limiting Setpoint 2 cement eg EHE tne et Eee eee ge ee ee p i gets 2 2 4 ME ASUPEMENES RT AE A ETA NEA E ENA OE Aa 3 3 Control eee 4 4 Configuration sorse sudderen aaea eee eee eee eee eee eee oaaao ua au uuu n 5 4 1 General Conflig tation iie edie rio rr a tenes E even IE degna ea taa ate ENTM AE RE ERE 6 4 2 Calibration Configuration 2 cote ce eter enne HERR etn E Re PRERRRI eR SOHO ikada 7 4 3 Motor Configuration rre o EE irae rp RATER Ea 8 4 3 1 Motor Temperature scale and offset sssessssssssssssssssee eene mene nennen nnne 10 5 PhasorSense e sseesssssuusssauassausnuauasuauasuuusasuu sse ua sRsu A sHa dA uuu uuu nu 10 5 1 Phase Voltage ERRORS deg e Re ela ewe ead eae eel adnan a 11 5 1 1 One Motor Phase Missing nusra ennta aa nennen nnne hene Da nnne nnns trenes 11 5 1 2 Twoor All Three Motor Phases Missing
11. emperature Constants Phase Sequence reversed M BC gt CE I f Scale Factor fi A11 Angle Hall Edge 0 e Offset fr Hall Transition Angles 49 011 gt 010 m 9 E 108 001 gt 011 j 3 3540e 003 i 167 101 gt 001 227 100 gt 101 S E 2 3677e 004 285 110 100 h 341 010 5110 C 3 5851 e 006 360 000 gt 000 360 000 gt 111 D 1 2553e 007 Reset Config Close Figure 5 Motor information tab on the Configuration dialog box A description of each motor configuration value along with its effect on the system is given in Table 4 Table 4 Motor Configuration Values Value rigure 4 Units Description Ref Active motor a The index of the motor currently in use by the con troller Tyre Diameter b m Outside diameter of the drive type Used for speed calculation If motor is geared scale this value by the gear ratio Description c Free text description of the motor Nr of PolePairs d The number of magnet north south pairs on the rotor of the motor Motor Cut out e NOT IMPLEMENTED temp Motor Temp f V V Scale factor multiplied by sensor reading offset Scale Motor Temp Off g pu Offset to be added to the sensor reading prior to set applying the scale factor Log Fit Constants h A B C amp D are constants associated with the con nected thermistor These values can be found in most thermistor datasheets 9
12. er that starts at 0 and counts each time a packet is seen on the CAN network After a few seconds all Tritium WaveSculptors on the CAN bus will be listed in list box b of Figure 1 A WaveSculptor controller is identified by its CAN identifier or address and its serial number The software will connect to the first WaveSculptor found on the CAN bus To change which controller you are watching simply click on the desired controller f WaveSculptor Driver Gomme ni x File view Log ELog Hel ag ah Poe 6694 ai L Reset CAN Baud Rate WS Base SerNum a _ fioookbps 0x400 b DvrCtrls Base Addr os Errors d Limiting Setpoint vel e f BusVolt Cur 4813V 105A 9 Controller Power 50 WW h i Velocity 787 rom 741 kph G k RMS Current A B 0 49 A 0 72 A I m MotorBEMF d g 0v 2181V n o OutVoltage d g Q18V 2134V p q OutCurent d g 002A 217A r s ___15V 1 65V Rails 15 20 V 120 V t u 12V 25VReils 125V 255V v w FanPWM Speed 0 00 rpm x Motor Temp 0C y Heatsink Temp 25 2 C z aa DSP AilnTemp 295 C 29 9 C ab ac AirOut CapTemp 206 C 20 6 C ad ae Odo Bus Ah af Figure 1 Main observation screen All configuration information stored in the WaveSculptor is downloaded to the PC when it becomes selected in list box b of Figure 1 The driver controls CAN identifier expected by the WaveSculptor is c
13. hed and is limiting the motor torque MEASUREMENTS All measurements are broadcast from the WaveSculptor at periodic intervals unless disabled in the configuration file Table 1 lists these measurements their descriptions and their update broadcast intervals For more details please refer to the CAN bus comms spec TRI50 008 Table 1 WaveSculptor Measurements Figure 1 Update TEN Measurement ref interval Description Bus Voltage f 200ms The input bus voltage of the controller Bus Current 9 200ms The input current to the controller Controller Power h 200ms Bus Voltage Bus Current calculated on the PC Motor RPM i 200ms Angular velocity of the motor in RPM Vehicle Velocity j 200ms Vehicle Velocity in km h Phase A Current k 200ms Phase A and B motor current in Arms Relies on a Phase B Current I 200ms RMS filter to smooth the motor frequency so value may not represent true cycle RMS at very slow motor frequencies BEMF D m N A Component of the BEMF aligned with the motor flux By definition this value is always zero BEMF Q n 200ms The motor back EMF Represents the peak voltage Vout D 0 200ms Component of the controller output voltage aligned with the motor flux Usually exists to drive the motor inductance Vout Q p 200ms Component of the controller output voltage aligned with the motor BEMF and resistive voltage drop lout D
