Prius A/C IPM Part 2: JaredTroller Assembly and Housing Machining

Much Progress! last post here. The JaredTroller boards arrived. The text got a bit messed up but other than that they looked great. The footprint I made fit the brick perfectly. It fit very snugly. The capacitors did not fit very well though, as they were wider than expected. Some slight belt sanding was necessary to […]

Getting Into IMPs: Prius A/C IPM Motor

Recently I bought a little BMX bike. Obviously it will not stay pedal powered for long. Over winter break I’d been thinking a lot about what motor to put on it. I had a few 6374 SK3s kicking around, which seemed good but would be just slightly underpowered for a bike. The calculations I did suggested that it […]

ESC MK 2: F303 DRV8323SR Motor Controller

In last week’s post, I showed the design of a new motor controller I’ve been working on. This motor controller is better than my last one mostly just due to its elegant simplicity. It uses the DRV8323SR, a recently released chip by TI, which contains all six gate drives,  three shunt amplifiers, and even a […]

October, and a New Motor Controller

October has been a month of pretty hardcore board layout fun. Two days ago I submitted a 3pcb order with 5 WHOLE BOARDS. First up, a new ESC, ESC Mk 2: Second up, basically the same board but without the microcontroller: Third up: an NRF24L01+ controller board, using an STM32F303. Fourth up: another NRF24L01+ controller […]

Motor Control: The Velocity Estimator Saga

Last time, I’d managed to make current control work on my new board, and now it was time for servo position control. After a bit of hacking around and trying random PID gains, I wrote some code to generate a position profile for the motor to track. Using this framework I could easily run sinusoid or step response tests and […]

Motor Controller: Board 5!!!

When we left off last time, I’d dealt with a bunch of issues with misused current sensors. Here is a photo of the lovely Motor Science Rig in all its glory, taken with Bayley’s ViewCamera. With the current sensors installed properly, it was time to move from voltage-mode FOC to current-mode FOC. I had some minor issues doing […]

FOC PART 4: More Hardware Debugging!!!

The Motor Science Rig. When I left off last time, I had bestowed the ADCs with capacitor-based magic which caused them to function properly. The next step was to hook up the current sensors and forcefully request that they, too, function properly. Wary of hardware problems, I collected some data before jumping straight to current-mode FOC. Through […]

FOC Motor Controller part 3: The Delinquent Current Sensors Persist

Welcome back to the motor control suite. After blowing up the last board, I decided to design a new one.  Changes included new current sense amplifiers and a different power regulator setup. The current sense amps were the LMP8481, which required an additional 3.3v trace to be routed to the sense amplifier area. This proved […]

Back Burner Project: FOC Motor Controller!

It seems as if building a motor controller is somewhat of a MITERS rite-of-passage. Inspired by Ben’s and Bayley’s motor control work, I decided to embark on my own motor control adventures. This morning, I pressed the 3pcb button for a batch of 10 boards. Chips onboard: IRSM005-800MH half bridges with integrated gate drive STM32F446 […]