Protection of Solar Electric Car DC Motor with PIC

Controller

Ahmed M.A. Haidar1, Ramdan Razali1, Ahmed Abdalla1, Hazizulden Abdul Aziz1,
Khaled M.G. Noman2, and Rashad A. Al-Jawfi3
1
University Malaysia Pahang, Malaysia
2
Sanaa University
3
Ibb University, Yemen

Abstract. The electric car may represent new opportunities for any country and
its electric utilities. Widespread use of electric cars can reduce the consumption
of both imported and domestic oil, substitute abundant fuels such as coal and
nuclear power. Since the charging of electric cars DC motor can be
accomplished to a large extent during utility off-peak hours, electric cars can
contribute to improve the utility load factors, as a result, reducing the average
cost of generation. The problem arising when the DC motor does not stop
automatically due to the abnormal condition and cause the loss of energy and
the damages to the motor itself. This paper is mainly about controlling ON and
OFF of Electric Car DC motor when the load is sharply varied. In this study, the
DC motor is connected to the current sensor interfaced with the PIC controller
and a booster IC is used to boost 12V to 24V from a rechargeable battery which
is supplied by a solar panel. The PIC is utilized for automatically stopping the
DC motor in order to save the Electric Car and reduce the lost of energies. The
Microcode Studio software has been used for PIC coding incorporating with the
Protues 7.5 simulation. Since the DC motor is being used extensively in
machineries and vehicles, the proposed controlling system in this paper could
reduce the cost in the industries and improve the quality of Electric Cars.

Keywords: Electric Car, DC motor, PIC controller, Temperature sensor.

1 Introduction
Nowadays, in many countries, the solar cell energy has been used to replace the fuel.
Solar cell energy does not create the pollution, but still has to be developed into
effective use. Many car manufacturers introduce a hybrid electric car in their gamut.
The required motor power has been determined from typical traffic load diagrams.
For a top speed of 80 km/h on slopes up to 20 % and a targeted vehicle weight of 650
kg and the motor power needs to be 17.5 kW nominal (30 kW peak) [1]. Of the
several technologies available, the ones adopted by the automotive industries
classified broadly into hybrid electric vehicles (HEVs) and electric vehicles (EVs).
The concept of hybrid electric vehicles initially came up as a stop gap approach to
facilitate a smoother transition from conventional to electric vehicles as and when

M. Zhu (Ed.): Electrical Engineering and Control, LNEE 98, pp. 149161.
springerlink.com Springer-Verlag Berlin Heidelberg 2011
150 A.M.A. Haidar et al.

EVs became viable. Compressed air based technologies, plug-in HEVs; solar
powered automobiles are some of the several alternative propulsion technologies
being worked on right now [2].
For a hybrid car, low fuel consumption is one of the most important goals because
the additional cost of the hybrid components must be amortized by the cost reduction
of fuel consumption. A long life cycle for the hybrid component is also an important
goal, because an amortization can only be achieved if all car components reach their
estimated age. With the respect to the life time, a battery is the most sensitive
component in electric car [3]. The current designs have relatively poor performance
when discharged at high rates and their use in automobiles is likely to be restricted to
low-power or reserve duties where their high specific energy is the main attractive
factor [4]. Currently, an electric car incentive is the possibility of using renewable,
liquid hydrocarbon fuels, such as methanol, in efficient reformer systems to replace
pure hydrogen storage and improve the fuel storage capacity [5].
Due to the technical demands and the progress in the field of car networks, enforce
continuing development of the existing electrical car sensors [6]. In the automotive
industry, sensors are mainly used to give information to the driver. In some cases
sensors are connected to a computer that performs some guiding actions, attempting
to minimize injuries and to prevent collisions. The application of sensors in the
intelligent transportation system is to provide assistance to some control elements of
the vehicle, like the throttle pedal and consequently, the speed-control assistance [7].
A cruise control system is a common application of these techniques. It consists of
maintaining the vehicle speed at a user (driver) pre-set speed and computer control
speeds their response times to road hazards so that the cars can travel more
safely [8]. The method of electrical array reconfiguration that is suitable to a
photovoltaic powered car is differentiating from that of the water pump which needs
only the maximum power. But photovoltaic powered car needs both torque and speed
which is changed by the appropriate situation. The switching of electrical
reconfiguration is controlled for automatic reconfiguration by fuzzy controller [3].
The DC motors that are used in the electric cars do not have an intelligent
controller to stop automatically during over load situation. This case will force the DC
motor to work more than its capacity and could cause a malfunction of the DC motor
or any electrical short at the wiring system. Therefore, the current protection of
electric cars should be modified in order to avoid this problem. This paper proposes
an effective protection based on temperature sensors to detect the changes of
temperature. A thermocouple converts temperature to an output voltage and the
output signal will be sent into the peripheral interface controller (PIC) which is
programmed to send commends to the switching systems for taking a further action to
stop the motor instantly via IRF 540 [9]. The effective protection controlled by PIC is
interfaced with the analog temperature sensor to switch ON or OFF the DC motor.
The designed source codes of PIC are considering the required conditions of the
system protections and the behavior of electric cars DC motor.
 Protection of Solar Electric Car DC Motor with PIC Controller 151

