Application Report

SLVA642–June 2014

Hardware Design Considerations Using a BLDC Mo

SrivatsaRaghunath

ABSTRACT

A traditional bicycle is a two-wheel vehicle that is propelled by the rider who delivers muscle power through pedals
that rotate one of the two wheels. The rider steers the front wheel to create a force that returns and maintains the
vehicle center of gravity into a stable zone whenever necessary, thus keeping the bicycle upright. An electric
bicycle carries batteries that deliver electric power to a motor that is coupled to either wheel. In most electric
bicycles the rider can chose to use muscle power to deliver all, part, or none of the propulsion power required to
maintain an adopted travel speed. Some models even sense pedal pressure and command the motor to deliver
more power whenever the rider pedals harder.

Conte nts

1
Introduction ...................................................................................................................
3
2
Motor Selection ..............................................................................................................
4
3
Stator
...........

4
4
Rotor...........................................................................................................................

4.1....................................................................................................
BatterySelection
9
=
4.2...............................................................................................
ControllerSelection
11
5
Key Electrical.................................................................... CharacteristicsofE-BikeController
11

5.1.............................................................................................
SensingMechanisms
12
6
Hardware........................................................................................................... Blocks
13

6.1.......................................................................................
VoltageRegulatingCircuit
13

6.2............................................................................................
BatteryVoltageDetect
14

6.3......................................................................................
HandbarVoltageDetection
15

6.4.....................................................................................
FeedbackCurrentDetection
15

6.5.........................................
OvercurrentDetectionandSystemOvercurrentProtectionCircuit
16

6.6.................................................................................................
BrakeMechanism
16
7
Hall Sensor........................................................................................... PositionDetection
17

7.1....................
P2PWMOUTRegisterConfigurationDuringNon-SynchronousRectificationMode
19
8
Power......................................................................... MOSFETandIntegratedDriverCircuit
20

8.1.....................................................................................................
Mi crocontrol e r

20
8.2....................................................................................................
Otherfunctions
21

8.3.................................................................................
Miscellaneousfeatureselection
21
9
Conclusion ..................................................................................................................
23
10
Reference ...................................................................................................................
23

List of Figures

1
Range of Mass ...............................................................................................................

3
2
BLDC Motor Mechanical Structure ........................................................................................

4
3
.................................................................................................................................

7
4
.................................................................................................................................

8
5
Typical Controller Block Diagram ........................................................................................

11
6
Hardware description .....................................................................................................

12
7
TPS54360 Schematic......................................................................................................

13

SLVA642 –June 2014

Hardware Design Considerations for an Electric Bicycle Using a BLDC Motor
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8
Battery Voltage Detection Schematic....................................................................................
14
9
Handbar Voltage Detection Schematic ..................................................................................
15
10
Feedback Current Detection Schematic .................................................................................
15
11
Overcurrent Protection Schematic .......................................................................................
16
12
................................................................................................................................
16
13
Brake Mechanism Schematic.............................................................................................
17
14
Hall Sensor Position Detection Schematic..............................................................................
17
15
Hall Sensor Position Waveform Diagram ...............................................................................
18
16
DRV8312 Application Diagram for Three-Phase Operation ..........................................................
20
17
................................................................................................................................
21

List of Tables

1
Range of Mass ...............................................................................................................
3
2
DC Motors ....................................................................................................................
4
3
Types of Drive Train .........................................................................................................
6
4
.................................................................................................................................
7
5
.................................................................................................................................
8
6
Available Battery Types .....................................................................................................
9
7
Sequence of Forward Rotating ...........................................................................................
18
8
Sequence of Reverse Rotating ...........................................................................................
18
9
Sequence of Forward Rotating ...........................................................................................
19
10
Sequence of Reverse Rotating ...........................................................................................
19
11
Brushless DC Motors ......................................................................................................
23
2
Hardware Design Considerations for an Electric Bicycle Using a BLDC Motor
SLVA642 –June 2014

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www.ti.com Introduction

Introduction

A controller for an electric bicycle must deliver power that varies from zero to the rated peak of the propulsion-
motor, at motor speeds corresponding to bicycle speeds from zero to 48 km per hour (30 mph). With DC
propulsion motors, power can be controlled with pulse-width modulated (PWM) transistors. AC motors need
variable frequency. Hardware requirements for design of an electric-bicycle control are postulated and basic
blocks along with their usage are shown.

An electric bicycle has a conventional bicycle frame, pedals, cranks, chain, and freewheel assembly. Electric
propulsion replaces or supplements muscle power. This adds to the bicycle an electric motor, gear reducer,
battery, and power control. The following defines the requirements of an electric bicycle:

The complete bicycle must have the lowest practical mass. All mass must be hauled over hills with energy
supplied by the battery. Lower mass gives more range between recharging of the battery.

Bicycle stability is another important requirement. Total mass need not affect stability, but the placement of mass
is important.

Table 1 lists the range of mass that is considered to be propelled.

Table 1. Range of Mass

COMPONENT
MASS IN KG
Bicycle assembly
10
Motor and gear
6
Power control
1
Battery
6
Cyclist
80
Total weight
106

Figure 1 shows the required power to develop the necessary wheel torque for the indicated travel conditions:
Fwf = windage and friction drag
Fd = downhill force from gravity FP = propulsion force = Fwf + Fd
Vb = bicycle speed = 20 km/hr
Fd = m sin x = 106 kg × 0.06 × 9.8 = 63 N
Pd = F × Vb = 63 × 5.56 m/s = 350 W
Headwind speed = 25 km/hr, adds 30-W power to propel

Figure 1. Range of Mass

Hence the power required by the motor to propel the bicycle and rider is 380 W.

SLVA642 –June 2014

Hardware Design Considerations for an Electric Bicycle Using a BLDC Motor
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