MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS AUTOMOTIVE ENGINEERING TECHNOLOGY ANALYSIS OF VEDDER ELECTRONIC SPEED CONTROLLER: A SOFTWARE-BASED APPROACH INSTRUCTOR: NGUYEN TRUNG HIEU, MSc. STUDENT: NGUYEN MINH HOANG PHAN DUONG THANH SON SKL012836 Ho Chi Minh City, June 2024 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF INTERNATIONAL EDUCATION GRADUATION PROJECT ANALYSIS OF VEDDER ELECTRONIC SPEED CONTROLLER: A SOFTWARE-BASED APPROACH NGUYỄN MINH HOÀNG Student ID: 20145036 PHAN DƯƠNG THANH SƠN Student ID: 20145017 Major: AUTOMOTIVE ENGINEERING TECHNOLOGY Supervisor: NGUYỄN TRUNG HIẾU, M. Ho Chi Minh City, June 2024 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, January 20, 2024 GRADUATION PROJECT ASSIGNMENT Student name: Nguyễn Minh Hoàng Student ID: 20145036 Student name: Phan Dương Thanh Sơn Student ID: 20145017 Major: Automotive Engineering Technology Class: 20145CLA3 Supervisor: Nguyễn Trung Hiếu, M. Sc Phone number: _________________ Date of assignment: _____________________ Date of submission: _____________ 1.
Initial materials provided by supervisor: ___________________________________ 3. Content of the project: _________________________________________________ 4. Final product: ________________________________________________________ CHAIR OF THE PROGRAM SUPERVISOR (Sign with full name) (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness ------------ SUPERVISOR’S EVALUATION SHEET Student name: Nguyễn Minh Hoàng Student ID: 20145036 Student name: Phan Dương Thanh Sơn Student ID: 20145017 Major: Automotive Engineering Technology Project title: Analysis of Vedder Speed Controller: A Software-based Approach Supervisor: Nguyễn Trung Hiếu, M. Content of the project:.
Approval for oral defense? (Approved or denied). Ho Chi Minh City, month day, year SUPERVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- PRE-DEFENSE EVALUATION SHEET Student name: Nguyễn Minh Hoàng Student ID: 20145036 Student name: Phan Dương Thanh Sơn Student ID: 20145017 Major: Automotive Engineering Technology Project title: Analysis of Vedder Speed Controller: A Software-based Approach Name of Examiner:. Content and workload of the project. Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, month day , year EXAMINER (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER Student name: Nguyễn Minh Hoàng Student ID: 20145036 Student name: Phan Dương Thanh Sơn Student ID: 20145017 Major: Automotive Engineering Technology.
Project title: Analysis of Vedder Speed Controller: A Software-based Approach. Name of Defense Committee Member:. Content and workload of the project .) Ho Chi Minh City, month day, year COMMITTEE MEMBER (Sign with full name) Acknowledgements Today I write this thank you with all my heart as a student who has been studying at the Ho Chi Minh University of Technology and Education for 4 years, I would like to sincerely thank teachers in my University especially in Faculty Vehicle and Energy Engineering, supervisor, family, and friends for their companionship and support throughout the process of implementing this graduation project. This project would not have been successful without the help and encouragement from everyone.
First of all, I would like to sincerely thank MSc. Nguyen Trung Hieu for his generous time, passion, and committed assistance in providing advice and direction for the preparation and execution of the graduation project. In addition to the information gained from the experience of the automotive industry during the limited period spent working on the graduation project, lessons about persistence, attitude, style, and discipline were also acquired. the process of developing a project.
His mentoring has been extremely valuable to me as I've improved myself and developed. I also wish to thank the teachers of my thesis committee, MSc. Nguyen Quang Trai for their constructive criticism and suggestions that greatly enhanced the quality of my research. I also want to thank my family and friends for always being there to encourage and support me throughout the project.
