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ELECTRICAL SYSTEM (MOTOR CONTROL) OF A SERIES HEV
Thesis · May 2013
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ELECTRICAL SYSTEM (MOTOR CONTROL)
OF A SERIES HEV
Project Final-Defense Report
National University of Sciences and Technology (NUST), Islamabad, Pakistan
Ali Khalid Asadullah Khan 2009-NUST-BE-EL-14

Daniyal Bin Amir 2009-NUST-BE-EL- 27
Muhammad FahadAthar 2009-NUST-BE-EL- 56
Usman Nasir 2009-NUST-BE-EL-109
Project Title: “Electrical System of a series hybrid electric vehicle”
Name of group members:

Ali Khalid Asadullah Khan 2009-NUST-BE-EL-14
Signature: _______________________________
Daniyal Bin Amir 2009-NUST-BE-EL-27
Signature: _______________________________
Muhammad FahadAthar 2009-NUST-BE-EL-56
Signature: _______________________________
Usman Nasir 2009-NUST-BE-EL-109
Signature: _______________________________
Project Co-advisor: Mr. Habeel Ahmed
Signature: ________________________
Project Advisor: Dr. Awais Kamboh
Signature: ________________________
1
DEDICATION
This project is dedicated to Dr. Syed Muhammad Raza Kazmi for helping and
providing us with the deep understanding of some really important concepts
that are required for the completion of this project.
2
Table of Contents
INTRODUCTION 7
Parallel Hybrid Electric Vehicle: 8
Series Hybrid Electric Vehicle: 8
PROJET GOALS: 9
PROBLEM STATEMENT: 9
Challenges: 9
DELIVERABLES: 10
LITERATURE REVIEW 11
INVERTERS: 11
Single phase inverters: 11
Three phase inverters: 11
120° Conduction mode: 12
Gating signals and output voltages: 12
180° Conduction mode: 13
Why 180° conduction mode? 14
Multi-level inverters: 15
150° conduction mode: 16
Why 150° conduction mode? 17
COMPARISON OF 120°, 180° AND 150° CONDUCTION MODES: 18
DISCUSSION 35
THREE PHASE INVERTER DESIGN: 35

Requirement of a gate driver: 35
Working of a bootstrap capacitor: 36
METHODOLOGY 39
CODE FOR 180 DEGREE CONDUCTION: 43
3
CODE FOR SINE WAVE PWM(PIC18f4431): 49
CODE FOR SINE WAVE PWM (ARDUINO MEGA 2560): 52
RESULTS 57
PROTEUS SIMULATIONS: 57
Gating signals: 57
Output waveform: 58
PCB layout and 3-D visualization: 58
Simulated output voltage (180 degree conduction): 60
MATLAB SIMULATIONS: 69
Field Oriented Control 69
Vector Control Module: 71
PROBLEMS: 73
CONCLUSION 73
REFERENCES 74
4
List of Figures
Figure 1-1 Parallel Hybrid Electric Vehicle .........................................................................................8

