05/03/2024 | Hi-Dynamic Family Controller Product Description

Reference No. XX-PR-05/04 | Revision 01-B

Hi-Dynamic Family Controller

Product Description

This document contains proprietary information of IRP Nexus Group Ltd. and
may not be reproduced, copied, disclosed or utilized in any way in whole or in
part, without the prior written consent of IRP Nexus Group Ltd.
Contents
Revision Control ...................................................................................................................................... 4
Applicable Documents ............................................................................................................................. 4
1. What Is Evver Hi-Dynamic Controller? ................................................................................... 5
Hi-Dynamic Controller ......................................................................................................................... 5
2. Key Advantages...................................................................................................................... 6
Pushing the Cost / Performance Envelope ........................................................................................... 6
Designed for safety .............................................................................................................................. 6
Top level durability .............................................................................................................................. 6
Driving Experience ............................................................................................................................... 6
Multiple Advanced Control Methods ................................................................................................... 6
Features .................................................................................................................................................. 7
Smart Driving Profiles .......................................................................................................................... 7
Regenerative Braking ........................................................................................................................... 7
Smart Vehicle Protection ..................................................................................................................... 7
Cruise Control...................................................................................................................................... 7
Reverse Mode (optional) ..................................................................................................................... 7
Safety ...................................................................................................................................................... 8
Derating .............................................................................................................................................. 8
Active Limiters ..................................................................................................................................... 8
Driving Assistance ................................................................................................................................ 8
System and Maintenance ....................................................................................................................... 8
The TrueDrive Manager ....................................................................................................................... 8
TrueDrive Manager parameters configuration screen .......................................................................... 9
Data Logging ........................................................................................................................................ 9
Straightforward Integration ................................................................................................................. 9
3. Specifications ....................................................................................................................... 11
4. Product Dimensions (Mechanical) ........................................................................................ 12
...................................................................................................................................................... 12
5. System Description .............................................................................................................. 13
External Connectivity ......................................................................................................................... 13
Main Modules and External Interfaces ............................................................................................... 13
35 Pos digital connector .................................................................................................................... 14
Pos Layout ......................................................................................................................................... 14

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 6. Functional Safety – ISO 26262 .............................................................................................. 15
Key Protection Parameters ................................................................................................................ 15
7. Quality and Durability Tests ................................................................................................. 15
8. System Output Indicators .................................................................................................... 16
Monitoring Indicators ........................................................................................................................ 16
9. Faults and Alerts .................................................................................................................. 16

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 Revision Control
Rev. No Date Change Description Edited By Approved By
Refael Saadon,
00-A 08.12.2023 First draft Paul Price
Alon Ben-Dor
Refael Saadon,
01-A 20.01.2024 Revised final version Paul Price
Alon Ben-Dor
02-A 05.03.2024 Updates Kobe Mesika Paul Price

Applicable Documents
ID Document Name Reference No. Rev. Date
[D1]
[D2]
[D3]
[D4]

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 1. What Is Evver Hi-Dynamic Controller?

The Hi-Dynamic is an advanced high-voltage electric motor controller, especially designed for light
commercial vehicles and compact vehicles. Using proprietary control algorithms, the Hi-Dynamic
controller enables groundbreaking electric powertrain efficiency with maximal performance (range,
speed, torque) at any operational working point, while keeping powertrain costs affordable.
IRP’s Hi-Dynamic Controller provides:
- Top-level performance – high torque at any operational working point
- Top-level quality, reliability, and robustness
- Top-level functional safety
- Supreme driving experience
- Advanced functionality

Hi-Dynamic Controller

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 2. Key Advantages
Pushing the Cost / Performance Envelope
Using IRP’s patented design and algorithms, the Hi-Dynamic controller enables maximal motor efficiency
and an enhanced operational envelope. The controller’s enhanced operational envelope opens-up an
opportunity for vehicle developers to improve their competitive position by providing superior
performance at lower costs.

Designed for safety

The Hi-Dynamic Controller was developed and designed as defined by ISO 26262 automotive standard.
The product is designed to meet ASIL B (Asil C optional) safety level and can be integrated as a safety
element in the OEM’s vehicle, ensuring the highest level of safety for its drivers.
To further ensure the platform's safety and longevity, the Hi-Dynamic features various Active Limiters
that protect the controller and the system from extreme cases and conditions.