2 System Description
Since the contribution of this work is mainly focusing on the DC electric car
protection, more details describing the PIC and temperature sensor are given in this
section. Whereas the other parts involved directly to the electric system are briefly
outlined.

2.1 Solar Panel

PV panels convert sunlight to electrical energy used to supply power directly to the
electrical car. Generally, PV is considered as an expensive method of producing
electricity but it offers a cost-effective alternative to expensive grid. The development
of new PV technologies for applications of PV in public electricity has grown rapidly.
Solar system panel were the main supply for the system which supplies a maximum
of 12 V to the battery.

2.2 Solar Charge Controller

A solar charge controller is needed in virtually all solar power systems that utilize
batteries. The function of the solar charge controller is to regulate the power going
from the solar panels to the batteries. Overcharging batteries will significantly reduce
battery life. The most basic charge controller simply monitors the battery voltage and
to open the circuit (stopping the charging) when the battery voltage rises to a certain
level. Older charge controllers used a mechanical relay to open or close the circuit.

2.3 PIC Microcontroller

PIC microcontrollers have attractive features and they are suitable for wide rang of
applications. PIC is a family of a microcontrollers and use Harvard architecture. The
instruction is set to be non-overlapping or mutually independent. The Harvard
architecture makes use of separate program and data memories. The separation of data
and address buses is allowing increased data flow to and from the CPU and making
the different widths between these busses. PIC microcontroller can be used to model
the behavior of the machine as a logic program. The PIC 16F877 used in this work is
shown in Figure 1, for the protection system, the OSC pin is connected with the
crystal 8Mhz, RAD/ AND connected to the temperature sensor. The pin k1 is
connected to the LED, Pin P1 is connected to the motor and the Pin Rbs are connected
to the LCD display. All the features of the PIC are illustrated in Table 1 and given as
follows:
Full Speed USB 2.0 (12Mbit/s) interface
1K byte Dual Port RAM + 1K byte GP RAM
Full Speed Transceiver
16 Endpoints (IN/OUT)
Streaming Port
Internal Pull Up resistors (D+/D-)
48 MHz performance (12 MIPS)
152 A.M.A. Haidar et al.

Fig. 1. PIC 16F877.

Table 1. Features of PIC16F877.

Specification Value
Program Memory Type Flash
Program Memory Type (KB) CPU 32
Speed (MIP) 12
RAM Bytes 2,048
Data EEPROM (bytes) 256
DigitalCommunication Peripherals 1-A/E/USART,1-MSSP (SPI/I2C)
Capture/Compare/PWM Peripherals 1 CCP, 1 ECCP
Timers 1 x 8-bit, 3 x 16-bit
ADC 13 ch, 10-bit
Comparators 2
USB (ch, speed, compliance) 1, Full Speed, USB 2.0
Temperature Range (C) -40 to 85
Operating Voltage Range (V) 2 to 5.5
Pin Count 40
Packages 40 PDIP, 44 TQFP, 44 QFN
I/O pins 34