Figure 1-2 Series Hybrid Electric Vehicle ............................................................................................8
Figure 1-3 Electrical System of a series hybrid vehicle.......................................................................9
Figure 2-1 Block Diagram of a Inverter ............................................................................................11
Figure 2-2 Three Phase Inverter circuit ...........................................................................................12
Figure 2-3 Gating signals for 120 degree conduction.......................................................................12
Figure 2-4 Gating signals for 180 degree conduction.......................................................................13
Figure 2-5 Output waveforms for 180 degree conduction...............................................................14
Figure 2-6..........................................................................................................................................15
Figure 2-7..........................................................................................................................................15
Figure 2-8 Multi-level Inverters ........................................................................................................15
Figure 2-9 Gating signals for 150 degree conduction......................................................................16
Figure 2-10 Output waveforms for 150 degree conduction.............................................................17
Figure 2-11 Three Phase Inverter circuit..........................................................................................18
Figure 2-12 Understanding the gating of 150 degree conduction ...................................................19
Figure 2-13 degree (0-30 degree).....................................................................................................20
Figure 2-14 150 degree (30-60 degree)............................................................................................21
Figure 2-15 150 degree (60-90 degree)............................................................................................22
Figure 2-16 degree (90-120 degree).................................................................................................23
Figure 2-17 150 degree (120-150 degree) .......................................................................................24
Figure 2-18 150 degree (150-180 degree)........................................................................................25
Figure 2-19 150 degree (180-210 degree) ......................................................................................26
Figure 2-25 Output waveform for 150 degree conduction ............................................................31
Figure 2-26 Output waveform for 180 degree conduction .............................................................32
Figure 2-27 Output waveform for 120 degree conduction .............................................................32
Figure 2-28 Gating signals and output waveform for PWM sine wave single phase inverter ........34
Figure 3-1 Low side IGBT..................................................................................................................35
Figure 3-2 High side gate driver for IGBT.........................................................................................36
Figure 3-3 Mitsubishi IGBT Modules................................................................................................38
5
Figure 3-4 International Rectifiers low and high side gate driver ....................................................38
Figure 4-1 Simple block diagram of project.....................................................................................39
Figure 4-3 Circuit for Current sensor ...............................................................................................40
Figure 4-4 Incremental rotary encoder outputs A,B and Z...............................................................41
Figure 4-5 TFT 7 Inche’s car LCD ......................................................................................................42
Figure 5-1 Single phase inverter simulation ....................................................................................57
Figure 5-2 Gating signals for signle phase inverter simulation........................................................58
Figure 5-3 Single phase inverter output waveform simulation .......................................................58
Figure 5-4 PCB layout for single phase inverter ...............................................................................58
Figure 5-5 3-D Visualization of single phase square wave inverter..................................................59
Figure 5-6 3 phase inverter simulation............................................................................................59
Figure 5-7 Output of 3 phase inverter simulation -180 degree.......................................................60
Figure 5-8 PCB Layout of three phase sine wave inverter (optocoupler and gate driver) ..............60
Figure 5-9 3-D Visualization of three phase sine wave inverter (optocoupler and gate driver) .....61
Figure 5-10 PCB Layout of three phase sine wave inverter (IGBT Module) ....................................61
Figure 5-11 3-D Visualization of three phase sine wave inverter (IGBT Module) ............................62
Figure 5-12 Gating signals for PWM sine wave inverter (G1&G4) ..................................................63
Figure 5-13 Gating signals for PWM sine wave inverter (G3&G6) ...................................................64
Figure 5-14 Gating signals for PWM sine wave inverter (G5&G2) ...................................................65
Figure 0-15 Phase to phase voltages for PWM sine wave inverter (Vab & Vbc) plot 1...................66
Figure 5-16 Phase to phase voltages for PWM sine wave inverter (Vab & Vbc) plot 2...................66
Figure 5-17 Phase to ground voltages for PWM sine wave inverter (VaN & VbN) ..........................67
Figure 5-18 Phase to phase voltage for PWM sine wave inverter- Frequency Verification............68
Figure 5-19 Simulink model for estimation of parameters ..............................................................70
Figure 5-20 Matlab Simulink- Vector Control Module.....................................................................71
Figure 5-21 Car is accelerating from 0-100km/hr. in 20secs ............................................................72
Figure 5-22 Increased Torque at Constant Speed ............................................................................72
6
INTRODUCTION
The conventional cars contain an ICE (Internal Combustion Engine) and the engine purely
works on fuel or gasoline. The increase in the number of cars on daily basis and the
increased consumption of fuel or gasoline in the past few years forces us to look for the
alternatives that can efficiently utilize the fuel or gasoline.
Statistics show that the increase in the prices of fuel or gasoline in under developing
countries like Pakistan is increasing on day to day basis. For instance the average price of
petrol in year 2008 was about 60 Rs while the average price of petrol in year 2012 is found
out to be 100 Rs. This immense increase in the fuel prices specifically petrol let people to
think of increasing the efficiency of conventional ICE’s by integrating an electric motor
with it According to the data provided there is nearly 80% increase in the price of petrol
considering the last 5 years in Pakistan.
Year 2008 2012
Price 60 Rs Approx. 98 Rs (May 12th 2013)
Oil reserves are running out and the economy of the country like Pakistan is getting worst
day by day. Considering the mentioned issues, the solution lies in the use of an electric
motor by integrating the ICE (Internal Combustion Engine) with it. The technique of using
an electric motor with an ICE leads to the concept of “Hybrid Electric Vehicle”.
There are two ways to integrate the ICE (Internal Combustion Engine) with the electric
motor and this develops the two types of hybrid electric vehicle i.e. Series Hybrid Electric
Vehicle or Parallel Hybrid Electric Vehicle.
∑ Series HEV (Hybrid Electric Vehicle)

∑ Parallel HEV (Hybrid Electric Vehicle)
7
Parallel Hybrid Electric Vehicle:
A parallel hybrid vehicle integrates the electric motor with ICE in a way that ICE is
connected in parallel with the electric motor. The following figure illustrates the
combination of ICE with electric motor.
Figure 1-1 Parallel Hybrid Electric Vehicle
Series Hybrid Electric Vehicle:

A series hybrid vehicle integrates the electric motor with ICE in a way that ICE is
connected in series with the electric motor. The following figure illustrates the
combination of ICE with electric motor.
Figure 1-2 Series Hybrid Electric Vehicle
The main difference between the two technologies is that series hybrid electric vehicle uses
generator to charge the batteries and the function of an ICE (Internal Combustion Engine)
8
is limited to charge the batteries whereas the parallel hybrid electric vehicle uses the ICE
(Internal Combustion Engine) as a source of propulsion in the vehicle. The vehicle propels
using the combination of an ICE and an electric motor.
PROJET GOALS:
∑ To develop a simulation of motor control using a software like Matlab.
∑ Designing an efficient inverter to convert DC (from batteries) to three phase AC.
∑ Motor controller for a three phase AC inverter duty induction motor (Siemens
7.5kW).
∑ Integration of race and brake pedals with the motor control unit.
PROBLEM STATEMENT:
“Designing of an efficient motor control system for a three phase induction motor in Series
Hybrid Electric Vehicle”
Challenges:
• Ability of the hardware to handle large currents
• Back EMF production in the motor during the breaking mechanism can destroy the
circuits.
• Efficiency of inverter
Figure 1-3 Electrical System of a series hybrid vehicle
9
DELIVERABLES:
Project consists of three deliverables;
1. Design of an efficient inverter

ÿ Six Step VSI (120 or 180 degree Conduction)
ÿ PWM VSI ( Unipolar or Bipolar Sinusoidal PWM)
2. Motor controller for AC induction motor ( Inverter Duty 7.5 kW)

ÿ Motor control using FOC (Field Orientation Control) or Vector control
ÿ Complete implementation of the Field Oriented Controller for the Induction
Motor
ÿ Tuning the control parameters for maximum performance and efficiency.
3. Interfacing of Controller with race pedal/ Interfacing

ÿ Interfacing of inverter (deliverable 1) with motor controller (deliverable 2).
ÿ Interfacing of race pedal and brake pedals with motor controller (deliverable 2).
ÿ Interfacing of 12 volt TFT car LCD
ÿ Interfacing of encoder
ÿ Interfacing of Temperature sensor
ÿ Interfacing of Current sensor
ÿ Improvisations in algorithm
10
LITERATURE REVIEW
INVERTERS:
Inverters are circuits which convert DC (Direct Current) to AC (Alternating Current). The
following figure shows the basic block diagram for “Inverters”.
Figure 2-1 Block Diagram of a Inverter
Single phase inverters:

