What is an automotive motor controller
The automotive motor controller (MCU) is the core electronic module of new energy vehicles, located between the power battery and the drive motor. It is mainly responsible for converting direct current into alternating current to drive the motor to operate, and dynamically adjusting the motor's speed, torque and direction according to driving instructions, achieving control of the vehicle's starting, acceleration, braking, climbing and other driving states.
Core function
Youdaoplaceholder0 Voltage conversion : Convert the direct current from the power battery into three-phase alternating current to drive the AC motor. This process is achieved through an internal inverter, which uses semiconductor switching devices such as transistors or IGBTs to control the frequency and amplitude of the current.
Youdaoplaceholder0 Speed and torque control : Adjust the motor speed and torque according to driving requirements (such as gear position, accelerator, brake), and achieve precise control through PWM (pulse width modulation) technology.
Youdaoplaceholder0 System protection : It is equipped with overload protection, fault detection, battery input terminal protection and other mechanisms to ensure the safe operation of the system.
Youdaoplaceholder0 Energy recovery : During braking, kinetic energy can be converted into electrical energy through an inverter process to charge the battery, thereby enhancing the driving range.
Key components
Youdaoplaceholder0 control module : Processes driving instructions and generates PWM signals to control the inverter.
Youdaoplaceholder0 power module : It contains IGBT and other switching components to achieve voltage conversion.
Youdaoplaceholder0 sensor : monitors the motor status (such as temperature, speed) and feeds it back to the control system.
Youdaoplaceholder0 heat dissipation system : maintains a stable operating temperature under high load conditions.
The performance of the motor controller directly affects the driving experience and energy efficiency of electric vehicles and is a key hub connecting the power battery and the drive motor.
The automotive motor controller is a core component of electric vehicles, and its main functions include:
Speed and torque control
The motor speed and torque are adjusted according to instructions such as the accelerator and brake. The voltage and frequency are regulated through PWM technology to achieve precise speed regulation, meeting driving requirements such as acceleration, braking, and climbing slopes.
Energy conversion and drive
The direct current from the power battery is converted into alternating current to drive the motor, and the current direction is adjusted through the inverter to control the forward and reverse rotation of the motor. When braking, kinetic energy can be converted into electrical energy and recovered to the battery.
System protection and diagnosis
Monitor parameters such as motor temperature and voltage, diagnose faults in real time (such as overheating and overload), and take protective measures to prevent damage. At the same time, communicate and share data with other systems (such as BMS) through the CAN network.
Dynamic response control
Torque and magnetic flux are independently adjusted through vector control algorithms to achieve rapid response to driving instructions. Smooth transition during start/stop to reduce the sense of shock.
The faults of the motor controller in new energy vehicles are mainly manifested as decreased power performance, difficult starting, increased energy consumption and other problems. The specific causes need to be comprehensively judged in combination with the fault phenomena.
Common fault manifestations
Youdaoplaceholder0 Power performance decline : The accelerator pedal responds slowly, making it difficult for the vehicle to accelerate and limiting the maximum speed.
Youdaoplaceholder0 Abnormal startup : There may be difficulty in starting, multiple failed attempts to start, or abnormal sounds/vibrations during startup.
Youdaoplaceholder0 Increased energy consumption : Controller failure may lead to reduced motor efficiency and shortened vehicle range.
Youdaoplaceholder0 Fault indicator light prompt : The instrument panel shows the power system fault light or the motor system fault light.
Fault diagnosis method
Youdaoplaceholder0 Basic tests :
Check if the power supply voltage is normal (use a multimeter to measure if the 5V voltage is abnormal)
Observe whether there is an overheating phenomenon in the main circuit of the controller (6 MOS switch tubes)
Youdaoplaceholder0 signal detection :
Measure the voltage change when turning the handle (normal range: 0-4.2VDC)
Check if the connecting wires are loose or worn
Youdaoplaceholder0 alternative test :
If the pushcart resistance disappears after disconnecting the three thick phase lines of the motor, it may be a controller fault
Use professional tools (such as a multimeter) to test parameters such as diode and handle voltage
Analysis of Fault Causes
Youdaoplaceholder0 Hardware damage : Aging or overheating damage to internal power devices (such as IGBT modules)
Youdaoplaceholder0 connection problem : Loose and worn signal lines result in the loss of control signals
Youdaoplaceholder0 Design defect : insufficient heat dissipation design or unreasonable configuration of circuit parameters
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