2.4 Temperature Sensor (LM35)

The LM35 series are precision integrated-circuit temperature sensors, and its output
voltage is linearly proportional to the Celsius temperature. It does not require any
external calibration or trimming to provide typical accuracies of C at room
temperature and C over a full -55 to +150C temperature range. The LM35's low
output impedance, linear output, and precise inherent calibration make interfacing to
readout or control easily. In LM35 temperature sensor, the output voltage is 10mV per
degree centigrade. If output is 300mV then the temperature is 30 degrees. It can be
used with single or more power supplies and has very low self-heating that is less than
0.1C because it only draws a 60 A from its supply. Basically, there are 3 type of
sensors; thermistor, thermocouple and resistance temperature detectors (RTD). A
thermistor is a type of resistor whose resistance varies significantly with temperature.
Thermistors are widely used as inrush current limiters, temperature sensors, self-
resetting over current protectors, and self-regulating heating elements. A
 Protection of Solar Electric Car DC Motor with PIC Controller 153

thermocouple temperature sensor which is the junction between two different metals
that produces a voltage related to a temperature difference. An RTD is mainly a
temperature sensitive resistor. It is a positive temperature coefficient device, which
means that the resistance increases with temperature [10]. The Characteristics of
LM35 are:
Calibrated directly in Celsius (Centigrade)
Linear + 10.0 mV/C scale factor
0.5C accuracy guaranteable (at +25C)
Rated for full 55 to +150C range
Suitable for remote applications
Low cost due to wafer-level trimming
Operates from 4 to 30 volts
Less than 60 A current drain
Low self-heating, 0.08C in still air
Nonlinearity only 14C typical
Low impedance output, 0.1 W for 1 mA load
For the above mentioned characteristics, the electrical specification, storage
temperature and lead temperature of the LM35 packages are given in Table 2, 3 and 4
respectably.

Table 2. Distributors for availability and specifications of LM35

Input/Output Sources Voltage/Current

Supply voltage +35V to 0.2V
Output voltage +6V to 1.0V
Output current 10 mA

Table 3. Storage Temperature for LM35 packages

Package Temperature range

TO-46 60C to +180C
TO-92 60C to +150C
SO-92 65C to +150C
TO-220 65C to +150C

Table 4. Lead Temperature for LM35 Packages Storage.

Package Lead Temperature

TO-46 (Soldering, 10 seconds) 300C
TO-92 (Soldering, 10 seconds) 260C
TO-220 (Soldering, 10 seconds) 260C
SO Vapor Phase (60 seconds) 215C
Infrared (15 seconds) 220C
ESD Susceptibility 2500V
Specified Operating Temperature Range: TMIN to T MAX
154 A.M.A. Haidar et al.

2.5 MOSFET

The Metal oxide semiconductor field-effect transistor (MOSFET) is a device used for
amplifying or switching electronic signals. In MOSFETs, a voltage on the oxide-
insulated gate electrode can induce a conducting channel between the two other
contacts called source and drain [11]. The channel can be of n-type or p-type (see
article on semiconductor devices), and is accordingly called an nMOSFET or a
pMOSFET (also commonly nMOS, pMOS). It is a common transistor in both digital
and analog circuits [9].

2.6 Boost Converter

A boost converter (step-up converter) is a power converter with an output DC voltage

greater than its input DC voltage. It is a class of switching-mode power supply
(SMPS) containing at least two semiconductor switches (a diode and a transistor) and
at least one energy storage element [12]. Filters made of capacitors (sometimes in
combination with inductors) are normally added to the output of the converter to
reduce output voltage ripple [13]. In this project, a 12 to 24 V boost converter are
needed to supply voltage to 24 V DC motor [14]. A replacement had been made to the
boost circuit with TDA 2004 fixed among components of application circuit as given
in the data sheet. TDA 2004 is an amplifying IC which has many advantages
compared to electronic switch [12].

2.7 Battery

A 12 V lead acid battery is chosen to ensure maximum battery performance, this

battery can be both charged and desolated at the same time. Lead acid batteries are
designed by considering all the important aspects to avoid the main problems and
failures due to the sulfation build-up on the battery plates. It is made using six
identical two volt cells. All the cells contain lead plates of different types of sitting in
dilute sulphuric acid.

2.8 DC Motor

DC motors were the first practical device to convert electrical energy into mechanical
energy. Although AC motors and vector-control drives now offer alternatives to DC,
there are many applications where DC drives offer advantages in operator
friendliness, reliability, cost, effectiveness, and performance. The DC motor is
extensively used as a positioning device because of its speed as well as torque that can
be controlled precisely over a wide range. The wide Applications of DC motor in
automobiles, robots, movie camera, electric vehicles, in steel and aluminum rolling
mills, electric trains, overhead cranes, control devices, etc [15].