There are two main topologies for making a single phase inverter. The single phase
inverter can be made using;
∑ 2 switching devices
∑ 4 switching devices
The inverter design using four switching devices is common and is of practical importance
than as compared to using the two switches for the conversion of voltage from DC to AC.
Three phase inverters:

A three phase inverter can be implemented using six switching devices and the output of
the three phase inverter is dependent on the sequence and the combination of these
switching devices. As there are a total of six switching devices controlling the output in a
three phase inverter and each one of the switches can have a state of either “0” or “1” then
this provides us with a total of 36 combinations of these switches. There are only a few
feasible combinations for which the output is a modified sinusoidal wave. Hence, there are
only two switching topologies used in the control of three phase inverter.
∑ 120° Conduction mode
11
∑ 180° Conduction mode
Figure 2-2 Three Phase Inverter circuit
120° Conduction mode:

Each one of the six switches is “on” for duration of 120 degree out of the total 360 degree.
The gating signals for the switches are as follows;
Gating signals and output voltages:
Figure 2-3 Gating signals for 120 degree conduction
12
∑ The rms fundamental component VL1 of the output line voltage is VL1=0.6753Vs
∑ The gating signals are shifted from each other by 60 degrees
180° Conduction mode:

13
Figure 2-5 Output waveforms for 180 degree conduction
∑ The rms fundamental component VL1 of the output line voltage is VL1=0.7798Vs
∑ The gating signals are shifted by 120 degree
Why 180° conduction mode?

The output waveforms of the explained switching techniques are different and distinct
therefore producing different rms line and phase voltages. In 180° conduction mode, the
rms value of the output voltage is greater than as compared to the output voltage in 120°
conduction mode. So, this is one of the main reasons for giving preference to 180°
conduction mode.
Another reason for giving preference to 180° conduction mode is that 180° conduction
mode utilizes the switches better and also that there are three switches that are “on” at any
instant whereas in 120° conduction mode there are only two switches that are “on” at any
instant.
Apart from the reasons explained in the above paragraph, the most important reason which
is usually neglected is the presence of a floating node in the 120° conduction mode.
This phenomenon can be explained better using the following two circuit diagrams;
Let us suppose a moment or a time (180 Let us suppose a moment or a time (120
degree conduction mode) when switches degree conduction mode) when switches Q1
Q1, Q5 and Q6 are on then we will have the and Q6 are on then we will have the
following circuit diagram at the load side. following circuit diagram at the load side.
14
Figure 2-6 Figure 2-7
The circuit diagram in 120 degree conduction mode has a floating node at phase “b”. This
floating node is responsible for the poor performance and efficiency of the inverter. The
absence of floating node in 180 degree conduction mode makes it a better switching
technique for practical applications.
Multi-level inverters:
For large industrial applications multi-level inverters are designed. Multi-level inverters
divides the main supply DC voltage into smaller DC sources which are used to produce an
AC voltage into a staircase or stepped which is surely the approximation of the desired
sinusoidal output voltage.
The number of steps is increased comparatively than 180 or 120 degree conduction modes
and the increase in the number of steps will provide a wave at the output which is a closer
approximation of a sinusoidal signal.
The following figure illustrates the concept of multilevel inverters.
Figure 2-8 Multi-level Inverters
This scheme not only provides us with a closer approximation of a sinusoidal wave at the
output but it also reduces the total harmonic distortion. The EMI effect is introduced in the
inverters being operated at high frequencies i.e PWM inverters. EMI effect can be
considerably reduced by using the technique of multi-level inverters.
There are three main types of multi-level inverters;
∑ Diode clamped inverters
∑ Capacitor clamped inverters
∑ Cascade inverters
15
150° conduction mode:
16
Figure 2-9 Output waveforms for 150 degree conduction
∑ The gating signals are shifted by 90 degree
Why 150° conduction mode?

