Design and research of permanent magnet synchronous motor controller for electric vehicle

• Published in: Energy science & engineering 2023-01, Vol.11 (1), p.112-126
• Main Authors: Huang, Qi, Huang, Qiuhong, Guo, Hangcheng, Cao, Jichao
• Format: Article
• Language: English
• Subjects: Algorithms; Circuit design; Control systems design; Control theory; Controllers; cooling channel; Design; Efficiency; electric vehicle; Electric vehicles; Electronic components; Field weakening; Hardware; Low noise; Magnetism; permanent magnet synchronous motor; Permanent magnets; Signal processing; Structural strength; Synchronous motors; Transistors; Weight reduction
• ISSN: 2050-0505; 2050-0505
• DOI: 10.1002/ese3.1316

Permanent magnet synchronous motors (PMSM) have high power density, stable output torque, low noise, and good speed regulation performance, making them very suitable for electric vehicle propulsion. In this paper, a PMSM controller, based on Renesas MCU, is designed. To meet the requirements of small size, lightweight, wide speed range, and power generation of the PMSM controller the design has been carried out from three aspects: hardware circuit, structural components, and software algorithm, including electronic component selection, hardware protection circuit, printed circuit board layout, control algorithm, structural strength, and the cooling channel. The controller prototype was produced and an experimental platform was built. The controller efficiency test, generator test, field weakening test, and temperature rise test were carried out. The experimental results verify the rationality of the design scheme. Compared with earlier motor controllers, this controller is small in size, light in weight with low cost. A 600 V/36 kW/5600 rpm permanent magnet synchronous motor controller is designed for electric vehicles. To meet the requirements of small size, lightweight, wide speed range, and power generation of the permanent magnet synchronous motor controller, the design is carried out from three aspects: hardware circuit, structural components, and software algorithm. The use of surface‐mounted components, film capacitors, and integrated power modules can effectively reduce the volume of the controller. The spiral water cooling system ensures that the temperature rise of the controller is within the specified range. The hardware protection circuit and software protection algorithm jointly improve the reliability of the controller.