Design And Research On Extended Range Controller For Extended Range Motorcycle

As vehicle exhaust emission caused increasing prominent environmental problems, energy-saving and emission-reduction, low carbon-consuming life and sustainable development become the global consensus. The 2015 Annual Report of Chinese Vehicle Emission Control showed that 45.473 million tons of motor vehicle emission is released in China during 2014, vehicle exhaust has become top priority pollutants in China. In order to reduce the exhaust emissions of motor vehicles, research and development of electric vehicles is promote actively in many countries. The use of Battery Electric Vehicles(BEV)gradually increased in nowadays, however, there are still many technical problems on BEV, such as battery technology, charging facilities, motor control technology and etc.. Therefore, as a transition developing process of traditional fuel vehicles to BEV, the Extended-Range Electric Vehicles(EREV) still attract widely attentions and researches.Extended-Range Motorcycle is a kind of EREV and installs a Range Extender(RE) to increase its driving range. At present stage, the RE of the EREM is always composed of a small gasoline engine and generator linked by mechanical assembly, hand pulling starting usually, which need complicated operation, and of low intelligent degree; however, the electric starter RE must be equipped with reliable RE controller, in cooperation with the vehicle main controller, the starting, power generation and state monitoring of the process are completed. The electric starter RE still has many defects in nowadays, such as the high cost, large RE controller, low reliability, and the overvoltage or overcurrent damage is easily to occur. Thus it is of great significance to the study of extended range controller.On the basis of learning the knowledge of EREV, EREM, RE, ISG, control theory, converter circuit and inverter circuit, this paper focuses on the design and research of the extended range controller, and completed the overall structure design, module design, hardware circuit design, main program software design, subroutine software design, system debugging and testing analysis. The main function modules of the controller includes a driving circuit, an inverter circuit, detection and protection function of motor starting voltage, detection and protection function of motor starting current, communication module, motor speed detection, detection of the battery charging current, detection of the battery charging voltage, fault indication etc.. The controller hardware circuit uses a main control chip and a special motor control chip. The main control chip PIC16F873 complete s the detection of battery charging voltage and current, speed detection and communication function; the dedicated motor control chip FCM8201 completes the starting control of the RE, and complete the process of bus voltage and current detection and protection, compile the hall signal acquisition and PWM logic output.The system debugging and preliminary real vehicle test are completed; the system debugging result shows that each module can meet the design requirements. Each State detection and protection module is reliable. The preliminary real vehicle test focus on the verification of the starting state and power generating state, test result shows that the starting target speed is 1000r/min, the starting current is 16.3A and the starting time is 2s-2.7s. The output of the generator is stable, and can meet the design requirements. The controller has a good control effect on the RE, during the starting and power generation stage, the RE is stable and every module of extended range controller works properly.