150 degree conduction mode provides a better approximation of a sinusoidal wave because
it provides more steps than as compared to the 120 or 180 degree conduction modes. One
of the biggest advantages of using the 150 degree conduction mode is that the total
harmonic distortion is reduced. 120 and 180 degree conduction modes have approximately
a THD of 33 percent whereas it is found that the value of THD reduces to 17 percent for
150 degree conduction mode.
17
Comparison of 120°, 180° and 150° conduction modes:
There are mainly two types of conduction modes that are being used according to the
literature (Power Electronics by Rashid) and which are 120°and 180°conduction modes. In
120 conduction mode, each switch is on for duration of 120 degrees out of 360 degrees
whereas in case of 180 conduction mode, each switch is on for duration of 180 degrees out
of 360 degrees. A more practical, efficient and simple control is explained in the following
research document.
(http://telkomnika.ee.uad.ac.id/n9/files/Vol.9No.3Des11/3RP9.3.12.11.03.pdf)
This research document allows us to think of an idea that involves the hybrid of 120 and
180 conduction modes. 150 conduction mode, as depicted from the name, each switch
turns on for duration of 150 degrees out of 360 degrees.
How 150 degree conduction works?
Figure 2-11 Three Phase Inverter circuit
Now, consider the following gating signals that are being provided to the circuit as shown
above using a microcontroller unit.
18
Figure 2-12 Understanding the gating of 150 degree conduction
A total of 360 degrees is divided into 12 equal segments of 30 degrees interval each. We
will analyze each interval.
19
0-30 Degree Interval:
3 switches are on which are 1,5 and 6 whereas all other switches are on for the mentioned
time interval. For this specific interval the phases a and c will have a voltage VDC also
that the phase b will be connected to ground.
Figure 2-13 degree (0-30 degree)
Van = [(R/2)/(R/2 + R)] x VDC
=[0.5R/1/.5R] x VDC
=1/3VDC
2 switches are on which are 1 and 6 whereas all other switches are on for the mentioned
time interval. For this specific interval the phase a will have a voltage VDC also that the
phase b will be connected to ground.
20
Figure 2-14 150 degree (30-60 degree)
Van = [(R/2] x VDC
=1/2VDC
phase b and c will be connected to ground.
21
Van = [(R)/(R/2 + R)] x VDC
=[R/1.5R] x VDC
=2/3VDC
phase c will be connected to ground.
22
Figure 2-16 degree (90-120 degree)
Van = [(R/2] x VDC
=1/2VDC
time interval. For this specific interval the phase a and b will have a voltage VDC also that
the phase c will be connected to ground.
23
Van = [(R/2)/(R/2 + R)] x VDC
=[0.5R/1.5R] x VDC
=1/3VDC
time interval. For this specific interval the phase b will have a voltage VDC also that the
phase c will be connected to ground.
24
Van = 0 volts (Floating Node)
3 switches are on which are 2, 3 and 4 whereas all other switches are on for the mentioned
phase a and c will be connected to ground.
25
Vna = [(R/2)/(R/2 + R)] x VDC
=[0.5R/1.5R] x VDC
=1/3VDC
Or Van = -Vna
Van = -1/3 VDC
phase a will be connected to ground.
26
Vna = [(R/2] x VDC
=1/2VDC
Or Van = -Vna
Van = -1/2 VDC
time interval. For this specific interval the phase b and c will have a voltage VDC also that
the phase a will be connected to ground.
27
Vna = [(R)/(R/2 + R)] x VDC
=[R/1.5R] x VDC
=2/3VDC
Or Van = -Vna
Van = -2/3 VDC
time interval. For this specific interval the phase c will have a voltage VDC also that the
phase a will be connected to ground.
28
Vna = [(R/2] x VDC
=1/2VDC
Or Van = -Vna
Van = -1/2 VDC
phase a and b will be connected to ground.
29
Vna = [(R/2)/(R/2 + R)] x VDC
=[0.5R/1.5R] x VDC
=1/3VDC
Or Van = -Vna
Van = -1/3 VDC
phase b will be connected to ground.
30
Van = 0 volts (Floating Node)
Plot of Van for 150 conduction:
Figure 2-14 Output waveform for 150 degree conduction
31
Similarly the plots for Vbn and Vcn can be obtained by the same method as explained
above. The Phase to Phase voltages such as Vab, Vbc and Vca can be obtained by the
following formula;
Vab= Van - Vbn
Vbc = Vbn - Vcn
Vca = Vcn - Van
32
Conclusion:
The total number of steps in 180 conduction modes is 6 whereas 150 conduction provides
us with 12 steps which is twice as we get in 180 conduction mode. So, 150 is a better
approximation of a sinusoidal wave therefore less total harmonic distortion in case of 150
degree conduction method.
33
PWM Sine Wave Three Phase Inverter:
Figure 2-17 Gating signals and output waveform for PWM sine wave single phase inverter
A triangular signal is compared with the sinusoidal signal and the output obtained is
provided to the gates of the IGBTs. The important point in this method is again the fact
that there should be delay between the gating signals of the same leg so that there will not
be a shoot through problem that will not cause the IGBTs of the same leg to turn on at the
same time while allowing the DC voltage to be shorted. The diagram shown above is for a
single phase inverter, the three phase inverter concept can be extended by comparing the
same triangular signal with the shifted versions of sine wave having 120 and 240 degrees
phase difference.
34
DISCUSSION
THREE PHASE INVERTER DESIGN:

We are having a three phase AC inverter duty induction motor (Siemens model #
1LA71334AA60) and 12 Volt DC batteries. Conversion of DC to three phase AC will
require an efficient three phase inverter. The design of the inverter is highly important
specifically the key concepts such as bootstrap capacitors, bootstrap diodes and selection
of gate drivers for the design of a particular three phase inverter.
Requirement of a gate driver:

A mosfet or IGBT (switch) works well when used in the common source topology where
the source of the mosfet is connected to the ground and the gate of the mosfet is then
clearly referenced to the ground or source. A problem usually occurs when the source is
not connected to ground and is at some voltage. Assuming that the voltage at the source is
about 10 volts and the voltage at the gate of the high side mosfet is about 15 volts. So, this
will provides us with a low gate to source voltage therefore causing a big problem in
turning the mosfet “on”.
Figure 3-1 Low side IGBT
35
The above explanation creates the requirement of a circuitry that can effectively handle the
switching of the high side mosfet.
The driver’s output stage is implemented either with two n-channel MOSFETs in the totem
pole configuration (source follower as a current source and common source for current
sinking), or with an n-channel and a p-channel CMOS inverter stage.
Working of a bootstrap capacitor:

The gate driver IC is shown below where;
Cbs = Bootstrap capacitor
Dbs = Bootstrap diode
Figure 3-2 High side gate driver for IGBT
When the Q1 (high side mosfet) is “off” the low side is on and the lower end of the
bootstrap capacitor or Vs is connected to ground therefore allowing the bootstrap capacitor
to charge. During this time, the bootstrap diode conducts and charges the bootstrap
capacitor a voltage of Vcc (10-20 volts).
When the low side mosfet turns “off” the Q1 will turn on therefore producing a voltage of
Vdc at its source. Now, the gate has to be at the voltage above the voltage present at the
source of the high side mosfet (Q1). Bootstrap capacitor tracks the voltage present at the
source of Q1 and then maintains the gate of Q1 (10-20 volts) higher than the voltage
present at its source.
36
Bootstrap Capacitor Selection or “Sizing” method:
The following method clearly describes the way to “size the bootstrap capacitor value”
We are using the IGBT modules with a combination of gate drivers i.e. Mitsubishi
CM150DU-12F and IR2101. We can extract the following values of the mentioned terms
as follows;
Qg = 930 nC (CM150DU-12F)
Qls = 50 nC (CM150DU-12F)
Ilk_ge = 100 uA (CM150DU-12F)
Iqbs = 55 uA (IR2101)
Ilk = 50 uA (IR2101)
Ilk_diode= 150 uA (FR103 has a reverse recovery time of 150 nS and typically for reverse
recovery time < 100 nS -> Ilk_diode = 100 uA)
Ilk_cap = 0 (neglected for ceramic capacitance)
Ids or Iin-= 10 uA (IR2101)
T.Hon = 10 uS (Assumed Value)
Q total = (930 + 20) x 10^-9 + (100 + 55 + 50 + 150 + 0 + 10 ) x 10^-6 x 10^ -5
=983.55 nC
∆Vbs <= Vcc –Vf – Vge_min – Vce_on
= 17- 1.3 (FR103-> Forward Voltage Drop) -9.5 – 3.9
=2.3 Volts
C Boot_min>= (983.55 nC / 2.3)
C Boot_min >= 427.630 nF
37
Figure 3-3 Mitsubishi IGBT Modules
Figure 3-4 International Rectifiers low and high side gate driver
38
METHODOLOGY
12 volt batteries connected in series are used to produce a high DC voltage which is then
converted to AC voltage using a three phase inverter. The output of the three phase inverter
is connected to a three phase AC induction motor and the speed of the motor can be
controlled using a race pedal.
Figure 4-1 Simple block diagram of project
We talked about the inverter design and its integration with the race pedal and motor. Now,
we will talk about the protection methodologies that are being used in our project.
Over heat protection:
We implemented a temperature sensor using LM335a and the idea is that the resistance of
this particular sensor increase with the increase in the temperature. So, when used as a
potential divider topology it provides us with a changing voltage up to 5 volts. This change
39
is then fed to microcontroller unit that has an 8-bit analog to digital converter and
microcontroller then interprets this value and using an algorithm converts it into a
temperature value which will be displayed on an LCD module.
Figure 4-2 Circuit for Temperature sensor

Over current protection:
Over current protection is being done a Hall Effect based current sensor which is directly
connected to the dc line which is then fed to the inverter. The amount of current that passes
through the inverter circuit is being monitored by this current sensor.
This current sensor provides a voltage of Vcc/2 when no current is passing and a change of
20 mV/A.
The following circuitry is being used for this current sensor.
Figure 4-3 Circuit for Current sensor
40
RPM Meter:
It is highly important that the RPM’s of the motor are being displayed while the driver is
driving the hybrid electric car. To make this possible we have used a “Incremental Rotary
Encoder” because it is highly efficient in calculating the number of revolutions at very high
speeds.
Figure 4-4 Incremental rotary encoder outputs A,B and Z
Either we can compare the outputs “a” and “b” to calculate the RPMs in a microcontroller
unit or we can just use the interrupt function in microcontroller on output “z”.
41
7 Inches TFT Car LCD:
We are using a TFT 7 Inches car lcd to display the run time values of temperature of IGBT
modules and current of IGBTs. Revolutions per minute are also being displayed on the
same lcd.
Arduino UNO has a library for connecting a TV OUT/ RCA Video to Arduino.
Figure 4-5 TFT 7 Inche’s car LCD
42
CONTROL METHODOLOGIES:
We implemented 180, 120, 150 degree conduction modes practically using Arduino
MEGA 2560 and also PWM Sine Wave using Arduino MEGA 2560 and PIC18f4431 by
developing the following codes;
CODE FOR 180 DEGREE CONDUCTION:

int x1 = 13;
int x2 = 12;
int x3 = 11;
int x4 = 10;
int x5 = 9;
int x6 = 8;
// the setup routine runs once when you press reset:

void setup() {
// initialize the digital pins as an output.
pinMode(x1, OUTPUT);
}
// the loop routine runs over and over again forever:

void loop()
{
//To produce 60Hz, time period = 1/60 = 166667ms
//Time for 1 step = 166667/6 = 2777ms
digitalWrite(x2, LOW);
delayMicroseconds(78); //Delay to avoid short between Vdc and Ground //Delay to avoid short between Vdc
and Ground
digitalWrite(x1, HIGH);
43
delayMicroseconds(2700); //Delay for 1 step //Delay for 1 step
delayMicroseconds(78); //Delay to avoid short between Vdc and Ground
delayMicroseconds(2700); //Delay for 1 step
44
}

//This code provides at 60Hz SixStep gating signals using Delay functions
int g6 = 13;
int g5 = 12;
int g4 = 11;
int g3 = 10;
int g2 = 9;
int g1 = 8;
// the setup routine runs once when you press reset:

void setup() {
// initialize the digital pins.
pinMode(g1, OUTPUT);
}
void loop()
{
//To produce 60Hz, time period = 1/60 = 20000ms
//Time for 1 step = 20000/6 = 3333ms
digitalWrite(g1,HIGH);
digitalWrite(g5,LOW);
45
}

//This code provides at 60Hz SixStep gating signals using Interrupts
#include "C:\Users\Ali\Desktop\arduino-1.0.2\hardware\libraries\Timer1\TimerOne.cpp"
#include "C:\Users\Ali\Desktop\arduino-1.0.2\hardware\libraries\Timer3\TimerThree.cpp"
#include "C:\Users\Ali\Desktop\arduino-1.0.2\hardware\libraries\Timer3\TimerFour.cpp"
unsigned int i;
unsigned int j;
float sine[1000] = {0};
int f=0;
int num=1000;
float deg;
int sfreq = 1000;
int t;
float m=0;
int value1,value2,value3 = 0;
void Update()
{
if(i>999)
{i = 0;}
46
if(m>0.8)
m=0.8;
value1 = ceil(512*m*sine[i]) + 512;