Their unconditional support motivates me to overcome challenges and achieve my target. Finally, I would like to thank the members of the Automotive Mechatronics Lab for creating a healthy, energetic working environment for me, giving me concentration as well as entertaining but no less stressful moments which is the best condition for me to be able to complete this project. These sentences cannot fully express my gratitude to everyone. I will always remember these contributions and everyone's valuable support throughout my future journey.
i Abstract Electric vehicle (EV) technology has advanced significantly as a result of the growing need for eco-friendly and efficient transportation. The Brushless DC (BLDC) motor is unique among the other parts because of its high efficiency, dependability, and small size which is applied in automotive and E-bike. The design, and performance analysis of BLDC motors particularly made for EV applications is examined in this thesis. The primary objective of the thesis is to enhance the performance characteristics of BLDC motors in order to meet the high demands with Field Oriented Control algorithm control method.
We conducted a thorough analysis of several BLDC motor designs and build the firmware for the controller in order to achieve this. The component controls the flux, and the component controls the torque. In most BLDC motor applications, the goal is to maximize torque production, so the is often set to zero to minimize the flux-producing current and maximize the torque- producing current. Sophisticated algorithm techniques were used to model the current applied in the motor‘s performance and electromagnetic behavior under different operating conditions.
The results of the study show the operation of the Field Oriented Control the unique parameter of this control which is impacted to the torque ripple during the BLDC in operation. Advanced control algorithms increase the motor's dynamic responsiveness and stability, which improves driving enjoyment and vehicle performance. Optimal BLDC motor designs may greatly increase efficiency and torque density. To sum up, this thesis offers insightful information about the creation of high- performance BLDC motors for electric vehicles.
In addition to meeting industry requirements, the suggested design and control methodologies go above and beyond, with this thesis can open a new view to invent more the mobility equipment with BLDC motor more effective and environmentally friendly electric vehicle solutions. ii Table of Contents Acknowledgements. ii Table of Contents. iii List of Figures.
vii List of Tables.x List of Abbreviation. xi Chapter 1: INTRODUCTION .1 Research in Viet Nam .2 Research in foreign .3 The necessity of the topic .5 Research subject and research range .6 Research method and content.4 Chapter 2: THEORETICAL BASIS .2 Working principle of the motor .2 Concept of BLDC .1 BLDC motor structure.2 BLDC motor classification .1 In-runner motor .2 Out-runner motor .3 Sensor using in BLDC motor .3 Overview of VESC .5 Motor control technique .1 BLDC motor principle .2 Mathematic of the BLDC motor .3 Six-step commutation.4 Field-oriented current control .25 Chapter 3: MEASURING AND PROCEDURE BLDC MOTOR .2 Resistor of each phase and layout of stator .1 The delta network .3 The induction Lq, Ld.5 Motor flux linkage.33 iv Chapter 4: OVERVIEW OF VESC 75100 HARDWARE .1 Introduction to VESC75100 .2 VESC pin out .3 Microcontroller in VESC 75100 .4 Safety and Protection .5 Configuration and Monitoring .4 Gate driver of VESC 75100 .5 Power divider in VESC75100 .45 Chapter 5: OVERVIEW OF VESC 75100 FIRMWARE .2 Measure motor current .4 The invert state .3 Overview of ChibiOs .1 Real-time Operating system (RTOS) .3 Tasks and Threads .4 Developing VESC firmware .1 Introduction to Eclipse IDE .2 C/C++ Development with Eclipse .3 Programming and debugging the VESC Firmware .5 Test case: ADC toggle duty cycle .1 Flowchart of the main program .2 Flowchart of PID algorithm and ADC application .68 Chapter 6: TESTING MODEL ESTABLISHMENT .5 Model control BLDC motor .6 Interfacing with VESC tool .7 Measurement by Oscilloscope .84 Chapter 7: CONCLUSION AND RECOMMENDATIONS .87 vi List of Figures Figure 2.2 LION EV 48V 1250W BLDC MOTOR.3 BLDC Motor