14. ides five functions Save open upload download and reset configuration file The save and open functions are under the File menu they provide a means of storing the configuration file on PC It also provides a means for the configuration files to be send to Tritium for update or inspection The upload functions transfers all the information currently in the configuration dialogs to the WaveSculptor The download does the opposite The upload and download progress is reflected on progress bar q of Figure 3 The configuration dialog box consists of three tabs The first contains general controller information that the user is free to adjust the second contains calibration information used by the manufacturer and the third tabs contains motor information 5 of 15 TRITIUM GENERAL CONFIGURATION USERS MANUAL WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 Figure 3 shows the general controller information tab x File Transfer General Calibration Motor m Controller Limit Set Points Controller ID a MEI Current Limit A 100 Controller serial number p h b L Speed Limit m s LEN Firmware version XN i c Ide Limit A 100 DSP FPGA Hardware Version fo d Heatsink Limit C jo Sa ae e Max bus voltage V 160 Base address p k f Min bus voltage v fo Driver controls address soo I 9 Hard current limit A 190 CAN Baud Rate fiaookbps v m
15. is a tab delimited text file with one header row and six decimal points of accurately on each measurement The only encoded log entries are the error and limiter bits Tables 5 amp 6 shows the bit decoding Table 5 Error Bit Fields Bits Parameter 15 6 0 Config Read Error some values may be set to defaults Watch Dog caused last reset Bad Hall Sequence Bus Over Voltage Software Over Current CO P NI wl 5 U1 Hardware Over Current 13 of 15 TRITIUM Table 6 Limiting Bit Fields USERS MANUAL WaveSculptor PC Interface Bits Parameter 15 7 0 Heatsink Temperature Bus Voltage Lower Limit Bus Voltage Upper Limit Bus Current Velocity Motor Current CO e N WwW BR Oo Oo Bridge PWM ERROR LOG TRI50 026 ver 1 28 February 2007 The WaveSculptor controller logs all error conditions to flash when they happen This interface software provides a facility to view all of these errors Choose ELog gt View Log from the main menu the dialog box of Figure 8 presents Enter the past number of errors you wish to view in edit box a of Figure 8 and press GO button b Error Log Review B Getlast errors x Hardware Phase A Over Current Bad Hall Sequence Volt Curr Bad Hall Sequence Halls Bus Over Voltage Hardware Phase A Over Current Hardware Phase A Over Current Hardware Phase A Over Current 1
16. mp ad 5s The temperature of the controller s bus capacitors NOT USED IN THE 20kVA VERSION Odometer ae 1s The distance travelled in km since reset Bus integrator af 1s The charge drawn from the bus in Amp Hours since reset Please note that a mouse click on any of the measurement text boxes of Figure 1 will request the measurement from the DSP using a CAN remote request Hence the measurements can still be read even if its periodic send flags are disabled in the configuration file 3 CONTROL The purpose of the control dialog box is provide a rudimentary driver controls interface This allows the system to be tested it is not meant to be used to actually drive a vehicle Figure 2 shows a screen grab of the dialog box x Motor Current a 9 Velocity b c f 2059m s TL c Bus Current d e J monos Figure 2 Controls dialog box Slider a of Figure 2 controls the motor current setpoint it ranges from 0 to 100 of the maximum current setpoint in the configuration file Text box b of Figure 2 displays exact current setpoint The current setpoint can also be adjusted with the buttons of group g in Figure 2 Slider c of Figure 2 controls the vehicle velocity The setpoint is in metres per second and is displayed in text box d of Figure 2 If this slider is pulled below the actual vehicle speed the controller will regenerate in an attempt to slow the
17. nitor current in phase A and phase B SWOC Software Overcurrent This error occurs if the firmware on the controller samples a bus phase A or phase B current that is over 1596 above the expected maximum current So if the current limit in the configuration file is set to 100Arms this trip point will be at 100 x 2x 1 15 162A OV Over Voltage This occurs if the bus voltage exceeds the over voltage trip point in the private section of the configuration file This is to protect the MOSFETs in the controller against over voltage during regeneration Tritium WaveSculptors come shipped with this trip point at 180V HALL Hall Sequence Error This occurs if a hall transition is invalid The hall sequence is recorded during the PhasorSense routine and this same sequence must be followed by the motor hall effect sensors at all times WD Watch Dog This is a warning message more than an error as the controller will still function with this error An independent hardware watchdog needs to be kicked at least 4 times per second by the firmware in the controller If it is not kicked this often the controller will reset something that the driver of the vehicle would feel as a short loss of power This error will stay set until the controller is next reset CFG Configuration File Error An error occurred while reading the configuration file This error will occur just after reset during the initialisation sequence If all or some of the configura