Top level durability

Rigorous testing is carried out under the most challenging road and environmental conditions, to ensure
the highest levels of durability and quality for the drivers, including EMI, sealing, shocks and vibrations,
thermal stress tests and more. These tests are carried out to withstand the most challenging OEMs’
durability requirements characterizing the LCV segment.

Driving Experience
One of the key barriers for the adoption of electric mobility platforms lies in the driving experience they
offer. The Hi-Dynamic controller was designed, configured, and carefully optimized to enable e-mobility
platforms to provide a superior driving experience. The Hi-Dynamic controller unique control algorithm
enables the vehicle to provide quick response times, smooth acceleration and braking, and in-control
feeling for the driver. The system offers the flexibility to fine tune the driving experience and customize
it per each vehicle and per each manufacturer’s specific needs.

Multiple Advanced Control Methods

The Hi-Dynamic controller provides OEMs with the flexibility to tailor and configure their e-mobility
platform to meet their unique needs.
IRP’s Controller supports:
• Torque/current control.
• 4 Quadrants operation, allowing motoring and braking in forward and reverse modes.
• Energy recuperation while driving.
• Field weakening is activated automatically, and in a minimal amount in order to optimize
efficiency at high speeds.

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Features
Smart Driving Profiles
IRP’s Hi-Dynamic Controller supports up to 5 configurable driving profiles, enabling the vehicle provider
to flexibly define the desired driving modes of each vehicle model. Driving profiles can include, for
example the following profiles:
- Sport – optimized for aggressive performance - quick acceleration and high torque at various
speeds
- Eco – optimized for battery saving
- Normal – optimized for maximal range while keeping good enough performance
- Limp home – limits the vehicle operation in a case of a malfunction to enable safe drive to the
nearest service center while preventing damage to the vehicle’s components

Additional profiles, customized per specific customer requirements, can be added and be applied for the
relevant vehicles.

The TrueDrive Manager enables accurate and extensive control over the driving profiles. Each profile
includes:

- The power map for drive and regeneration modes

- Torque ramp-up and ramp-down definition - providing a moderated response to the throttle
input
- Speed limits - adjustable for each of the 5 forward drive profile, and the reverse drive mode

Regenerative Braking
The Hi-Dynamic Controller supports regenerative braking - the recharging of the vehicle’s battery while
the vehicle is braking. Regenerative braking enables the extension of the driving range according and
can be configured according to platform requirements.

Smart Vehicle Protection

The controller protects the driver by disabling the vehicle in potentially dangerous situations. The
controller disables the motor’s operation when:
1. The vehicle is not set to drive mode (or the gear of the vehicle is not engaged, or the “Ready”
button isn’t pressed).
2. The controller detects faults in the powertrain system

Cruise Control
In Cruise Control mode, the vehicle is set to drive at a selected throttle percentage. Cruise Control is set
and released manually by the driver.

Reverse Mode (optional)

Reverse Mode is a unique driving profile that enables driving backwards. Reverse mode includes several
limitations and restrictions on speed and acceleration, to enable safe reverse driving.

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Safety
Derating
The Hi-Dynamic activates the Derating function, limiting the vehicle's performance in predefined
conditions to protect and prolong the life of its powertrain and electronic components. OEMs
can configure the derating functionality and its % levels in the following parameters:
- Motor Temp
- Controller temp
- Bus voltage
- Bus current

Active Limiters
With the Hi-Dynamic controller, OEMs can use active limiters to pre-define limits in a variety of
driving conditions. The following parameters can be controlled:
- Top speed limitation
- Motor and MCU temperature
- Maximal bus current – discharge
- Minimal bus current – regeneration
- Maximal bus voltage – regeneration
- Minimal bus voltage – discharge

Driving Assistance
A number of safety features in the Hi-Dynamic help reduce risks in challenging road conditions. These
include:
- Uphill assist – brakes the vehicle until the throttle is applied to prevent rollback on an incline

System and Maintenance

The TrueDrive Manager
The TrueDrive Manager application enables the vehicle provider or its certified mechanics to control and
configure the controller using an easy-to-use GUI over CAN bus communication. It enables:
- Monitoring the controller’s status
- Configuring the controller
- Identifying issues and solve them
- Flexibly defining customized driving profiles
- Updating firmware versions

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The image below depicts the flexible driving profiles configuration UI:

TrueDrive Manager parameters configuration screen

Data Logging
The Hi-Dynamic controller features data logging, a powerful tool for monitoring, collecting, and
analyzing parameters to optimize the performance of the vehicle. Furthermore, it helps improve the
quality and reliability of the vehicle and its components. Hi-Dynamic data logging allows the following:
- Integration and optimization to the vehicle’s system components (battery, motor etc.)
- Vast analysis capabilities to detect errors, analyze performance, power demand, uncover latent
errors and anomalies.
- Configuration of vehicle’s performance according to customers’ needs.
- Environmental testing (road conditions, driver profiles, payload etc.)
The Hi-Dynamic logging is done via the UART communication channel.

