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CaroFocIW

A small form factor servo inverter for BLDC motors to be mounted directly to the back of the corresponding motor. Intended use in the autonomous 1:10 scale vehicle Carolinchen XI of the Team CDLC (https://www.team-cdlc.de/, german). Firmware compatible with VESC and the custom firmware of the previous iteration. This repository only contains the hardware design.

Features:

  • Field oriented control with sine commutation
  • 3× in phase current measurement with oversampling
  • 14bit position encoder
  • 16kHz sampling rate and PWM frequency
  • JST-GH connector with supply and CAN bus interface

Main components:

Function used part
Microcontroller STM32F405RGT6
Gate Driver TLE7185-1E
Current Sensors 3× ACS71240KEXBLT-010B3
Encoder AS5048A
CAN Transceiver TCAN332
Voltage Regulator LMR16006YQ3
Power MOSFETs 6× BSZ013NE2LS5I

Renderings:

PCB Rendering Front

PCB Rendering Back

Progress:

  • Schematics finished
  • Layout finished
  • PCB fabricated
  • PCB assembled
  • Mechanical assembly finished
  • Basic functional tests done
    • Microcontroller working
    • Gate driver working
    • Current sensors working
    • CAN interface working
    • DC link voltage measurement working
    • Angle encoder working
  • Fully operational
  • Tested on vehicle
  • Long term real world testing

Link to Schematics

Link to Interactive BOM

Link to PCB assembly and test instructions

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