Introduction
Power Inverters (PI) are becoming more popular everyday. From creating an AC outlet in your car, generating AC power for your house from Solar charged batteries or driving Hybrid or Electric vehicles' motors, this device plays a major role in several applications. The advances in IGBTs and the research for material, like SiC devices, opens possibilities and enhance the system's overall efficiency, a big concerne nowadays, mainly for Electrical Vehicles (EV).
This project, initially intended for EV applications, may be useful in a great range of equipaments. The main focus here are the PI which drives motors. It may be an elevator or escalator motor, industrial machines and, the inspiration of it all, EVs.
In high power applications, a fail in any inverter's leg may be catastrophic, not only for itself but for the device connected to. So, the hability of self-monitoring and self-diagnosing may prevent accidents and bigger damages. And here is where MAX31875 saves the day.
The tiny package allows precise monitoring of each IGBT, making possible not only just monitor the system but predict failures and adjust power output to work always at the most efficient range. An additional sensor measuring ambient temperature may give one more info to the system, helping it to adjust its behavior for every environment condition.
So, this project documents the idea of using a small, precise and low-power temperature sensor to allow the main controller to monitor, adjust and predict the behavior of power invertes, preventing overtemperature damages and enhancing system's efficiency and reliability.
BOM
The project will be devided in four parts: Power supply, inverter, driver and main controller.
To build an prototype, I suggest the following parts:
Inverter board:
- 6x IKA06N60T 600 V, 6 A IGBT;
- 6x FFPF10UP60S 10A, 600 V Ultrafast Diode;
- 1x 10 pins, 90° pin header.
Driver board:
- 3x IR21094D IC;
- 3x 1N5819 Diodes;
- 6x MBRS140T3G Diodes;
- 6x 10 Ohms 1/4 W resistors;
- 3x 22 uF 50 V electrolytic capacitors;
- 6x 47 uF 50 V electrolytic capacitors;
- 1x 10 pins, 90° pin header;
- 1x 8 pins, 90° pin header.
Rectifier (in case you don't have a battery to power your motor):
- 6x 10A06 diodes;
- 1x 10 A fuse (with holder);
- 1x 10 A 47uH inductor (value not optimized yet);
- 1x 330uF 400V Electrolytic capacitor.
Main Controller:
- 1x PIC16F1933;
- 1x 1 kOhms linear potentiometer;
- 2x 100 nF ceramic capacitor;
- 1x 100 uF 16 V electrolytic capacitor;
- 1x 10 uF 50 V electrolytic capacitor;
- 1x 1117-3.3 voltage regulator;
- 1x power supply DC Jack;
- 1x 8 pins, 90° pin header.
All these parts were found online at Mouser website.
Schematics
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Instructions
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Video
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Source Code
CAD Files
Attach or link to any CAD files if relevant to your project.
Power Inverters (PI) are becoming more popular everyday. From creating an AC outlet in your car, generating AC power for your house from Solar charged batteries or driving Hybrid or Electric vehicles' motors, this device plays a major role in several applications. The advances in IGBTs and the research for material, like SiC devices, opens possibilities and enhance the system's overall efficiency, a big concerne nowadays, mainly for Electrical Vehicles (EV).
This project, initially intended for EV applications, may be useful in a great range of equipaments. The main focus here are the PI which drives motors. It may be an elevator or escalator motor, industrial machines and, the inspiration of it all, EVs.
In high power applications, a fail in any inverter's leg may be catastrophic, not only for itself but for the device connected to. So, the hability of self-monitoring and self-diagnosing may prevent accidents and bigger damages. And here is where MAX31875 saves the day.
The tiny package allows precise monitoring of each IGBT, making possible not only just monitor the system but predict failures and adjust power output to work always at the most efficient range. An additional sensor measuring ambient temperature may give one more info to the system, helping it to adjust its behavior for every environment condition.
So, this project documents the idea of using a small, precise and low-power temperature sensor to allow the main controller to monitor, adjust and predict the behavior of power invertes, preventing overtemperature damages and enhancing system's efficiency and reliability.
BOM
The project will be devided in four parts: Power supply, inverter, driver and main controller.
To build an prototype, I suggest the following parts:
Inverter board:
- 6x IKA06N60T 600 V, 6 A IGBT;
- 6x FFPF10UP60S 10A, 600 V Ultrafast Diode;
- 1x 10 pins, 90° pin header.
Driver board:
- 3x IR21094D IC;
- 3x 1N5819 Diodes;
- 6x MBRS140T3G Diodes;
- 6x 10 Ohms 1/4 W resistors;
- 3x 22 uF 50 V electrolytic capacitors;
- 6x 47 uF 50 V electrolytic capacitors;
- 1x 10 pins, 90° pin header;
- 1x 8 pins, 90° pin header.
Rectifier (in case you don't have a battery to power your motor):
- 6x 10A06 diodes;
- 1x 10 A fuse (with holder);
- 1x 10 A 47uH inductor (value not optimized yet);
- 1x 330uF 400V Electrolytic capacitor.
Main Controller:
- 1x PIC16F1933;
- 1x 1 kOhms linear potentiometer;
- 2x 100 nF ceramic capacitor;
- 1x 100 uF 16 V electrolytic capacitor;
- 1x 10 uF 50 V electrolytic capacitor;
- 1x 1117-3.3 voltage regulator;
- 1x power supply DC Jack;
- 1x 8 pins, 90° pin header.
All these parts were found online at Mouser website.
Schematics
Upload your schematic files or images
Instructions
Explain how you built your project! Please be sure to include rich technical information and images. You can drag and drop images from your desktop directly into this editor.
Video
Let's see your project in action! Paste the YouTube link here and it will automatically be embedded.
Source Code
Code (Text):
- Paste your project source code here, or upload an attachment.
Attach or link to any CAD files if relevant to your project.