3 The Approach for Electric Car Protection

This work is mainly about the DC motor protection of electric car which is controlled
automatically using PIC when there is an increase in load indicated by the
 Protection of Solar Electric Car DC Motor with PIC Controller 155

temperature. The circuit protection of DC Motor should be designed first. Then a

simulation must be carried out to evaluate the performance of the system before
assembling the hardware protection system. For this purpose software Proteus 7 is
used to check the accuracy of PIC coding.

3.1 Construction of Electric Car Protection

The constructed block diagram of the system is shown in Figure 2. The PIC reads the
data from the temperature sensor which is connected to the DC motor. The normal
operating temperature for the 24V DC motor is 35 to 36 C (degree celcius). When
there is an increase in the temperature above 36 C, the motor will be stopped by PIC

Solar Panel Solar Charge Battery

Controller

Booster (TDA 2004)

PIC 16F877 MOSFET

Temperature
Sensor (LM35) 540

24V DC motor of
Electrical Car

Fig. 2. Block diagram of the system

using PWM signal. The TDA 2004 IC is used in the system to boost up voltage from
12 V to 24 V. The solar panel is the main power source to charge the 12 V lead acid
battery which is connected into charge controller and the 12 V output is boosted to the
24 V using the TDA 2004. The output is connected to the motor through the PIC
16F877 for interfacing. A Temperature sensor is linked to the PIC and the MOSFET
is directly connected to the motor. For the Hardware implementation, the components
were selected and tested according to the data of tables as given in section 2. Then, all
components are collected based on the created design. The maximum operating
156 A.M.A. Haidar et al.

temperature of the selected DC motor was measured to check whether the data of the
datasheet are correct or not before inserting the coding values. The written codes were
compiled into the HEX file before burning into the PIC. A 5V DC was supplied into
the PIC and LCD display. The motor connected into 24V DC and the heavy load was
applied to the mechanical output of the DC motor.

3.2 Temperature Effect on the DC Motor

Due to the load increase, the flux in the stator will be increased as well as the torque.
If the torque is decreased by decreasing the field current, the following sequences are
found [16]:
Back EMF drops instantly, the speed remaining constant because of the inertia
of heavy armature
Due to decrease of EMF, armature current is increased
A small decrease of flux is more than counterbalanced by a large increase of
armature current
If torque increases the speed also increases
If applied voltage is kept constant, motor speed has inverse relation with flux and
RPM is [5],
N = K (V IR) / (1)

where, N - revolutions per minute (RPM); K - proportional constant; R - resistance

of armature (ohms); V - electromotive force (volts), I - current (amperes); - flux
(webers).
According to Eq. (1), when the current is increased the RPM will be increased and
more heat generation as a temperature rise of DC motor. The increase in temperature
makes the atoms in the material getting energetic to hinder the flow of the electrons
[16]. In the normal range of operating temperature, as the temperature is increased,
the residual flux density at the stator and intrinsic coercively of the magnet will come
down. But, this is a reversible process because, when the temperature is reduced, the
flux density and coercively will return to the original value [17]. This variation in
residual flux density of the magnet along with the variation in armature resistance of
the motor with temperature influences the torque capability and efficiency of the
motor [18, 19].

3.3 PIC Coding of Electric Car Protection

Microcode studio was used to compile the PIC coding. The constructed cods have
been compiled and simulated using Protues software to insure the accuracy of the
coding commands. For the hardware implementation, the PIC was loaded by the
following cods:
Define crystal being used
'
DEFINE OSC 8 'Using 8Mhz external crystal
'
 Protection of Solar Electric Car DC Motor with PIC Controller 157