Stator .4 The surface mounted magnet and interior magnet rotor .5 In runner and outrunner BLDC Motor .6 Opening and closing of switches in an ESC circuit .7 VESC sample products .8 GUI of supported VESC tool .9 Full brigde of the inverter .11 The alternative of the Back EMF .13 Hall state and the value of voltage.14 Hall state of each sector of rotor .15 Specification of moment and the speed of motor .16 Vector current in stator of the motor .17 Clarke transformation of FOC .18 The park transform .19 Block Diagram of a PID Controller .1 Motor stator windings network .2 Measure one phase to each other .3 Measure 2 phases to each other .4 Using VESC to measure the Lq and Ld params .5 Back emf of BLDC motor .6 The hall sequence when rotating 360 degree.7 The signal collected from the motor .1 The FSESC 75100 with Aluminum case.2 Available pinouts on FSESC 75100 .3 Core specifications of STM32F405RGT6 .4 MCU STM32F405RGT6 .5 Module CAN interface MCP2551 .6 Schematic of MCUs in FSESC .7 Phase A of Inverter for BLDC output .8 EG3112 diagram circuit .9 Phase C of Inverter for BLDC output .10 Phase B of Inverter for BLDC output .11 Voltage Regulator of 12V, 5V and 3.3V built-in hardware .1 FOC with PI controller using Hall sensor .2 Firmware architecture of VESC .3 Flowchart of the firmware .4 Time distributed in RTOS .5 Tasks State in ChibiOS .6 The priority of the threads .7 Example of Task sheduling .8 Description of the task .9 The Eclipse Platform .10 Stlink-v2 debugger with SWD and JTAG interfaces.11 Correct looking interface of the IDE.12 The success building message of the firmware.13 Connecting hardware with stlink-v2 debugger.14 Successful connection with stlink-v2 debugger .15 Success message of Stlink connection.16 Debugging section on the IDE .17 Flowchart of Main program .18 Flowchart of PID algorithm and ADC application .1 Specification of Power supply .2 Power supply in Inventor .3 BLDC motor in model .4 BLDC motor in Inventor .6 Installation layout drawing .7 Design of the model .8 Model after implementation .9 VESC tool welcome page .10 Success Motor Detection .11 Choose type of ADC input .12 Mapping ADC input .13 Select control type of ADC input .14 Success ADC configuration window .15 FOC Real-time Diagram .16 Motor RPM Real-time Diagram .17 PWM of High side Out phase B and phase C of the MOSFET .18 Low side Out of phase B and phase C measured by oscilloscope.19 Hall Sensor of phase B and phase C .85 ix List of Tables Table 2.1 Categorized Electric Motor .2 Hall Section table .1 Comparison of wye network and Delta network .1 MCU driver mapping .2 ADC Group Mapping.3 Specification of power supply .4 Dimensions of a power switching .5 Specification of motor .6 Wiring of the BLDC in color .7 Dimensions of a BLDC .8 Dimensions of a aluminum frame .76 x List of Abbreviation Abbreviation Full Form EV Electric vehicle BLDC Motor Brushless Direct Current.Motor E-bike Electric bike IoT Internet of Things VESC Vedder Electronic Speed Controller PID Proportional – Integral – Derivative SVPWM Space Vector Pulse Width Modulation FOC Field Oriented Control ADC Analog Digital Converter PM DC Permanent Magnets Direct Current SyRM Synchronous reluctance motor VFD Variable frequency drive DC Direct Current AC Alternating current PMSM Permanent magnet synchronous motors ESC Electronic speed control MCU Microcontroller unit MOSFET Metal-oxide-semiconductor field-effect transistor RPM Revolutions Per Minute GUI Graphical User Interfaces. xi UART Universal asynchronous receiver-transmitter CAN Controller Area Network SPI Serial Peripheral Interface GPIO General Purpose Input Output RTOS Real-time Operating System VOM Volt-Ohm-Meter IDE Integrated Development Environment CPU Central Processing Unit OS Operating System VESC Vedder Electronic Speed Control ADC Analog-to-Digital Converter DMA Direct Memory Access USB Universal Serial Bus PWM Pulse Width Modulation I2C Inter-Integrated Circuit Wb Weber A Amper V Volt xii Chapter 1: INTRODUCTION 1.1 Topic background In the modern industrial era with the applying electric motor in our life especially in the manufacturing industry and mobility, researching and applying BLDC motor control technology not only brings technical benefits but also significant economic and social value.