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15V to 60V – Three-Phase Brushless DC Motor Pre-Driver
- Rajkumar Sharma
- 3.513 Views
- medium
- Tested
- SKU: EL107616
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The project presented here is a three-phase BLDC motor pre-driver. The project consists of 3x half-bridge IR2101 driver IC and 6 channel high current N-MOSFETS. The project can be configured as 3 independent half-bridges H-bridge for a brushed DC motor, or a single high current brushless motor driver. The rotor position can be detected using 3 hall sensors assembled in the motor. Hall-effect shaft position sensors are used to control the switching sequence of the three 1/2 bridge outputs. The bridge voltage can vary between 15V and 60V and the maximum summed bridge current is 10A with a large size heat-sink and sufficient airflow using a fan. This motor driver can be used for multiple applications including e-bikes, battery-powered tools, electric power steering, wheelchairs, or any other application, where a BLDC motor is utilized. Motor start/stop, forward/reverse rotation, braking with closed-loop speed control. The project also includes 3 phase current sense circuit which can be used to detect 3 independent phase currents. An LM317 regulator provides 5V DC to op-amp circuitry. All inputs and feedback outputs provided for an easy micro-controller or DSP interface.
Current Sense Circuit: Current sense circuit measures the current across all 3 half-bridges and provides 3 independent current feedback outputs, this can be used for overcurrent sense or senseless FOC configuration, the default output at 0A is 1.45V, and provides approx. 100mV/Amp. User may change the Gain of an op-amp, current shunt resistors as per requirement, LM317 power 5V to op-amp circuit.
User need to generate 6 PWM pulse sequence to control the motor, the board accepts TTL input, more information about brushless motor driver available here:
- https://www.digikey.com/en/articles/why-and-how-to-sinusoidally-control-three-phase-brushless-dc-motors
- https://www.microchip.com/wwwappnotes/appnotes.aspx?appnote=en1001927
Features
- Operating Supply-Motor 15V to 60V
- Load 5 Amps (10Amps Maximum)
- Gate Driver Supply 12-15V DC
- 3 Independ Half-Bridge
- H-Bridge (DC Brushed Motor Driver)
- 3 Phase Brushed DC Motor Driver
- DC Bus Voltage FeedBack (Load Supply)
- LED for Gate driver supply
- 3 Phase Current sense output 100mV/Amp
- PWM Frequency up to 20Khz.
- Required 6 PWM Signals
- PCB Dimensions 143.69 x 52.40 mm
Schematic
Parts List
| NO. | QNTY. | REF. | DESC. | MANUFACTURER | SUPPLIER | SUPPLIER PART NO |
|---|---|---|---|---|---|---|
