P

P
ulse
ulse
W
W
idth
idth
M
M
odulation
odulation
Electric Vehicle
Electric Vehicle
DC Motor Controller
DC Motor Controller
Eric Rodda Eric Rodda AEVA Adelaide AEVA Adelaide - - October 2010 October 2010
For this example we will assume that For this example we will assume that
the Electric Vehicle has a total the Electric Vehicle has a total battery battery
voltage of 120 Volts voltage of 120 Volts and also that the and also that the
accelerator pedal mechanically accelerator pedal mechanically
connects to a connects to a potbox potbox which in turn which in turn
electrically connects to the electrically connects to the controller controller. .
P
P
ulse
ulse
W
W
idth
idth
M
M
odulation
odulation
Electric Vehicle
Electric Vehicle
DC Motor Controller
DC Motor Controller
For this example we will assume that For this example we will assume that
the Electric Vehicle has a total the Electric Vehicle has a total battery battery
voltage of 120 Volts voltage of 120 Volts and also that the and also that the
accelerator pedal mechanically accelerator pedal mechanically
connects to a connects to a potbox potbox which in turn which in turn
electrically connects to the electrically connects to the controller controller. .
P
P
ulse
ulse
W
W
idth
idth
M
M
odulation
odulation
Electric Vehicle
Electric Vehicle
DC Motor Controller
DC Motor Controller
Image courtesy of
EV Works -
Western Australia
POTBOX
DC MOTOR CONTROLLER
DC MOTOR CONTROLLER
The
The
controller
controller
uses sophisticated control
uses sophisticated control
circuitry and power output stages
circuitry and power output stages
(MOSFET or IGBT) which takes the high
(MOSFET or IGBT) which takes the high
voltage from the traction battery pack and
voltage from the traction battery pack and
converts it into variable width pulses,
converts it into variable width pulses,
controlled by the
controlled by the
potbox
potbox
, and then sends
, and then sends
these pulses to the drive motor.
these pulses to the drive motor.
PWM
PWM
Pulse
Pulse
-
-
Width Modulation
Width Modulation
is a very
is a very
efficient way of providing
efficient way of providing
intermediate amounts of electrical
intermediate amounts of electrical
power between fully off and fully on.
power between fully off and fully on.
DUTY CYCLE
DUTY CYCLE
The term
The term
duty cycle
duty cycle
describes the
describes the
proportion of
proportion of
on
on
time to the regular
time to the regular
interval or
interval or
period
period
of time; a low duty
of time; a low duty
cycle corresponds to low power,
cycle corresponds to low power,
because the power is off for most of the
because the power is off for most of the
time. Duty cycle is expressed in percent,
time. Duty cycle is expressed in percent,
100% being fully on.
100% being fully on.
PWM Frequency
PWM Frequency
The
The
frequency
frequency
of operation of a DC Motor
of operation of a DC Motor
Controller is generally above the audio
Controller is generally above the audio
spectrum and often around
spectrum and often around
22Khz
22Khz
(22,000 cycles per second) giving a period
(22,000 cycles per second) giving a period
of approx 45uS.
of approx 45uS.
PWM in Action
PWM in Action
The
The
following slides show five progressing
following slides show five progressing
stages of the accelerator position.
stages of the accelerator position.
Of course, in real life, this process will be
Of course, in real life, this process will be
continuous and smooth from one stage to
continuous and smooth from one stage to
the next
the next

V
O
L
T
S
TIME
120
0
What the motor sees
Foot off accelerator pedal Foot off accelerator pedal Potbox Potbox at rest position at rest position
V
O
L
T
S
TIME
120
0
One Period with a Duty Cycle of
approx 15%
18
What the motor sees
Foot on accelerator pedal Foot on accelerator pedal Potbox Potbox partly open partly open
V
O
L
T
S
TIME
120
0
One Period with a Duty Cycle of
approx 50%
60
What the motor sees
Foot on accelerator pedal Foot on accelerator pedal Potbox Potbox half open half open
V
O
L
T
S
TIME
120
0
One Period with a Duty Cycle of
approx 75%
90
What the motor sees
Foot on accelerator pedal Foot on accelerator pedal Potbox Potbox open more open more
V
O
L
T
S
TIME
120
0
One Period with a Duty Cycle of 100% What the motor sees
Accelerator pedal to floor Accelerator pedal to floor Potbox Potbox fully open fully open
P
P
ulse
ulse
W
W
idth
idth
M
M
odulation
odulation
Electric Vehicle
Electric Vehicle
DC Motor Controller
DC Motor Controller
Eric Rodda Eric Rodda - - AEVA October 2010 AEVA October 2010
You are now all experts in this
You are now all experts in this
subject
subject

P
P
ulse
ulse
W
W
idth
idth
M
M
odulation
odulation
Electric Vehicle
Electric Vehicle
DC Motor Controller
DC Motor Controller
Eric Rodda Eric Rodda - - AEVA October 2010 AEVA October 2010
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