18. o or All Three Motor Phases Missing All phase to phase voltage waveform will be flat lined but not necessarily at zero volts Excessive Acceleration or Faulty Motor Each phase zero crossing is expected to be within 25 where it should occur If not an error is reported in text box b of Figure 6 HALL ERRORS The hall plot c of Figure 6 is the actual sampled logic signals So any error with the hall signals should be easily seen The only requirement for a successful hall transition allocation is only one hall transition must occur within 15 around each phase voltage zero crossing PARAMEXTRACT The ParamExtract routine is designed to extract the motor resistance and inductance Parameter Extraction j r x Phase to Neutral Impedance a Resistance 252 6mR Inductance 265 1uH b DC V curve to find phase resistance c 15 0 zi t 10 0 3 50 EI 0 0 5 0 0 0 40 8 0 12 Voltage V d Decay of motor current through resistance and inductance 20 0 z t 15 0 5 10 0 Q Measured 5 0 BestFit 0 0 0 0 0 5 1 0 15 20 2 Time s x10 3 e Extract Params Figure 7 An example PhasorSense acquisition The ExtractParams button e of Figure 7 starts the acquisition this process requires the bus voltage and motor to be present A bus voltage between 30V and 60V should be used The algorithm linearly ramps the phase AB cur
19. ontained in this configuration information hence the Driver Controls Base Address c of Figure 1 is displayed only after a controller is selected The driver controls base address is needed by the controls dialog window which pretends to be a driver controls unit at this address 1 of 15 2 1 2 2 2 3 G USERS MANUAL TR ITIUM WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 The selected baud rate and windows positions are stored in the Windows registry and therefore will remain set between closing and opening the interface software MAIN MENU Menu ag of Figure 1 is the menu main of the software and is referred to as such throughout the rest of this document The View menu option contains links to the four main dialog boxes The Controls Section 3 Configuration Section 4 PhasorSense Section 5 and ParamExtract Section 6 The Log menu option is discussed in Section 7 and the ELog menu option is detailed in Section 8 ERRORS Controller errors are presented in text box d of Figure 1 Six different types of errors can occur These errors usually would only occur one at a time however it is possible to have multiple error displayed at once The possible error messages are listed below HWOC Hardware Overcurrent A hardware comparator is used to generate this signal and if the current exceeds the hardware over current trip point for even an instant this error will occur The hardware comparators mo
20. ound and over writing errors that occurred months or years ago The WaveSculptor could generate 50 error logs per day for a whole year before over writing old error logs REVISION HISTORY Version Date Description 1 28 February 2007 Document Creation DAF 15 of 15
21. r with the aid of a voltage to frequency converter A 5V signal on the MotorTemp pin gives 9096 of max frequency and OV on the same pin gives 1096 of max frequency Hence the default offset is 0 1 and the default scale factor is 1 0 8 If there is a need to change the offset and scale factor remember to include these offset and scale factors PHASORSENSE PhasorSense is an algorithm designed to find phase and hall sequence along with the relation between them Both the phase voltages and hall effect signals are displayed which makes any error with the test setup or equipment obvious Graph a of Figure 6 shows an example grab of the three phase motor voltages Text window b of Figure 6 gives the results of the phase voltage processing Graph c of Figure 6 is a plot of hall 10 of 15 USERS MANUAL TRITIUM mee 5 1 5 1 1 TRI50 026 ver 1 28 February 2007 effect sensor output Text box d of Figure 6 display either the success or failure of the algorithm Finally list box e of Figure 6 displays the hall transition angles PhasorSense B Line to line voltages acquired by the controller x a __ zm Y a 3 v wo m I ns Time s c Hall inputs to the controller 011 2010 001 2011 101 gt 001 100 gt 101 110 gt 100 010 gt 110 ooo gt 000 000 111 Time s Close Figure 6 An example PhasorSense acquisition To start a
