Dual 48V – 2x26kVA boost LEV Motor Controller
The DDMO48V500A1 controller is part of a modular inverter structure family suitable for a wide range of automotive applications, integrating functionalities available on two separate inverters into a single unit: it is the only dual inverter solution for electrified axle equipped with two 48V in-wheel or near-wheel motors on the market today.
It is designed according to ISO26262 safety standard guidelines, having in mind specifically light electric vehicles (classes L6e, L7e) and EV equipped with two 3-phase motors for automotive applications (two 3-phase motors (including PMSM, TFM, AFM) or single 6-phases motor are supported).
This unique integration and modularity significantly reduces cost, space and cable connections while increasing quality and reliability compared with traditional multi ECU solutions.
Motor support
Traction inverter for 3-phase electric motors having: DC-Link: 48V (nominal), DC-Link Range: 36V – 54V, Current: 2x230A (rms continuous), 2x500A (rms boost for 10s), Power: 2x12kVA (continuous), 2x26kVA (boost); Power density: 11kVA/liter; Specific Power: 10kVA/Kg. Support for multiple motor types (eg.: PMSM, TFM, AFM). Full access motor control parameters and torque mapping.
Flexible support of position sensors and interfaces including digital Hall sensors, SSI, RS485 and analog Sin/Cos sensors. Support of motor temperature sensors.
Easy motor specific adaption independently of motor manufacturer. In case you do not have access to the detailed technical motor specification, I&M offers to characterize the motor for you on our in-house test bench.
High Efficiency Power Electronics and Motor Algorithms
Up to 98% efficiency. “Field Oriented Control“ (FOC) algorithm. Highest performance and maximum torque under all operating conditions and speeds with “Full Field Weakening“ and “Maximum Torque per Ampere“ (MTPA) support.
High energy efficiency due to recuperative breaking option. Minimum motor harmonics and torque ripple.
Additional functions
- Dedicated output signals for reverse battery polarity protection or for external relay command
- Dedicated peak&hold output signal to drive the contactor and pre-charge relay
- Comprehensive diagnostic and safety functions.
- System protection against over-voltage, over-current, over-temperature.
- Controlled derating in case of system protection.
- Designed according to ISO26262, supports up to ASIL-D level (through advanced safe power supply, lockstep and watchdog architecture)
- Support of vehicle management functions (VMU), including gyro, acceleration sensors, brake, throttle, steering angle, drive mode, auxiliaries
Communication
- Two CAN 2.0 buses connect DDMO48V500A1 controller with the rest of the system: auxiliaries, battery management system and optionally more DDMO units in slave mode. The first one is an isolated CAN, for improved reliability, the second supports remote wake-up.
- The CAN bus also serves as interface for SW updates, system monitoring and diagnostic checks supported by an UDS (Unified Diagnostic Services) standard protocol through ODB-2 port.
- One 100-BaseT Ethernet connection is also available for development purposes.
Mechanical Design
The DDMO48V500A1 mechanical housing has an aluminium base plate acting as a heatsink for the power electronic circuits, and shall be connected to a liquid cooler or an air cooler for proper functionality.
The mechanical housing has been designed to fulfil the following characteristics:
- Weight: less than 4kg
- Dimensions (LxWxH): 277x207x67mm
- Grade: IP67
Customization Required?
In case the DDMO48V500-1 controller functionality meets your general requirements but your specific application needs some adaptions please contact us. Due to the modular design many modifications can be made quickly and with low effort. Options include e.g. changes of nominal operating voltage to 60V or 72V, integrated body features, modified motor control algorithms etc.
Contact us and learn more
