Universal Motor Controller

I designed this universal motor controller capable on driving DC-, Stepper-, BLDC- and even AC – motors earlier. The design parameters was 12-24V at 15A. This is quite a capable controller, but I did a mistake that limit the controller to 12-20V since I connected the Gate Drivers to the Motor PSU directly. To compensate for this I need to modify the design and implement a separate 12V PSU. As I correct this I also want to consider some additional changes.

I am considering is to replace the RS485 with an isolated RS485 due to the amount of energy involved. The 3rd change is Ethernet on a separate adapter board. Basically I want to copy the modules I use on the Universal Adapter as soon as I have tested them.

I am not sure about Ethernet. Ethernet sound nice due to the functionality, but it is a clumsy, 4-wire 1:1 solution. RS485 is slower, but it is a 2-wire network. It actually makes more sense having dual RS485 to be honest. CAN & Ethernet is easier to deal with using an adapter board- RS485 is considered a lower level of communication than CAN because CAN have protocols like CANopen, J1939 etc. The reality is that if we use RS-X that changes.

What I probably should do at some point is to create a “Ethernet” on top of RS-X by using a dual RS-X connection. But, that is fun for later…

So the modified design will be

  • STM32F405RG MCU, 168Mhz, 32bit M4, 1MbFlash, 192KbSRAM
  • 4 x separate half bridge drivers, 30V @15A
  • Current sensors on all
  • BEMF sensors
  • PSU Voltage Sensor
  • Separate 3.3V supercap to sustain MCU in power dips.
  • 3 x hall sensors
  • 2 x temperature sensors.
  • 1 x resolver
  • 2 x end sensors
  • 1-2 x RS485
  • Adapter board for battery/caps
  • Adapter board for CAN/Ethernet/Wifi

Applications

  • Solenoid driver
  • DC Motor driver
  • Stepper Motor Driver
  • Brushless 3-Phase motor driver

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