value2 = ceil(512*m*sine[(i+(num/3))%num]) + 512;
value3 = ceil(512*m*sine[(i+(2*num/3))%num]) + 512;
// Serial.println(value1);
if(m==0)
{Timer3.setPwmDuty(5,0);
Timer4.setPwmDuty(6,1024);
Timer4.setPwmDuty(8,1024);}
else
{
Timer3.setPwmDuty(5,value1-100);
Timer4.setPwmDuty(6,value1+100);
i = i + (1000/(sfreq/f));
}
47
void setup()
{
// put your setup code here, to run once:
pinMode(2,OUTPUT);
pinMode(3,OUTPUT);
pinMode(5,OUTPUT);
pinMode(6,OUTPUT);
pinMode(7,OUTPUT);
pinMode(8,OUTPUT);
Serial.begin(9600);
// num = ceil(sfreq/f);
deg = 360.0/num;
t = 1.0/sfreq*1000000;
/* Serial.println(num);
Serial.println(deg);
Serial.println(t);
Serial.println("Sine:");*/
for(j =0;j<1000+1;j++)
{
sine[j] = sin(0.36*(3.14/180)*j);
}
Timer1.initialize();
//Timer3.pwm(5,512,1000);
//Timer3.pwm(2,512,1000);
// Timer3.pwm(3,512,1000);
Timer4.pwm(8,0,1000);
Timer4.pwm(6,0,1000);
Timer4.pwm(7,0,1000);
delayMicroseconds(952);
Timer3.pwm(5,0,1000);
48
Timer3.pwm(2,0,1000);
Timer3.pwm(3,0,1000);
//Timer4.pwm(8,512,1000);
//Timer4.pwm(6,512,1000);
//Timer4.pwm(7,512,1000);
//Serial.begin(9600);
Timer1.attachInterrupt(Update, t);
}
int x,xx;
void loop()
{
// put your main code here, to run repeatedly:
x = analogRead(A15);
//Serial.println(x);
if(x<213)
m=0;
if(x>=215)
{
xx = x;
f = ((x-215.0)/605.0 * 55.0) + 5.0;
m = (f * 10.0)/258.0*0.8;
/* if(x-xx>50 || x-xx<-50)
{ Serial.println(f);
Serial.println(m);
}*/
}
}
CODE FOR SINE WAVE PWM(PIC18f4431):

#include "built_in.h"
unsigned int i=0;
49
unsigned int sine[101] = {0};
unsigned int duty1,duty2,duty3;
unsigned int j;
void main() {
for(j =0;j<101;j++)
sine[j] = 512*sin(3.6*(3.14/180)*j);
if(j<=50)
sine[j] = 512 + sine[j];
if(j>50)
sine[j] = 512 - sine[j];
PORTA=0;
PORTB=0;
PORTD=0;
PORTE=0;
T0CON=0b10001000;
INTCON=0b10100000;
TRISE=0b00000000;
TMR0H=0xF9; // 6000
TMR0L=0x7D;
PTCON0=0b00000000; //prescalar, postscalar and edge aligned free runing mode
PTCON1=0b10000000; //pwm timer enable
PWMCON0=0b01010000; // enabling pwm 1 and 0 in complimentary mode
PWMCON1=0b00000000;
PTPERH=0x01; // pwm period set
50
PTPERL=0xFF;
PDC0L=0;
PDC0H=0;
PDC1L=0; // duty cycle 2
PDC1H=0;
PDC2L=0; // duty cycle 3
PDC2H=0;
DTCON=0b01000001;
//while(1);
void interrupt(void)
//if(i>100)
//i=0;
INTCON=0b10100000; //clear flag
TMR0H=0xF9;
TMR0L=0x7D;
duty1 = sine[i%100];
duty2 = sine[(i+33)%100];
duty3 = sine[(i+66)%100];
PDC0L=Lo(duty1);
PDC0H=Hi(duty1);
51
PDC1L=Lo(duty2); // duty cycle 2
PDC1H=Hi(duty2);
PDC2L=Lo(duty3); // duty cycle 3
PDC2H=Hi(duty3);
i=i+1;
CODE FOR SINE WAVE PWM (ARDUINO MEGA 2560):

