My name is Berca Iulian, i`m from Romania, i have electrical engineering studies i work develop new 3Phase inverters for Brushless motors and PMSM.

PA202935_cr
I`m designing in Eagle-cad : brushless controller circuits, dc motor controller circuits,protection circuits,etc.
I`m constantly improving my design for a robust brushless controller, with all protection needed (overcurrent, over-temperature,fault output, torque control) also ramp acceleration and deceleration and adapting timing angle.
Now i also work on a new design of a large 48 pole 60kW direct drive brushless motor.

http://www.masinaelectrica.com/60kw-bushless-motor-design/

I am interested in a possible collaboration for electric car projects. How to build  and efficient brushless controller based on Motorola  MC33035  step by step. I ordered from On semiconductor as free sample 5pcs.maximum. You only pay for transport and handling.

  1. Features:
  • – Uses analogical chip with no software inside.
  • – Work only with sensored brushless motors.
  • – Speed adjustable via a potentiometer
  • – Adjustable acceleration deceleration
  • – Loop Control
  • – Fackword / Forward
  • – Dynamic breaking
  • – Over-current sense from external  shunt resistor 100mV threshold level.
  • – Overheat protection.
  • – Undervoltage protection.
  • – Fully Accessible Error Amplifier for Closed Loop Servo Applications
  • – Adjustable PWM frequency
  • – 6.25 V Reference Capable of Supplying Hall Sensor Power

I used Eagle Cad to make the schematic and the board.

 

New version of the schematic and it is easy to understand :

brushless controller schematic

 

 

This is another version with more mosfets in parallel and different drivers.

I used only N-channel mosfets in junction with  IR2110 half bridge mosfet driver.

You also need a inversor gate for the Top Drives (4049)

This is the newest version with 4 mosfet in parallel per switch  IR4110 but doesn`t matter what mosfet you use as the volgate and current is good for you.

top driver_cr

The pin 3 JP8  goes  to the Board 2 (Comand module) at JP20 pin 1

The pin 1 JP8 goes to Board 2 JP20 pin 2

The Pin 3 JP9 goes to the Board 2 at JP20 pin 3

The pin1  JP9 goes to the Board 2 JP20 at pin 4

The pin 3 JP10 goes to the Board 2 JP20 pin 5

The pin 1 JP10 goes to the Board 2 jp20 pin 6

The pin 1 gnd of the JP5, JP6. JP7  can be left in the air. because gnd is common.

 

 

 

 

Brushless controller schematic mc33025

In the upper part you can se the current sensor Allegro ACS758 200A.

You can also see in the left the bottom module next to it the driver+ top module.

In the right upper corner command module and in lower corner a dc-dc converter module from ebay.

to power the cmomand module and the driver board.

You can put any mosfets channel N you need. Best are with internal resistance as low as possible and higher current.

Board 3 mc33035 Brushless controller

 

 

 

 

 

 

This diagram was draw by a website visitor by name “Bill Catalena” from my specification.

Brushless controller schematic mc33035

This is the 3-rd Board with bottom mosfets.

The U,V,W need to be connected to the U,V,W to the top part of the mosfets.

The Pin 1 of the JP1 goes to the pin 2 JP5 from the Board 1

The pin 2 of the JP1 goes to the pin 2 JP6 from the Board 1

The pin 3 of the JP1 goes to the pin 2 JP7 from the Board 1

Ground pin is connected from the power supply of 48v

 

 

 

bottom mosfets mc33035 driver

P7010977

 

Toyota Prius IGBT module

This toyota prius igbt module inverter was from a scrap and i took apart the driver board. now i-m building my own diver board.igbt module toyota prius

In order to be able so start the motor  you need to put a floating dc power supply to the IR2110

I have tested some of 1200V 600A FZ600R12KE3 IGBT module and the input capacitance was ~ 55nF. The time rinse obtained with avago IC ACPL-P343 was 1,2uS at 12Khz, not so good  if you want the switching losses low. the datasheet:  http://www.farnell.com/datasheets/1676975.pdf

In this video i used 12 Mosfets irf3205z and IR2110 driverInfineon IGBT

 

 

 

 

 

 

Now the big thing : Testing the Electric Go Kart to measure the results