The traction motor controller design includes a 240MHz CPU core, a microcontroller with multiple functionalities, and a power management system suitable for HEVs and EVs.
The Traction Motor Controller is primarily designed for motor control in Hybrid Electric Vehicle (HEV) and Electric Vehicle (EV) applications. This system comprises two main components: the Controller and Power boards. The Controller board manages the motor driver and oversees both digital and analogue sections. In contrast, the Power board is equipped with Power MOSFETs essential for driving the motor.
Renesas’s traction motor controller reference design features the RH850/C1M-A1 microcontroller, a robust component of the RH850 Family. It utilizes a G3MH CPU core, operating at an impressive frequency of 240MHz, ensuring substantial processing capability. This microcontroller is well-equipped with essential components like ROM, RAM, and DMA, alongside specialized features. These include a motor control timer and a variety of serial interfaces, notably CAN, which is compatible with CAN FD. Additionally, it integrates a 12-bit A/D converter (ADC) and an R/D converter (RDC3A) adept at transforming resolver output signals into digital angle data. The unit also comprises a CPU and a parallel motor control unit (EMU3), among other elements, making it an ideal solution for motor control in Hybrid Electric Vehicles (HEVs) and Electric Vehicles (EVs).
The Controller board in the system is equipped with three ISL78434 MOSFET Pre-Driver Stages and μPC1251A Operational Amplifiers, which are integral for the Analog and fault generation circuits. It also includes a Power Management Integrated Circuit (PMIC), Low Dropout Regulators (LDO), and a Power MOSFET Board featuring RBAZ25N10CHPF. The power capabilities of this setup are substantial, with a continuous output of 5KW and a peak output of 8KW. The number of MOSFETs per phase is carefully determined to match the necessary load and includes load dump protection.
The system’s hardware is organized into distinct categories, each defined by its specific function. These include the Power Supply section responsible for delivering the necessary electrical power. This converter regulates the DC/DC output to a stable 15.6V, which is then utilized to generate the various other power supplies needed for the controller and the onboard logic systems.
The Intelligent Power Device (IPD) section manages power devices for various loads, and the System I/O connections facilitate the interface with other systems. Additionally, a section is dedicated to Microcontroller Function Mapping, which is crucial for controlling and coordinating various operations. The hardware also encompasses sections for Analog Functions, addressing analogue signal processing needs, and Digital Input and Output Functions, which handle the digital signal interactions. Each category plays a vital role in the overall functionality and efficiency of the hardware system.
Critical protection features are in place for Over-Current, Over-Voltage, Under-Voltage, and Over-Temperature, along with relevant status indicators and preventive measures. The design integrates various interfaces like CAN-FD, LIN, SENT, and Isolated UART, ensuring a robust and versatile operation.
Renesas have tested this reference design. It comes with a Bill of Material (BOM), schematics, etc. You can find additional data about the reference design on the company’s website. To read more about this reference design, click here.