#include "C:\Users\Ali\Desktop\arduino-1.0.2\hardware\libraries\Timer1\TimerOne.cpp"
#include "C:\Users\Ali\Desktop\arduino-1.0.2\hardware\libraries\Timer3\TimerThree.cpp"
#include "C:\Users\Ali\Desktop\arduino-1.0.2\hardware\libraries\Timer3\TimerFour.cpp"
unsigned int i;
unsigned int j;
float sine[1000] = {0};
int f=0;
int num=1000;
float deg;
int sfreq = 1000;
int t;
float m=0;
int value1,value2,value3 = 0;
void Update()
52
if(i>999)
{i = 0;}
if(m>0.8)
m=0.8;
value1 = ceil(512*m*sine[i]) + 512;
value2 = ceil(512*m*sine[(i+(num/3))%num]) + 512;
value3 = ceil(512*m*sine[(i+(2*num/3))%num]) + 512;
// Serial.println(value1);
if(m==0)
{Timer3.setPwmDuty(5,0);
Timer4.setPwmDuty(8,1024);}
else
53
i = i + (1000/(sfreq/f));
void setup()
// put your setup code here, to run once:
pinMode(2,OUTPUT);
pinMode(3,OUTPUT);
pinMode(5,OUTPUT);
pinMode(6,OUTPUT);
pinMode(7,OUTPUT);
pinMode(8,OUTPUT);
Serial.begin(9600);
// num = ceil(sfreq/f);
deg = 360.0/num;
t = 1.0/sfreq*1000000;
/* Serial.println(num);
Serial.println(deg);
54
Serial.println(t);
Serial.println("Sine:");*/
for(j =0;j<1000+1;j++)
sine[j] = sin(0.36*(3.14/180)*j);
//Timer3.pwm(5,512,1000);
//Timer3.pwm(2,512,1000);
// Timer3.pwm(3,512,1000);
Timer4.pwm(8,0,1000);
Timer4.pwm(6,0,1000);
Timer4.pwm(7,0,1000);
delayMicroseconds(952);
Timer3.pwm(5,0,1000);
Timer3.pwm(2,0,1000);
Timer3.pwm(3,0,1000);
//Timer4.pwm(8,512,1000);
//Timer4.pwm(6,512,1000);
//Timer4.pwm(7,512,1000);
//Serial.begin(9600);
55
Timer1.attachInterrupt(Update, t);
int x,xx;
void loop()
// put your main code here, to run repeatedly:
x = analogRead(A15);
//Serial.println(x);
if(x<213)
m=0;
if(x>=215)
xx = x;
f = ((x-215.0)/605.0 * 55.0) + 5.0;
m = (f * 10.0)/258.0*0.8;
/* if(x-xx>50 || x-xx<-50)
{ Serial.println(f);
Serial.println(m);
}*/
56
RESULTS
PROTEUS SIMULATIONS:
We implemented a single phase square inverter (two switches) using “ISIS 7 Professional”
as shown below;
Figure 5-1 Single phase inverter simulation
Gating signals:
57
Figure 5-2 Gating signals for signle phase inverter simulation
Output waveform:
Figure 5-3 Single phase inverter output waveform simulation
PCB layout and 3-D visualization:
Figure 5-4 PCB layout for single phase inverter
58
Figure 5-5 3-D Visualization of single phase square wave inverter
We implemented a three phase square inverter (six switches) using “ISIS 7 Professional”
as shown below;
Figure 5-6 3 phase inverter simulation
59
Simulated output voltage (180 degree conduction):
Figure 5-7 Output of 3 phase inverter simulation -180 degree
Figure 5-8 PCB Layout of three phase sine wave inverter (optocoupler and gate driver)
60
Figure 5-9 3-D Visualization of three phase sine wave inverter (optocoupler and gate
driver)
Figure 5-10 PCB Layout of three phase sine wave inverter (IGBT Module)
61
Figure 5-11 3-D Visualization of three phase sine wave inverter (IGBT Module)
PWM Sine Wave Inverter:
Gating Signals (1 & 4):
Gate 1 is represented by “red” and Gate 4 is represented by “blue”. The waveforms on

oscilloscope shows that the two IGBT’s of on leg are having a delay between them because
we have to ensure that the IGBT’s belonging to one leg should never turn on a same time
as it will cause a short circuit problem.
62
Figure 5-12 Gating signals for PWM sine wave inverter (G1&G4)

63

64
Phase to Phase voltage waveforms:
The phase voltage Vab is shown in “red” whereas the phase voltage Vbc is shown in
“blue”. It is clear from the figure shown below that both waveforms are nearly 120 degree
apart and there is a clear phase difference between the two.
There is a total of 360 degrees interval so an overlap of 240 degrees is present i.e.
360/120=3
From the observed waveforms;
(20 ms)/(6.8 ms) = 2.92
So, it clearly shows that both phases are 120 degree apart and the output we are getting
will be able to drive a three phase ac squirrel cage induction motor. Similarly we can
obtain the phase difference between Vab and Vca.
Another method to verify it can be;
65
X= (120 x 20 ms)/ 360 = 6.66 ms whereas in practical we are getting nearly same result so
there exists a phase difference of 120 degrees.
Figure 0-15 Phase to phase voltages for PWM sine wave inverter (Vab & Vbc) plot 1
Figure 5-16 Phase to phase voltages for PWM sine wave inverter (Vab & Vbc) plot 2
66
We can verify the phase difference by using the following plots. The two plots represent
two phase to phase voltages.
Figure 5-17 Phase to ground voltages for PWM sine wave inverter (VaN & VbN)
It is clear the switching frequency is 1kHz and the output waveform is just as the required
waveform for a pure sine wave three phase inverter. This plot represents Phase to ground
voltages.
67
Figure 5-18 Phase to phase voltage for PWM sine wave inverter- Frequency Verification
This plot clearly shows that the frequency of the output wave is 60 Hz and which is
required for a three phase AC induction motor.
68
MATLAB SIMULATIONS:
Field Oriented Control
As operating heavy motors such as the 10hp motor that we planned to implement in our
project require dealing with high voltage and currents, it is essential to first simulate the
system to find approximate rating for any circuits that have to be built.
Also, through simulation the Field Oriented Control principle can be tested and understood
so that it is easier to implement in hardware on a later stage. Currently we are working on a
Vector (Field-Oriented) Control Model in Simulink. The motor model being used is a
preset found in Simulink which closely matches the 7.5KW motor that we have to use.
Before simulating the model, we approximated the torque to be applied to the motor to
simulate the torque that will be present on the motor due the weight of the car. This was
done as follows:
• Weight of car: 700 Kg

• Car tire Radius = 0.2 m
• If we want to speed-up our car from 0 km.h-1 to 100 km.h-1 in 20s then,
×
• car acceleration = = 1.38 . −2
• Force = Mass x Acceleration = 700 x 1.38 = 972N

