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Microchip E Scooter Reference Design Title (MT)

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Microchip E-Scooter reference design

Microchip E Scooter Reference Design main content (MM)

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Why E-Scooters now?

The demand for micro-mobility devices such as e-scooters and e-bikes is on the rise. This can be explained by multiple factors including an increased need for fuel-efficient vehicles due to concerns over carbon and greenhouse gas emissions, increasing adoption of electric scooter sharing services and the “pandemic effect” as more people explore options of individual, socially-distanced travel with micro-mobility devices over public transportation.

The global e-scooter market is expected to grow from $20 to $42 billion from 2020 to 2030 according to Grand View Research. To capture additional market share of this growing market, e-scooter OEMs must develop smaller, more efficient and higher-performance designs.

Design challenges:

  • Competitive cost
  • Limited battery size
  • Low operating acoustic noise
  • Regenerative braking capability
E-scooter standing still

Microchip E Scooter Reference Design BD (LC)

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E-Scooter reference design overview

  • A high performance BLDC/PMSM motor driver board used to demonstrate the capabilities offered by the dsPIC33CK high performance Digital Signal Controller (DSC) in conjunction with three MIC4104 (MOSFET gate drivers) for motor control applications like E scooters and E bikes
  • Designed to drive BLDC/PMSM motors of up to 350W power and up to 15A RMS phase currents. The input voltage range is between 18V and 42V covering the applications powered from battery strings of up to 10S (Li Ion cells)
  • The board is developed to meet the stringent demands of modern motor control applications:
    • High battery efficiency and performance
    • Low noise operation
    • Compact dimensions
    • Low cost

 

E-Scooter reference design board

Features

  • dsPIC33CK64MP105 DSC low cost motor controller includes three operational amplifiers used to implement the current sense amplifiers
  • Multiple feedback circuits support both Hall sensors and sensorless motor control algorithms (BEMF and FOC):
    • Support for 3 Hall sensors (mounted on the motor stator) for running 6 step block commutation or Hall sensored FOC
    • 3 low side shunt resistors (2 m Ω), one on each inverter phase for current measurement for running FOC
    • 3 resistor dividers for measuring the of each motor phase for running sensorless BEMF
  • Debugger/programmer interface for connecting an MPLAB® PICkit 4, MPLAB ICD 4, etc.
  • NTC thermistor for monitoring the temperature of the power MOSFETs
  • Auxiliary connector for other functions such as throttle input, voltage monitoring, I2C, UART, Bluetooth® and more
  • 3 Phase inverter stage:
    • 350 W maximum output power and 20A RMS (continuous) and up to 27A RMS (momentary) motor phase current
    • 6 N channel MOSFETs with low RDS(on) (typical 1.9 m Ω) to be able to handle high phase currents without excessive conduction losses
    • 3 MIC4104 half bridge high current (3A) MOSFET gate drivers
    • FASTON connectors to motor
  • 18-42V VBUS input voltage range (up to 10s battery pack) with XT30 type connector for the battery pack
  • System bias generation:
    • 12V is provided by a MCP16331 switching regulator for the MOSFETs drivers
    • 3.3V is provided by a MCP1754S 3 LDO voltage regulator for the digital circuits
    • 5V is provided by the MCP1754S 5 for auxiliary functions like the Hall sensors
E-Scooter Reference Design board - front and back side

 

E-scooter motor control block diagram

Key parts

MCP16331

50V/1A, Non-Synchronous Buck Regulator

The MCP16331 is a highly integrated, high-efficiency, fixed frequency, step-down DC-DC converter in a popular 6-pin SOT-23 or 8-pin TDFN 2x3 package that operates from input voltage sources up to 50V. Integrated features include a high side switch, fixed frequency Peak Current Mode Control, internal compensation, peak current limit and overtemperature protection. Minimal external components are necessary to develop a complete step-down DC-DC converter power supply.

Download Datasheet

 

Features

  • Up to 96% Efficiency
  • Input Voltage Range: 4.4V to 50V
  • Output Voltage Range: 2.0V to 24V
  • 2% Output Voltage Accuracy
  • Minimum 500 mA Output Current
  • 500 kHz Fixed Frequency
  • Adjustable Output Voltage
  • Low Device Shutdown Current: 6 uA
  • Peak Current Mode Control
  • Internal Compensation
  • Internal Soft-Start
  • Cycle-by-Cycle Peak Current Limit
  • Undervoltage Lockout (UVLO): 4.1V to Start; 3.6V to Stop
  • Overtemperature Protection
  • Available Package: 6-Lead SOT-23, 8-Lead 2x3 TDFN
Microchip MCP16331 non-synchronous buck regulator - top side

MCP1754

16V, High PSRR, 150mA LDO, Vout=5.0V

The MCP1754/MCP1754S is a 16 volt, high PSRR voltage regulator with short circuit current foldback. The MCP1754/MCP1754S regulator provides up to 150 mA of current. The input operating voltage range is specified from 3.6V to 16V continuous, 18V absolute maximum, making it ideal for automotive and commercial 12 VDC systems. The MCP1754/MCP1754S typically delivers 72 dB of ripple rejection at 1 kHz, performing well in AC sensitive applications like GFCI and AFCI circuit breaker designs. The Current Foldback feature is a true short circuit current foldback: the device current will gradually drop to 30 mA under short circuit conditions. When the short is removed, the device will recover and continue operating.