The standard logging parameters are:

- Motor and controller temperature
- BUS voltage
- Phase current (all phases)
- Speed
- Power input
- Throttle command

Straightforward Integration
IRP’s Hi-Dynamic controller was designed to enable straightforward integration with any permanent
magnet / brushless electric motor. It utilizes the Automatic Motor Calibration function to smoothly
integrate with the motor, for example by automatically identifying the sensor’s angle position.
It supports:
- Seamless motor interface
- Field Oriented Control (FOC)
- Hall-sensor configuration
- Quadrature Encoder

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 - Resolver
- A vast set of parameters for optimization, e.g. regeneration limits, speed limits, throttle ranges,
etc.

The controller digitally integrates with control & management systems for logging, telemetry, and
control via CAN 2.0A/2.0B interface ISO 11898-1 compliant. It supports 4 discrete signal inputs and 3
discrete signal outputs.

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 3. Specifications

Parameter Specification
Physical
Dimensions (L x W x H) 413 x 230 X 98 mm
Weight 6.7kg
Mounting 4 mounting holes (M8 screws)
Electrical
Operating Voltage Hi voltage (HV): 200-450 VDC
Low voltage (LV): 9-36 VDC
Hi dynamic 40 Hi dynamic 60 Hi dynamic 80
Rated Output Power [kW] 20 30 40
Peak Power [kW for 30 sec]* 40 60 80
Peak Phase Current [A RMS for 30 sec] * 110 160 220
Cont. Phase Current [A RMS for 30 Min] * 55 80 110
*Cooling System Requirements Coolant Flow rate Temperature
Water/Glycol 70/30 8 – 15 LPM 65oC max
Interfaces
Drive power input 2 lines, screw terminal
Motor 3 lines, screw terminal
Data Connector 35 Pos
Environmental
Operating Temp -10°C – 70°C
Sealing Enclosure: IP67
Connectors: IP6K9K
ISO 16750-4 V
EN 61000 V
LV 124, ISO 16750-3, ISO 19453-3 V
Shocks & Vibrations
Functional
Supports PMSM/BLDC, Induction V
and Other Motor Types
Voltage Sensor All Internal and External
Temp Sensor 2 on-board temperature sensors
2 motor temperature sensors
1 cooling plate temperature sensor
4 Quadrant Operation V
Current Sensor For V
Battery Bus & Phases
SW Bootloader Via Communication Port V
Feedback Via Hall sensors, ABZ Encoder or V
Resolver
Supports Communication V
Via 2 CAN-bus interfaces
Firmware Upgrade V
Supports Software Lock V

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4. Product Dimensions (Mechanical)

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 5. System Description
External Connectivity

The following picture describes the system’s external connections:

- U – U Phase output – to motor

- V – V Phase output – to motor
- W – W Phase output – to motor
- + - positive input, battery pack
- - - negative input, battery pack
- E - Data connector – 35 Pos

Main Modules and External Interfaces

The Hi-Dynamic Controller integrates with the following systems:

1. The vehicle’s motor – including the motor phases, hall, and temperature sensors
2. The Battery Pack
3. The Vehicle’s Computer – communicating using CAN bus.
4. A digital interface to the Vehicle’s peripheral components, including:
a. 3 Digital outputs (e.g brake light, pre-charge contactors)
b. 4 Digital inputs (including brakes)
c. 2 Analog inputs (e.g throttle, motor thermistor)
5. The TrueDrive Manager application - used for configuration, maintenance, and SW upgrades, is
connected using CAN bus
6. CAN bus termination option on the connector
7. Optional configuration of digital reference voltage (0V, 5V)

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35 Pos digital connector
The Hi-Dynamic controller is equipped with a 35 Pos digital connector to implement additional features
and basic VCU capabilities.
Mating connector for the 35 pins connector: 776164-1