22. rent from OA to 20A then switches off Note that the motor may rotate briefly during this time It should be disconnected from the drive wheel of the car or the wheel should be raised up from the ground before performing this test To produce 20A phase current a certain amount of power will be required The WaveSculptor will use 50W and the motor loss at zero speed is completely dependent on 12 of 15 6 1 6 2 6 3 6 USERS MANUAL TR ITIUM WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 resistive loss As an example the CSIRO motor has 75mR of phase resistance and the external inductor have 13mR of resistance So at 20A this leads to a 2 88mR 20 20 70W loss The more lossy the motor the more power will be required to preform this test To perform this test with a CSIRO motor a power supply rated higher then 120W will be needed You should be able to use a 60V 3A lab power supply for the CSIRO motor It should be noted that ParamExtract needs to have a 1Mb s CAN connection to the controller If any other CAN baud rate is selected ParamExtract will not be a selectable option It may also be required to have only the WaveSculptor on the CAN bus VOLTAGE CURRENT PLOT The voltage current plot c of Figure 7 shows the phase voltage versus phase current Expect this plot to be a straight line with a positive x intercept There is no mechanism in the WaveSculptor of directly measuring phase voltage Instead it is es
23. tant when testing the speed loop with no load on the motor as vehicle mass should be set to zero in this case Send Measure ment Flags Enables Disables the periodic broadcast of the asso ciated measurements Each flag will affect two measurements as each measurement CAN packet contained two measurements CALIBRATION CONFIGURATION This dialog tab is read only in the release version of the software It contains all the scale offset and thermistor data for all the WaveSculptor sensors It also has a few other values in section a of Figure 4 The over voltage trip point and the bus capacitance may be of 7 of 15 4 3 TRITIUM USERS MANUAL WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 interest to the user There shouldn t ever be a need for the user to access variables this dialog box The Base values are what the controller regards internally as 1 unit x File Transfer General Calibration Motor Serial Nr Base Voltage V a Base Current A Base Frequency Hz 200 0 400 0 500 0 Bus Capacitance F 1 000e 002 Bus Over Voltage V 180 0 411 reference amp rail voltage are relative to a base voltage of 15V 1 65V reference 0 15V rail thes 1 2V rail D 2 5V rail 0 20000 0 00000e 000 53333 0 00000e 000 20000 0 00000e 000 20000 0 00000e 000 ll bus dependant voltages are relative to base voltage Bus Voltage T 1 02000
24. timated from bus voltage times duty cycle this can introduce an offset in the estimated phase voltage causing the positive x intercept However the offset will remain constant over the phase current sweep so the slope will still accurately reflect the circuit resistance As the bus voltage is increased or a less lossy motor is tested this effect become more accentuated CURRENT DECAY PLOT Once the 20A current is reached zero voltage is applied to the phase The resulting current decay is plotted in chart d of Figure 7 Expect this plot to be an exponential decay starting at 20A and finishing at 2 5A The inductance is extracted from this plot FINAL OUTPUT The final resistance and inductance is displayed in text box a and b respectively of Figure 7 These values are quoted phase to neutral At the end of the test you are presented with an option as to which motor slot you wish to save this resitance and inductance to DATALOGGING A system for logging data is provided under Log on the main menu It has three options Start Stop and Update The Start command will start a new file name date time in the current operating directory Pressing this button while a file is already open will close the open file and start a new log file Clicking Stop will close the file and stop logging The Update sub menu allows three different logging speeds 200ms 1s and 10s The update rate can be changed at any time The format of the log file
25. tion values cannot be read from the configuration file default values will be used instead of the stored values This error does not disable the con troller meaning that the controller may not operate as expected Unless the error is with one of the more critical configuration constants it may be difficult to even notice the difference in operation LIMITING SETPOINT The WaveSculptor runs six concurrent control loops with the primary control loop regulating the motor current There is also control loops regulating the velocity bus current maximum and minimum bus voltage and heatsink temperature At any one time only one of these control loops is limiting the motor vehicles torque This limiting setpoint is given in text box d of Figure 1 all of the possible limiting setpoints are listed below PWM Not enough bus voltage to be able to produce more current and hence more torque Iq The motor current setpoint is being regulated in the motor Normal operation vel The vehicle velocity setpoint has been reached Normal operation 2 of 15 2 4 USERS MANUAL TR ITIUM WaveSculptor PC Interface TRI50 026 ver 1 28 February 2007 Idc The bus current setpoint is limiting further increase in motor torque VdcMax Motor regeneration torque is limited by the maximum bus voltage set point VdcMin Motor drive torque is limited by the minimum bus voltage setpoint sink The maximum heatsink setpoint has been reac
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