'Define LCD
'
DEFINE LCD_DREG PORTB 'Set LCD data port to PORTB
DEFINE LCD_DBIT 0 'Set data starting bit to 0
DEFINE LCD_RSREG PORTB 'Set RS register port to PORTB
DEFINE LCD_RSBIT 4 ' Set RS register bit to 4
DEFINE LCD_EREG PORTB 'Set E register port to PORTB
DEFINE LCD_EBIT 5 'Set E register bit to 5
DEFINE LCD_BITS 4 ' Set 4 bit operation
DEFINE LCD_LINES 2 ' Set number of LCD rows
'
'Define A/D converter parameters
'
DEFINE ADC_BITS 8 'A/D number of bits
DEFINE ADC_CLOCK 3 'Use A/D internal RC clock
DEFINE ADC_SAMPLEUS 50 'Set sampling time in us
'
'Definition for HPWM
'
DEFINE CCP1_REG PORTC 'Channel 1 port
DEFINE CCP1_BIT 2 'Channel 1 bit
DEFINE CCP2_REG PORTC 'Channel 2 port
DEFINE CCP2_BIT 1 'Channel 2 bit
'
'Variables
'
Res Var Word 'A/D converter result
Temp1 Var Byte 'Temperature in degrees C
TRISA = 1' RA0 (AN0) is input
TRISB = 0 'PORTB is output
PAUSE 500 ' Wait 0.5sec for LCD to initialize
D VAR BYTE 'HPWM calculated duty cycle
LED_D1 VAR PORTC.0 'PORTC.0 as LED_D1
OUTPUT LED_d1 'PORTC.0 as output
'
' Initialize the A/D converter
'
ADCON1 = 0 'Make AN0 to AN4 as analog inputs,
'make reference voltage = VDD
ADCON0 = %11000001'A/D clock is internal RC, select AN0
' Turn on A/D converter
LCDOUT $FE, 1 'Clear LCD
'
'Main Programs
'
MAIN:
'
'Start A/D conversion
158 A.M.A. Haidar et al.

'
ADCIN 0, Res ' Read Channel 0 data
Temp1 = 2 * Res ' Convert to degrees C
LCDOUT $FE,2,"TEMP = ",DEC2 Temp1, "C" ' Display
decimal part
PAUSE 500
'
'HPWM programs
'
d = 8*(Temp1 - 25) + 127
IF Temp1 >= 36 THEN
HPWM 1, 0, 2000
PAUSE 500
ENDIF
IF Temp1 < 36 THEN
hpwm 1, 255, 2000
PAUSE 500

ELSE
hpwm 1, D, 2000
PAUSE 500
ENDIF
'
'LED programs
'
IF Temp1 < 36 THEN
HIGH LED_D1
PAUSE 100
LOW LED_D1
PAUSE 100
ENDIF
IF Temp1 >= 36 THEN
HIGH LED_D1
ELSE
LOW LED_D1
ENDIF

GOTO MAIN 'Repeat Main

END

4 Case Study
A simulation has been carried out on the selected components of the circuit given in
Figure 3 and the HEX file inserted into the PIC for real testing of control commands
interfaced with Proteus 7.0. The output is obtained by setting the temperature above
and below 36 C as seen from Figure 4. The LCD LM 016L was used to display the
temperature based of the commands sent by PIC coding. The protection system was
 Protection of Solar Electric Car DC Motor with PIC Controller 159

Fig. 3. Simulation of Electric Car Protection

Fig. 4. Temperature is below 36 C motor is running

tested on real time application to validate the results of simulated coding. The
hardware components of protection system have been connected and then turned on
by supplying a 5V to the PIC and LCD display with a 24 V applied to the DC motor.
It was found that in some cases of real time testing, the motor is still functioning
160 A.M.A. Haidar et al.

according to the built cods when overload is occurred. This is due to the
environmental effect such as ambient temperature that gives double effects on the
motor. The output PWM at the motor is monitored by using digital oscilloscope at
50% Duty Cycle, and the obtained output can be seen in Figure 5.

Fig. 5. PIC 16F877As PWM output in digital oscilloscope

5 Conclusion
The Fast protection of an electric car DC motor is presented in this paper. In the
simulated case study, the DC supply is considered as renewable energy source. The
PIC codes were successfully tested on a real time application for automatic ON/OFF
motor based on the signals received by temperature sensor. At the hardware
implementation, the protection system of electrical car DC motor was efficiently
operated and commended by the PIC microcontroller. The advantages of this
protection system are safety, easy for implementation and space saving. Future works
will be carried out on the application of intelligent controller with a higher level
power booster for solar source, taking into account the improvement of alarm system.

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