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The principle and maintenance principle of electric vehicle controller

Release time:

2024-06-27

The controller refers to an important component in the electric vehicle that controls the speed of the motor. It is also the core part of the electric vehicle electric system. It mainly controls the speed of the motor and is the core component of the electric vehicle energy management system and various signal processing. In the electric vehicle industry, the controller is also required to have a series of corresponding protection functions such as brake power-off, undervoltage protection, undervoltage recovery and overcurrent protection.

The controller refers to an important component in the electric vehicle that controls the speed of the motor. It is also the core part of the electric vehicle electric system. It mainly controls the speed of the motor and is the core component of the electric vehicle energy management system and various signal processing. In the electric vehicle industry, the controller is also required to have a series of corresponding protection functions such as brake power-off, undervoltage protection, undervoltage recovery and overcurrent protection.

Electric vehicle controller can also be divided into brushless controller and brush controller. The brushless controller relies on electronic commutation, and the complexity of the circuit is much higher than that of the brush controller, so its manufacturing cost and manufacturability are much higher than that of the brush controller.

brush controller detection method:

(1) Diode detection for power disconnection

A red pen is connected to the positive pole of the controller power input, black pen is connected to the negative pole, charging is normal, short circuit is damaged.

B red pen connected to the controller power input negative, black pen connected to red, yellow, green, short circuit is damaged.

C red pen connected to the controller power input negative pole, black pen connected to the motor negative pole should have 400-700 parameters.

D the red probe is connected to the negative pole of the motor and the black probe is connected to the positive pole of the controller, with 100-300 parameters.

E turn red, black, green, there should be no short circuit phenomenon.

(2) Power-on measurement

F detect whether the positive and negative electrodes of the controller power input have voltages above 36V and 48V.

G detect whether the switch power supply has a voltage above 5V.

H turn the knob to detect whether the voltage changes between 0.8V-4.2V.

I turn the knob to detect the voltage output of the controller.

(3) Short-circuit brake wire breaker controller should stop output

brushless controller detection method:

1. outage detection

1. Check whether the positive and negative electrodes of the controller power input are short-circuited

2. Detect the winding wire parameters of the controller:

A connect the black stylus to the positive pole of the power supply, and contact the yellow, green and blue winding wires with the red stylus respectively. the parameters are between 400 and 700

B repeat step 2

3. Hall signal line detection: connect the black wire with the black probe, and connect the red, yellow, green and blue four wires with the red probe. There should be no short circuit fault.

2. power-on detection

1. Check whether the input voltage of the controller power supply is above 36V(48V);

2. Detect whether the Hall signal line has a voltage of 5-7V;

3. Check whether the switch power supply has more than 5V power supply;

4. Rotate the turn to detect whether the signal line changes between 0.8-4.2V.

At present, the brushless Hall-less controllers used by the mainstream electric vehicle brands in the electric vehicle market have also added a digital frequency conversion CPU control chip. It not only has the characteristics of high sensitivity, stable and reliable performance, but also It has the function of effectively reducing motor noise.

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