SinusLeistungsSteller - SLS Development/2009 |
In this section we provide frequently news on development and progress ... Details about the SLS are found here (click...) 25.11.2009: The Windows-monitor obtained a additional feature. Now the enduser can create his own signal curves (see below). With the help of a signal curve we can determine, which way the SLS processes the input signal - in other words the translation of the pulse length [µs] in RPM- or torque-reference values[%]. For each section, the rotational direction and parking brake activation can be selected. The signal curves will be written on the hard drive in form of a source file (*.SLG) as well as a binary file (*.DAT) when saving: The source file is ready for later changes and can be compiled to a binary file (*.DAT) that can be flashed into the SLS as a signal curve. ![]() 23.11.2009: The goal set for this year regarding the sensor-SLS is achieved: The software was able to turn a motor up to its maximum speed - without load, but in sensorless mode! The new hw/sw is far from being finished(!) we still have to work on many details ... First we will support a AS5040 sensor. This intelligent hall-sensor generates a "A-quad-B+index"-signal and provides the absolute angle position also on a SPI-interface. That is important for the correct determination of the starting position, as long as the motor has not moved over the index-position! With a resolution of 1024 positions for one complete mechanical turn, it should also be suited for motors with higher pole-pair numbers. As a side note: the sensor should be already mechanically integrated and adjusted by the motor manufacturer... 17.10.2009: The development of the sensored SLS advanced further: the re-worked hardware arrived with a more powerful DSP-core. Next we will transfer and extend the firmware. We have a lot to do, because the new hardware needs to support the sensorless operation and in addition make position sensors possible. This way full torque can be achieved at still-standing motor. If our "everyday work" gives us enough time, the first prototype could be finished at the beginning of 2010. For the moment we postponed activities towards higher currents (SLS-60-300). In our opinion we are well prepared: the prototype of the SLS-60-300 already works with a suitable motor (CuBa-II), which was tested at moderate power. Further tests at higher power can be done as soon as time and weather will allow it. In the moment however, the sensored SLS has highest priority... 10.08.2009: !!Important!! The update of the bugfixed Windows-monitor version 1.37 is ready for download. Older versions of the monitor and all parameter-files (*.SLC) created with it, can no longer be used and must be removed from the hard drive! 29.07.2009: Further updates for the Windows-monitor and firmware are ready for download in the download-area! Aside from a few minor bug fixes, while saving trace files, it is for example possible, to enlarge the status bar across the whole screen and analyze data more comfortably. The DEMO-version of the monitor (download area bottom) already shows the new features and brings a few LIVE-tested trace files and examples of signal curves with it. 03.07.2009: Our next important component (big copper winding motor (CuBa-II)) finished this week. For this attempt we optimized a HPD13.5 from Geiger/Eck. because we do not need to focus on the motor weight, the winding was replaced and the copper fill factor increased to its maximum - now we have a copper-profile troughout with 24mm² - at a (comparing with the orginal motor) nearly identical KV of 50RPM/V. We hope that the magnetic design is not to close to the saturation limit and therefore, by the high amount of copper we achieve a drastical decrease of the the copper losses and in addition the increase of the motor maximum current. The limit of 400Aac represents our goal ... All 6 segment-machine´s phases are wired seperately, which allows a high flexibility at running tests. E.g. one half of the maschine could be operated as a motor and the other half as a generator (controlled by another SLS) which will regenerate the energy back to the DC-side ... our DC voltage source will be sufficient for some time. The image at the very bottom shows the CuBa-II in size comparison with our first copper winding motor (inside-runner) since the turn of the year 2006/2007. With this motor we achieved powers over 8KW in the range of a few minutes. ![]() ![]() ![]() ![]() 01.07.2009: A velo mobile upgraded with a electro-motor by Wulf Kraneis for which we provided our SLS-42-110 and created a vehicle with very good efficiency ... (more here) ![]() 18.06.2009: The SLS can not always be cooled by airstream (e.g. our tests with the SLS-60-300 and impeller; see below). For this purpose we continued our development and designed a water-cooling system. Following our principle ("maximum power at minimum weight"), we kept an eye on a "slim" implementation. In the beginning this water cooling will be used at our test-bench with big impellers in connection with a SLS-60-300 (eventually SLS-60-400) - later it will be available as a option for everyone, if demanded. A full load in continuous operation is (from the SLS side) possible. ![]() ![]() ![]() ![]() 23.04.2009: The new SLS Windows-monitor can be downloaded for free in the download-area! 16.04.2009: Of course the SLS is not only able to handle small currents (9V-block-batteries, see below) very effectively. During first tests with the prototype of the new SLS-60-300 we reached 275Aac without any problems. For this test we used a motor from Lehner (LMT3080) in our TF8000-impeller. Our DC-source alone could not supply enough current; so we buffed our DC-side with additional 42S-NiCd high current-cells. We limited the current on 275Aac to prevent the motor from overheating; but we are sure, that 300Aac and even more are possible. The diagram at the end shows tests with the NiCd-accumulator till 250Aac (ca. 240Adc). As always: all in partial load! ![]() ![]() ![]() ![]() 02.04.2009: In order to demonstrate the SLS softstart behaviour, we powered Werner Eck´s HP-Direct 10 para-Motor (equipped with a 1,4m fold-propeller!) only with 4 in series connected 9V block-batteries. 9V-block batteries are not known for their high discharge currents - nevertheless the SLS was able to comfortably start the 10KW-motor at small RPM! Aside from that, the batteries were everything but new, which is visible on the starting voltage (slightly over 35V) in the trace below. The voltage drop down to 32V corrosponds to a DC-current of about 300mA. This batteries are not suited for higher RPM. Seriously, this is no joke or trick! We have no hidden battery in operation! For those who do not believe this: visit this weekend the AERO in Friedrichshafen at Joachim Geigers stand (hall B3) and see for yourself. Please bring your own 9V-batteries! ;-) Also observe the quite start! The "growl" appearing in the second start, is just a resonance of the test bench, which is caused by the field-frequency. ![]() 16.02.2009: Roland Gaber (a friend since old Siemens-days) came to us with a special challenge: For a RC-solar car (supervised by him in a "Jugend-Forscht"-project at SMA Solar Technology AG) he did not find a suitable controller, to power his two wheel hub motors. The actual obstacle represented the control of both wheels and additionaly implement a flawless steering of the vehicle! A very precise RPM-control is a must - the smallest differences would result in a uncontrollable curve-ride. The solar car (it was actually, only one axle of the vehicle with two driven wheels) was equipped with a SLS-24-25 each wheel. We supported it with a skid, to allow a stable stand of the vehicle and called the vehicle Scorpion. With a for RC-pilots so far unknown driving experience (caused by an incredible handling and almost noiseless driving) we spent the rest of the afternoon with test drives (=playing) ;-) ![]() ![]() 10.02.2009: For the upcoming tests with higher currents, we made a larger test-bench, to be able to work with bigger propellers. We will also need to buffer our 10kW-voltage controller with batteries, to enable 300A tests. Thorsten Wernecke provided 48 highload-NiCd-Zellen with 44Ah. We already built a SLS-60-300 prototype and are ready, to beginn with outside tests - but the weather does not allow it ... ![]() ![]() 07.01.2009: We wish all customers, friends and interested readers a happy new year! Of course we have this year some interesting projects and developments (even more current!) for the SinusLeistungsSteller. It is therefore, worthwhile to periodically visit and read about the newest status of the SLS! |