15V to 60V – Three-Phase Brushless DC Motor Pre-Driver

  • Rajkumar Sharma
  • 2.145 Views
  • medium
  • Tested

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:

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.MANUFACTURERSUPPLIERSUPPLIER PART NO
11CN114 PIN MALE HEADER 2.54MM PITCHWURTHDIGIKEY732-5325-ND
22CN22 Pin Screw Terminal 5.08MM PITCHPHOENIXDIGIKEY277-1247-ND
31CN33 PIN SCREW TERMINAL 5.08MM PITCHPHOENIXDIGIKEY277-1264-ND
41CN43 PIN MALE HEADER 2.54MM PITCHWURTHDIGIKEY732-5316-ND
53C1,C3,C510uF/25V SMD SIZE 1210MURATA/YAGEO
63C2,C4,C64.7uF/25V SMD SIZE 1210MURATA/YAGEO
78C7,C8,C9,C21,C26,C27,C29,C340.1uF/50V SMD SIZE 0805MURATA/YAGEO
86C10,C12,C14,C15,C16,C181K PF/50V SMD SIZE 0805MURATA/YAGEO
93C11,C13,C17OMIT
101C19100PF/50V SMD SIZE 0805MURATA/YAGEO
111C20100uF/16V SMD SIZE 1210MURATA/YAGEO
122C22,C24470uF/100VRUBYCONDIGIKEY1189-1712-ND
137PR1,C23,C28,C30,C31,C32,C33,DNP
7R34,R38,R40,R41,R42,R43,R46,DNP
4R48,R49,R50,R52DNP
143D1,D2,D3SS34 OR MBRS240ON SEMIDIGIKEYMBRS240LT3GOSTR-ND
156D4,D5,D6,D7,D8,D91N4148MICROCHIPDIGIKEY1N4148UR-1-ND
161D10LED SMD SIZE 0805OSRAMDIGIKEY475-1415-1-ND
176Q1,Q2,Q3,Q4,Q5,Q6FDH3632ON SEMIDIGIKEYFDH3632FS-ND
186R1,R2,R3,R4,R5,R610E 5% SMD SIZE 0805MURATA/YAGEO
193R7,R8,R90.01E/3W THTVISHAYDIGIKEYLVRB-.01RCT-ND
206R10,R12,R16,R19,R22,R2840.02E 1% SMD SIZE 0805MURATA/YAGEO
216R11,R13,R17,R20,R23,R30560E 1% SMD SIZE 0805MURATA/YAGEO
226R14,R15,R18,R21,R24,R316.04K 1% SMD SIZE 0805MURATA/YAGEO
231R2510K 5% SMD SIZE 1206MURATA/YAGEO
242R26,R2739K 5% SMD SIZE 1206MURATA/YAGEO
251R28100K 5% SMD SIZE 1206MURATA/YAGEO
2638 PIN DIP 8 PIN DIP IC SOCKETTEDIGIKEYA120347-ND
274R32,R53,R54,R551K 5% SMD SIZE 0805MURATA/YAGEODIGIKEY
281R33220E 1% SMD SIZE 0805MURATA/YAGEODIGIKEY
291R35680E 1% SMD SIZE 0805MURATA/YAGEODIGIKEY
306R36,R37,R39,R44,R45,R4710K 5% SMD SIZE 0805MURATA/YAGEODIGIKEY
311R510E SMD SIZE 0805MURATA/YAGEODIGIKEY
323U1,U2,U3IR2101 DIP8INFINIONDIGIKEYIR2101PBF-ND
331U4MCP6024-I/SLMICROCHIPDIGIKEYMCP6024-I/SL-ND
341U5LM317M DPAKSTDIGIKEY497-1574-1-ND
351C251uF/100VLLLINIOSDIGIKEY1572-1641-ND

Connections

Gerber View

Photos

Video

IR2101 Datasheet

Infineon-ir2101-DS-v01_00-EN

PCB

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