Project
| # | Title | Team Members | TA | Documents | Sponsor |
|---|---|---|---|---|---|
| 17 | Integrated Brushless Motor Exploration Platform |
Alex Roberts Jason Vasko |
Michael Gamota | design_document1.pdf final_paper1.pdf grading_sheet1.pdf presentation1.pptx proposal1.pdf |
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| # Integrated Brushless Motor Exploration Platform Note, project changed marginally from initial idea. Original idea post is [Multiple Motor Stimulation Hardware Investigation Tool](https://courses.grainger.illinois.edu/ece445/pace/view-topic.asp?id=76583) # Team Members: - Alex Roberts (asr9) - Jason Vasko (jrvasko2) # Problem Exploring topics in motor control requires at least a moderate knowledge of electronic hardware systems. Even when using commercial off the shelf motor drivers, microcontrollers, power regulators, and power supplies still need to be connected to the motor driver, which can cause confusion for people without a working electrical engineering knowledge. This makes it difficult for students in disciplines other than ECE, such as mechanical or aerospace engineering, to experimentally learn about motor control. # Solution We propose a single integrated device which is usable with minimal electronics experience that allows the user to test motors with different motor control algorithm parameters at different speeds. The board will act as an educational tool to allow people interested in topics such as field oriented control, or 3-phase power system in general, to operate brushless motors and explore control algorithms with as few external connections as possible. Our project integrates the microcontroller, sensors, power regulation, and motor drive circuitry required to spin a brushless DC motor into a single board. It will only require the user to connect a computer over USB, the 3 phase wires of the motor, and two simple power connections (one to a 12V wall adapter for logic and sensing power, and the other to a benchtop supply used only for motor bus voltage). On the computer there will be a GUI application that allows the user to control the motor, modify the motor control algorithms, and measure motor performance. Ultimately, the system will serve as a single platform for learning about brushless DC motor drivers and control algorithms with as few external tools needed as possible. # Solution Components ## Control Subsystem The control subsystem is responsible for driving and/or monitoring all other subsystems. It will periodically read data from the sensory array, monitor the health of the power subsystem, and generate PWM signals for the motor drive subsystem. It will also communicate with the PC app, updating the GUI periodically and allowing the user to set motor parameters such as speed and PID controller coefficients. This subsystem includes: - System Microcontroller (STM32F446RET6) ## Sensor Array The sensor array is responsible for recording data related to the motor’s operation and the overall health of the board. This subsystem includes: - Current and voltage sensors for the three-phase signals driving the motor and to monitor health of the voltage regulators (INA230AIDGSR) - We will use shunt resistors to use this same IC for both voltage and current monitoring. - Physical encoder to measure motor angle and speed (PEC11R-4220K-S0024) - We will use a 3D printed jig that the user attaches the motor to during operation. The motor shaft and encoder shaft will then be connected using gears attached to each, so the motor shaft position can be measured using the rotary encoder. ## Power Subsystem The power subsystem is responsible for generating the needed voltages for components on the board such as sensors and the microcontroller. A small 12V DC wall adapter will plug into a banana jack on the PCB, which is converted using a buck regulator to our logic voltage of 3.3V. We also require the user to connect a benchtop power supply which will provide motor bus voltage directly. This avoids needing to integrate a complex, multiple hundred watt converter into the board, which would be unrealistic given the timescale of this project. This subsystem includes: - Adjustable switching buck converter to convert the 12V supply to 3.3V to power the microcontroller (TPS562201DDCR) ## Motor Drive Subsystem The motor drive subsystem is responsible for generating the AC waveforms supplied to each phase of the motor. To do so, we will use gate drivers and half-bridges connected to the motor bus voltage coming from the benchtop power supply. This subsystem’s primary components are: - MOSFETs for the half-bridges for each phase (IRFI1310N) - Half-bridge gate driver ICs for each phase (DGD05473) # Criterion For Success We consider the project a success if it satisfies the following criteria: - User should be able to control motor speed and/or position through a PC app GUI connected to the board via USB. - User should be able to set and change motor driver parameters such as PID coefficients. - User should be able to see aspects of the motor control algorithm performance on the GUI, such as motor speed and three-phase voltages and currents. - User should only require four external connections to use the device: a wall power connection, a benchtop power supply, a usb connection to the laptop, and the motor phases. |
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