Download Datasheet

 

Features

  • High PSRR: 72 dB @1 kHz Typical
  • Low 56.0 µA Typical Quiescent Current
  • Wide Input Operating Voltage Range: 3.6V to 16.0V
  • 150 mA Output Current for All Output Voltages
  • Low Drop Out Voltage, 300 mV Typical at 150 mA
  • 0.4% Typical Output Voltage Regulation
  • Standard Output Voltage Options (1.8V, 2.5V, 3.0V, 3.3V, 5.0V), Additional Options Available on Request
  • Output Voltage Tolerances of ±2.0% Over Entire Temperature Range
  • Stable with Minimum 1.0 µF Output Capacitance
  • Power Good Output
  • Shutdown Input
  • True Current Foldback Protection
  • Short-Circuit Protection
  • Overtemperature Protection
  • ESD protection (>4kV HBM)
Top side of the Microchip's MCP1754 LDO voltage regulator

dsPIC33CK64MP105

100 MHz Single-Core 16-bit DSC

Microchip’s dsPIC33CK64MP10X family of digital signal controllers (DSCs) features a single 100 MIPS 16-bit dsPIC® DSC core with integrated DSP and enhanced on-chip peripherals. These DSCs enable the design of digital power, motor control, high-performance general-purpose and robust applications.

In the digital power segment, this family of devices is ideal for PFC applications, wireless power and high-density DC-DC applications. These DSCs are also well suited for switched mode power supplies such as AC/DC, DC/DC, UPS and PFC, providing high-precision digital control of buck, boost, fly-back, half-bridge, full-bridge, LLC and other power circuits to reach the highest possible energy efficiency.

In the motor control segment, this family is suited for lowest cost automotive, consumer and industrial applications. These DSCs are ideal for the control of BLDC, PMSM, ACIM, SR and stepper motors.

The rich feature set in this family of devices also make this family a very good fit for automotive sensors and industrial automation.

Download Datasheet

 

Features

  • High Performance Digital Signal Controller (DSC)
    • 100 MHz CPU instruction execution speed for tighter control loops
    • New instructions to accelerate DSP algorithm performance
    • Expanded context selected register sets for reduced interrupt latency
  • Optimized Peripheral Feature Set
    • Perfectly optimized for single motor control applications, automotive and industrial sensor interfaces and consumer appliances
    • Analog integration includes a single high speed ADC, 3 op amps, and one analog comparator with DAC
  • Improved Functional Safety Features and Support
    • Safety features include: ECC Flash, RAM BIST, Deadman Timer (DMT), Dual WDTs, BOR, Backup Fast RC Oscillator (BFRC), Fail Safe Clock Monitoring (FSCM), CRC, Virtual Pins for Redundancy, Flash OTP & Code Guard Security
    • Targets ASIL B(ISO 26262), SIL 2(IEC 61508), Class B Library(IEC 60730)
  • Hardware Development Tools
    • dsPIC33CK64MC105 Motor Control Ext. Op Amp PIM (MA330051 1)
    • dsPIC33CK64MC105 Motor Control Int. Op Amp PIM (MA330051 2)
    • dsPIC33CK64MC105 General Purpose PIM (MA330052)
  • Software Development Tools
    • MPLAB® X IDE, MPLAB® Xpress Cloud Based IDE
    • MPLAB® Code Configurator (MCC), XC16 C Compiler
    • motorBench® Development Suite
Microchip dsPIC33CK64MP105 digital signal controller - top side

MIC4104

100 V 3 A Half Bridge MOSFET Gate Driver

The MIC4103 and MIC4104 are high frequency, 100 V Half Bridge MOSFET drivers with faster turn-off characteristics than the MIC4100 and MIC4101 drivers. They feature fast 24 ns propagation delay times and 6ns driver fall times. The low-side and high-side gate drivers are independently controlled and matched to within 3 ns typical. The MIC4103 has CMOS input thresholds and the MIC4104 has TTL input thresholds. The MIC4103/4 include a high voltage internal diode that charges the high-side gate drive bootstrap capacitor. A robust, high-speed, and low power level shifter provides clean level transitions to the high side output. The robust operation of the MIC4103/4 helps ensure the outputs are not affected by supply glitches, HS ringing below ground, or HS slewing with high speed voltage transitions. Under-voltage protection is provided on both the low-side and high-side drivers. The MIC4103 and MIC4104 are available in an 8-lead SOIC package with a operating junction temperature range of -40°C to +125°C.

Download Datasheet

 

Features

  • Asymmetrical, low impedance outputs drive 1,000 pF load with 10 ns rise times and 6 ns fall times
  • Bootstrap supply max voltage to 118 V DC
  • Supply voltage up to 16 V
  • Drives high- and low-side N-Channel MOSFETs with independent inputs
  • CMOS input thresholds (MIC4103)
  • TTL input thresholds (MIC4104)
  • On-chip bootstrap diode
  • Fast 24 ns propagation times
  • Low power consumption
  • Supply under-voltage protection
  • Typical 2.5 Ω pull up and 1.25 Ω pull down output driver resistance
  • -40°C to +125°C junction temperature range
Microchip MIC4104 Half Bridge MOSFET Gate Driver - top side

 

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