| 1 | 1 | CN1 | 14 PIN MALE HEADER 2.54MM PITCH | WURTH | DIGIKEY | 732-5325-ND |
| 2 | 2 | CN2 | 2 Pin Screw Terminal 5.08MM PITCH | PHOENIX | DIGIKEY | 277-1247-ND |
| 3 | 1 | CN3 | 3 PIN SCREW TERMINAL 5.08MM PITCH | PHOENIX | DIGIKEY | 277-1264-ND |
| 4 | 1 | CN4 | 3 PIN MALE HEADER 2.54MM PITCH | WURTH | DIGIKEY | 732-5316-ND |
| 5 | 3 | C1,C3,C5 | 10uF/25V SMD SIZE 1210 | MURATA/YAGEO | ||
| 6 | 3 | C2,C4,C6 | 4.7uF/25V SMD SIZE 1210 | MURATA/YAGEO | ||
| 7 | 8 | C7,C8,C9,C21,C26,C27,C29,C34 | 0.1uF/50V SMD SIZE 0805 | MURATA/YAGEO | ||
| 8 | 6 | C10,C12,C14,C15,C16,C18 | 1K PF/50V SMD SIZE 0805 | MURATA/YAGEO | ||
| 9 | 3 | C11,C13,C17 | OMIT | |||
| 10 | 1 | C19 | 100PF/50V SMD SIZE 0805 | MURATA/YAGEO | ||
| 11 | 1 | C20 | 100uF/16V SMD SIZE 1210 | MURATA/YAGEO | ||
| 12 | 2 | C22,C24 | 470uF/100V | RUBYCON | DIGIKEY | 1189-1712-ND |
| 13 | 7 | PR1,C23,C28,C30,C31,C32,C33, | DNP | |||
| 7 | R34,R38,R40,R41,R42,R43,R46, | DNP | ||||
| 4 | R48,R49,R50,R52 | DNP | ||||
| 14 | 3 | D1,D2,D3 | SS34 OR MBRS240 | ON SEMI | DIGIKEY | MBRS240LT3GOSTR-ND |
| 15 | 6 | D4,D5,D6,D7,D8,D9 | 1N4148 | MICROCHIP | DIGIKEY | 1N4148UR-1-ND |
| 16 | 1 | D10 | LED SMD SIZE 0805 | OSRAM | DIGIKEY | 475-1415-1-ND |
| 17 | 6 | Q1,Q2,Q3,Q4,Q5,Q6 | FDH3632 | ON SEMI | DIGIKEY | FDH3632FS-ND |
| 18 | 6 | R1,R2,R3,R4,R5,R6 | 10E 5% SMD SIZE 0805 | MURATA/YAGEO | ||
| 19 | 3 | R7,R8,R9 | 0.01E/3W THT | VISHAY | DIGIKEY | LVRB-.01RCT-ND |
| 20 | 6 | R10,R12,R16,R19,R22,R28 | 40.02E 1% SMD SIZE 0805 | MURATA/YAGEO | ||
| 21 | 6 | R11,R13,R17,R20,R23,R30 | 560E 1% SMD SIZE 0805 | MURATA/YAGEO | ||
| 22 | 6 | R14,R15,R18,R21,R24,R31 | 6.04K 1% SMD SIZE 0805 | MURATA/YAGEO | ||
| 23 | 1 | R25 | 10K 5% SMD SIZE 1206 | MURATA/YAGEO | ||
| 24 | 2 | R26,R27 | 39K 5% SMD SIZE 1206 | MURATA/YAGEO | ||
| 25 | 1 | R28 | 100K 5% SMD SIZE 1206 | MURATA/YAGEO | ||
| 26 | 3 | 8 PIN DIP | 8 PIN DIP IC SOCKET | TE | DIGIKEY | A120347-ND |
| 27 | 4 | R32,R53,R54,R55 | 1K 5% SMD SIZE 0805 | MURATA/YAGEO | DIGIKEY | |
| 28 | 1 | R33 | 220E 1% SMD SIZE 0805 | MURATA/YAGEO | DIGIKEY | |
| 29 | 1 | R35 | 680E 1% SMD SIZE 0805 | MURATA/YAGEO | DIGIKEY | |
| 30 | 6 | R36,R37,R39,R44,R45,R47 | 10K 5% SMD SIZE 0805 | MURATA/YAGEO | DIGIKEY | |
| 31 | 1 | R51 | 0E SMD SIZE 0805 | MURATA/YAGEO | DIGIKEY | |
| 32 | 3 | U1,U2,U3 | IR2101 DIP8 | INFINION | DIGIKEY | IR2101PBF-ND |
| 33 | 1 | U4 | MCP6024-I/SL | MICROCHIP | DIGIKEY | MCP6024-I/SL-ND |
| 34 | 1 | U5 | LM317M DPAK | ST | DIGIKEY | 497-1574-1-ND |
| 35 | 1 | C25 | 1uF/100V | LLLINIOS | DIGIKEY | 1572-1641-ND |
Connections
Gerber View
Photos
Video
IR2101 Datasheet
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can i request code program with C language in arduino or stm