100kW Quad Inverter - Wisconsin Racing Formula SAE Electric

DESCRIPTION

My name is Jason Sylvestre. I am the team founder and currently am the Power Systems Lead for the University of Wisconsin-Madison's first electric Formula SAE team. Last year was our first year in the electric competition and we were able to design the United States' first all-wheel drive electric racecar and get first place in the design component of the competition. We were very happy with how the vehicle turned out. Check it out!

We learned from last year there aren't any good off-the-shelf options available for a 4WD system with in-hub motors so we plan to design four 30kW custom motors, a 100kW quad inverter, and a new battery this next year. Designing a fully custom electric powertrain is an ambitious feat, but we have the right people who are dedicated to making it happen. 

If successful, we will be the first team in the world to develop a quad inverter and the first US team to create our own custom electric powertrain. 

In our quad inverter, there are 13 PCBs that need to be manufactured. We would love to partner with PCBWay to sponsor the quad inverter project.  They are all complex 4 layer boards, but they are well within your capabilities. 

TECHNICAL DETAILS

•11 PCBs total (4 designs)  - all custom designed to optimize packaging and satisfy requirements

•Parent board 

        • Holds gate driver and control card 

        •Interface with IGBT module

        •Voltage Sensing conditioning circuitry

        •Power supplier 

• Control Card 

        •Processor: TMS320F28069F Piccolo 

        •Hardware comparator protection circuitry 

        •CAN hardware 

        •Current sense analog filter circuitry 

•Gate Driver 

        •Amplifies PWM signals from control card to +/-15V to drive IGBT gates 

•RGB Status board 

        •Array of four RGB LEDs that show the status of each inverter

Inverter Specs

·        Individual control of four motors

o   Bus Voltage: 180V – 252V

o   Peak Power = 30 kW mechanical, 33kW electrical

o   Peak Torque = 30Nm

o   Base speed = 9500RPM

o   Top Speed = 20000 RPM

o   Switching frequency = 20 kHz

·        Torque control

o   Field Oriented Control

§  Maximum torque per ampere

§  Field Weakening

o   Space Vector Modulation

·      Sensorless Control 

·       Protection

o   DC bus OV/UV hardware protection

o   Phase hardware overcurrent Protection 

o   Derates while operating at higher temperature

o   Processor watchdog

o   Voltage supervision on voltage supply rails for logic and gate drive

o   HV and LV systems are isolated

·        Physical Packaging Requirements

o   Two DC cables in, 12 phase cables out

o   < 5kG

o   Waterproof

o   Liquid cooling

·        Isolated CAN input

·        Status indicators for each inverter

·        350A continuous in high current path

Words to PCBWay

To reiterate what was said above, we would love to partner with PCBWay by having you manufacture qty 10 PCBs for our quad inverter.

By supporting our efforts to develop an electric car, you can not only showcase your intent to foster sustainability, but also support higher education and the advancement of electric vehicle technology. Your support is crucial to the success of this program.

We pride ourselves in making our sponsorship program a mutually beneficial relationship. We know that without our sponsors, none of this would be possible- so we strive to personally tailor each sponsorship to fulfill any additional requests you may have. We are always available and excited to speak with you about how we can develop a program that makes the world a cleaner place.