• Torque Required = 972 x 0.2 = 194 N.m
69
The simulation results are shown below;
Figure 5-19 Simulink model for estimation of parameters
70
Vector Control Module:
Figure 5-20 Matlab Simulink- Vector Control Module
71
Figure 5-21 Car is accelerating from 0-100km/hr. in 20secs
Figure 5-22 Increased Torque at Constant Speed
72
PROBLEMS:
The main problem identified by the above simulations is that the starting torque of the
motor is very large therefore it needs a current of about 155A in the start. In running
conditions the currents vary from about 35A – 75A.
If the components required for these specifications are not found, then a motor started may
have to be used or the control algorithm modified to reduce the currents, especially the
starting current.
CONCLUSION
The implementation of a three phase inverter requires a deep knowledge about the
terminologies involved in the inverter design and the selection of appropriate components
to acquire the desired output.
The techniques such as 120 or degree conduction modes are less efficient because of the
presence of harmonics which are much closer to the fundamental component. The
fundamental component is not easy to separate by applying a filter and it demands a costly
and higher order filter to separate the harmonic components from the fundamental
component.
The PWM technique such as “unipolar PWM” and “bipolar PWM” is far better than 120 or
180 degree conduction modes. The PWM techniques has one drawback i.e. higher
switching losses.
73
REFERENCES
http://telkomnika.ee.uad.ac.id/n9/files/Vol.9No.3Des11/3RP9.3.12.11.03.pdf
IRF Bootstrap Component Selection For Control IC’s
http://www.irf.com/technical-info/designtp/dt98-2.pdf
IRF Application Note AN-978 - HV Floating MOS-Gate Driver IC’s
http://www.irf.com/technical-info/appnotes/an-978.pdf
Texas Instruments - AN-1317 Selection of External Bootstrap Diode
http://www.ti.com/lit/an/snva083/snva083.pdf
The Design and Implementation of a Three Phase Power Converter in the Power
Electronics and Drives Subject
http://itee.uq.edu.au/~aupec/aupec06/htdocs/content/pdf/210.pdf
(A very helpful research paper)
http://www.irf.com/technical-info/designnote/dn501.pdf
IRF - Accurate Current Sensing in High Voltage Motor Drives
http://www.datasheetcatalog.org/datasheet/eic/FR103.pdf
Fast Recovery Diodes and their reverse recovery times
http://www.irf.com/technical-info/designtp/dt04-4.pdf
Using monolithic high voltage gate drivers – Bootstrap capacitor value selection
and sizing methodologies
http://www.irf.com/product-info/datasheets/data/ir2214.pdf
Gate driver selection and compatibility analysis with the IGBT modules
http://ir.lib.ntust.edu.tw/bitstream/987654321/14460/1/Inverter%20Low%20Side%20Switc
hes.pdf
A Current Reconstruction Algorithm for Three-Phase Inverters Using Integrated
Current Sensors in the Low-Side Switches
http://www.irf.com/technical-info/designnote/dn502.pdf
Short-Circuit Protection for Three-Phase Power Inverters
http://scholar.lib.vt.edu/theses/available/etd-01172010-160526/unrestricted/Lugo-
Nunez_DR_T_2007.pdf
High Power Density and Over current Protection Challenges in the Design of a
Three-Phase Voltage Source Inverter for Motor Drive Applications
74
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ELECTRICAL SYSTEM (MOTOR CONTROL) OF A SERIES HEV

Thesis · May 2013

New AC/AC Converter Topologies View project

The user has requested enhancement of the downloaded file.

Ali Khalid Asadullah Khan 2009-NUST-BE-EL-14

Name of group members:

Daniyal Bin Amir 2009-NUST-BE-EL-27

Muhammad FahadAthar 2009-NUST-BE-EL-56

Usman Nasir 2009-NUST-BE-EL-109

Project Co-advisor: Mr. Habeel Ahmed

Project Advisor: Dr. Awais Kamboh

COMPARISON OF 120°, 180° AND 150° CONDUCTION MODES: 18

THREE PHASE INVERTER DESIGN: 35

CODE FOR 180 DEGREE CONDUCTION: 43

CODE FOR 150 DEGREE CONDUCTION: 46

CODE FOR SINE WAVE PWM(PIC18f4431): 49

CODE FOR SINE WAVE PWM (ARDUINO MEGA 2560): 52

Figure 1-1 Parallel Hybrid Electric Vehicle .........................................................................................8

Year 2008 2012

Price 60 Rs Approx. 98 Rs (May 12th 2013)

∑ Series HEV (Hybrid Electric Vehicle)

Figure 1-1 Parallel Hybrid Electric Vehicle

Series Hybrid Electric Vehicle:

Figure 1-2 Series Hybrid Electric Vehicle

Figure 1-3 Electrical System of a series hybrid vehicle

1. Design of an efficient inverter

2. Motor controller for AC induction motor ( Inverter Duty 7.5 kW)

3. Interfacing of Controller with race pedal/ Interfacing

Figure 2-1 Block Diagram of a Inverter

Single phase inverters:

Three phase inverters:

Figure 2-2 Three Phase Inverter circuit

120° Conduction mode:

Gating signals and output voltages:

Figure 2-3 Gating signals for 120 degree conduction

180° Conduction mode:

Gating signals and output voltages:

Figure 2-4 Gating signals for 180 degree conduction

Why 180° conduction mode?

Figure 2-8 Multi-level Inverters

Gating signals and output voltages:

Figure 2-8 Gating signals for 150 degree conduction

∑ The gating signals are shifted by 90 degree

Why 150° conduction mode?

How 150 degree conduction works?

Figure 2-11 Three Phase Inverter circuit

Figure 2-13 degree (0-30 degree)

Van = [(R/2)/(R/2 + R)] x VDC

30-60 Degree Interval:

Van = [(R/2] x VDC

60-90 Degree Interval:

Van = [(R)/(R/2 + R)] x VDC

90-120 Degree Interval:

Van = [(R/2] x VDC

120-150 Degree Interval:

Van = [(R/2)/(R/2 + R)] x VDC

150-180 Degree Interval:

Van = 0 volts (Floating Node)

180-210 Degree Interval:

Vna = [(R/2)/(R/2 + R)] x VDC

Van = -1/3 VDC

210-240 Degree Interval:

value1 = ceil(512msine[i]) + 512;

value1 = ceil(512msine[i]) + 512;

value2 = ceil(512msine[(i+(num/3))%num]) + 512;

value3 = ceil(512msine[(i+(2*num/3))%num]) + 512;