Pos Layout
Pin Name / Function Configuration Notes
No.
1 KL15 Sense Connect to Ignition / KL15 / switched
12VDC source
2 Digital IN 2
3 CAN 2 Low CAN 2.0B Debug CAN bus
4 CAN 2 High Including internal 120Ω termination
5 Digital OUT 1
6 LV Return / KL31 Connect to KL31 / 12VDC negative
terminal
7 Reserved
8 Reserved Internal PT1000 Support either internal or external
PT1000 temperature sensor
9 Analog IN 2
10 CAN 1 Termination Low CAN 2.0B Main CAN bus
11 CAN 1 Low If termination is needed:
12 CAN 1 High - Short pin 10 to pin 11
13 CAN 1 Termination High - Short pin 13 to pin 12
14 Digital IN 4
15 Digital OUT 2
16 Digital OUT 3
17 Digital Reference Define how the digital inputs will work:
- Open-circuit/short to voltage – short
to pin 26
- open-circuit/short to ground – short
to pin 27
18 Resolver EXC High / Support either resolver or Quadrature
Encoder B High encoder
19 Analog IN 3 PT1000; 0-5VDC Motor temperature
20 Return / KL31
21 Resolver EXC Low / Support either resolver or Quadrature
Encoder B Low encoder
22 Digital IN 1
23 LV Input / KL15 / KL30 12VDC; up to 450mA Connect to 12VDC source – switchable
or fixed
24 HVIL 1
25 HVIL 2
26 LV Return / KL31
27 5DC Supply 5VDC; up to 200mA
28 5DC Supply 5VDC; up to 200mA

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 29 Resolver SIN High / Support either resolver or Quadrature
Encoder A High encoder
30 Resolver SIN Low / Support either resolver or Quadrature
Encoder Z High encoder
31 Chassis
32 Resolver COS High / Support either resolver or Quadrature
Encoder A Low encoder
33 Resolver COS Low / Support either resolver or Quadrature
Encoder Z Low encoder
34 Digital IN 3
35 LV Return / KL31

Use 20 AWG wires on all pins

6. Functional Safety – ISO 26262

IRP’s Hi-Dynamic controller is designed to meet the most demanding automotive requirements. The
entire development process followed the stringent ISO26262 standard. The Hi-Dynamic design ensures
smooth operation of the vehicle and top-level safety for the drivers.

Key Protection Parameters

The Hi-Dynamic controller enables the detection of the following key faults and actively implements
safety actions to prevent any damage to the vehicle components:

Parameter Value Comments

Over voltage V Configurable up to 450VDC
Under Voltage V
Over current V
Motor temp. V Derating available
Power stage temp. V
CAN bus errors V
Motor feedback V
Battery over current V
Battery low voltage V
VCU commands V

7. Quality and Durability Tests

The Hi-Dynamic is built to endure the toughest road conditions, environmental conditions, and driver
requirements. To meet these requirements, the Hi-Dynamic went through a series of quality tests, as
following:

Requirement Standard
Humidity Cycling ISO 16750-4
Shocks and Vibrations Tests LV 124, ISO 16750-3, ISO 19453-3
Temperature cycle Tests LV 124, ISO 16750-4, ISO 19453-4
Free fall LV 124, ISO 16750-3, ISO 19453-3

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 High and Low Temp Tests ISO 16750-4, LV 124
EMC CISPR 25, ISO 7637-2, ISO 11452-7, AIS004-3, IEC 61000-4
ESD ISO 10605
Sealing ISO 16750-4, LV 124

8. System Output Indicators

The Hi-Dynamic Controller system sends various signals, indicating the vehicle’s status and its
operational mode. These indicators are constantly updated and can be monitored using the TrueDrive
Manager application.

Monitoring Indicators

• Speed
• Bus voltage
• Bus current
• Phase currents
• Throttle voltage
• Digital inputs
• Motor temperature
• Controller temperature
• Run time
• Odometer
• Trip
• Input power
• Output power
• Torque
• Many more…

9. Faults and Alerts

System faults and alerts are saved and can be accessed using the GUI. Faults are managed as follows:

Name Description
Keeps the active system faults and alerts. The registry is reset whenever the
Fault Registry
system reboots (e.g. the vehicle is turned on/off)
Fault History Keeps the fault history log. Resets manually.

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