Data Sheet

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KBL1xxx Motor Controller Datasheet 1

KBL1xxx

Roboteq’s KBL1xxx is a rugged, feature-packed, high-current

single channel controller for brushless DC motors. Built in a

water and dirt resistant enclosure, the controller can operate

in one of several modes in order to sense the rotor position

and sequence power on the motor’s 3 windings in order to

generate smooth continuous rotation. The controller also uses

the Hall sensor and/or Encoder information to compute speed

and measure traveled distance. The motor’s may be operated

in open or closed loop speed mode, position mode or in

torque mode.

The KBL1xxx features several Analog, Pulse and Digital I/Os which

can be remapped as command or feedback inputs, limit switches,

or many other functions. The KBL1xxx accepts commands

received from an RC radio, Analog Joystick, wireless modem,

or microcomputer. Using CAN bus, up to 127 controllers can

be networked at up to 1Mbit/s on a single twisted pair.

The controller’s operation can be extensively automated and

customized using Basic Language scripts. The controller

can be conﬁgured, monitored and tuned in real-time

using Roboteq’s free PC utility. The controller can also

be reprogrammed in the ﬁeld with the latest features by

downloading new operating software from Roboteq.

Applications

• Small Electric Vehicles, Electric Bikes

• Electric Boats

• Terrestrial and Underwater Robotic Vehicles

• Automatic Guided Vehicles

• Police and Military Robots

• Material Lifting Systems

• Animatronics

• Industrial Controls

• Hydraulic Pumps control

Key Features

• RS232, RS485, 0-5V Analog, or Pulse (RC radio) com-

mand modes

• Auto switch between RS232, Analog, or Pulse based

on user-deﬁned priority

• CAN bus interface at up to 1Mbit/s

• Built-in 3-phase high-power drivers for one brushless

DC motor at up to 120A RMS (170A DC equivalent)

• Trapezoidal commutation based on Hall Sensor position

information

• Trapezoidal Sensorless

• Smooth and quiet three Phase sinusoidal mode

• Support for absolute angle encoders

- Sin/Cos analog

- SSI digital

- Resolver

• Field Oriented Control in Sinusoidal modes

• Full forward and reverse motor control. Four quadrant

operation. Supports regeneration

• Safe Torque Off - STO (Certiﬁcation Pending)

• Operates from a single power source

• Programmable current limit up to 120A RMS for pro-

tecting controller, motor, wiring and battery.

• Separate waterproof M12-type connector for Hall or SSI

rotor sensor

• Accurate speed and Odometry measurement using

Hall Sensor or encoder data

• Quadrature encoder input with 32-bit counter

• Up to six Analog Inputs for use as command and/or

feedback

• Up to six Pulse Length, Duty Cycle or Frequency Inputs

for use as command and/or feedback

• Up to six Digital Inputs for use as Limit Emergency

stop or user inputs

Environment-Proof 120A

Brushless DC Motor

Controller with

Field Oriented Control

USB and CAN

Summary of content (13 pages)

PAGE 1
KBL1xxx Environment-Proof 120A Brushless DC Motor Controller with Field Oriented Control USB and CAN Roboteq’s KBL1xxx is a rugged, feature-packed, high-current single channel controller for brushless DC motors. Built in a water and dirt resistant enclosure, the controller can operate in one of several modes in order to sense the rotor position and sequence power on the motor’s 3 windings in order to generate smooth continuous rotation.
PAGE 2
• • • • • • • • • • • • • • • Two general purpose 40V, 1.5A output for brake release or accessories Custom scripting in Basic language.
PAGE 3
Power Wires Identifications and Connection Important Safety Disclaimer Dangerous uncontrolled motor runaway condition can occur for a number of reasons, including, but not limited to: command or feedback wiring failure, configuration error, faulty firmware, errors in user script or user program, or controller hardware failure. The user must assume that such failures can occur and must make their system safe in all conditions.
PAGE 4
Figure 2, below, shows how to wire the controller and how to turn power On and Off. F2 1A SW1 Main On/Off Switch 1A PwrCtrl Note 1 U U Ground Motor Backup Battery V V Diode >20A Resistor 1K, 0.5W Note 3 W W Note 2 Rotor Sensors Sensors Connector VMot F1 Note 4 SW2 Emergency Contactor or Cut-off Switch Hall/SSI SinCos or Resolver Ground + I/O Connector Main Battery Note 5 Do not Connect! FIGURE 2. Powering the Controller.
PAGE 5
Motor Sensor Connector Note 4: Optionally ground the VMot input when the controller is Off if there is any concern that the motors could be made to spin and generate voltage in excess of the controller’s absolute max voltage rating. Note 5: Beware not to create a path from the ground pins on the I/O connector and the battery minus terminal. Controller Mounting During motor operation, the controller will generate heat that must be dissipated.
PAGE 6
Connecting Resolver Resolver wiring is similar to a Sin/Cos sensor with the addition of an excitation signal. Diagram below shows the necessary connections. Secondary 1 ASIN Primary EXC Secondary 2 ACOS GND FIGURE 4. Resolver wiring Commands and I/O Connections Connection to RC Radio, Microcomputer, Joystick and other low current sensors and actuators is done via the 15-pin connector located in front of the controller.
PAGE 7
Motor Sensor Connector For use in environments where liquid particles or fine dust may present, the controller’s cover is shaped for DSub connectors with waterproof hoods. Product references EDAC 627-230-015-010 or Assmann A-DS15HOOD-WP. FIGURE 6. dsub15 waterproof shell Default I/O Configuration The controller can be configured so that practically any Digital, Analog and RC pin can be used for any purpose.
PAGE 8
Enabling Analog Commands For safety reasons, the Analog command mode is disabled by default. To enable the Analog mode, use the PC utility and set Analog in Command Priority 2 or 3 (leave Serial as priority 1). Note that by default the additional securities are enabled and will prevent the motor from starting unless the potentiometer is centered, or if the voltage is below 0.25V or above 4.75V. The drawing shows suggested assignment of Pot 1 to ANA1. Use the PC utility to enable and assign analog inputs.
PAGE 9
Safe Torque Off - STO (Certification Pending) Additional status information may be obtained by monitoring the controller with the PC utility. The communication LED gives status information on the CAN and USB. Always off: No USB, No CAN Always On: USB Active, No CAN Flashing On: No USB, CAN Enabled Flashing Off: USB Active, CAN Enabled FIGURE 10.
PAGE 10
Electrical Specifications Absolute Maximum Values The values in Table 3, below, should never be exceeded. Permanent damage to the controller may result. TABLE 3.
PAGE 11
Safe Torque Off - STO (Certification Pending) Parameter Measure point Min Short Circuit Detection threshold (10) Between Motor wires or Between Motor wires and Ground 200 (11) Motor Acceleration/Deceleration range Motor Output 100 Typ 500 (12) Max Units 500 (11) Amps 65000 milliseconds Note 1: Negative voltage will cause a large surge current. Protection fuse needed if battery polarity inversion is possible Note 2: Maximum regeneration voltage in normal operation.
PAGE 12
Operating & Timing Specifications TABLE 6. Parameter Measure point Min Typ Max Units Command Latency Command to output change 0 0.
PAGE 13
Safe Torque Off - STO (Certification Pending) Mechanical Specifications TABLE 9. Parameter Measure point Weight Board Power Wire Gauge Power Terminals Min Typ Max 380 (0.84) Units g (lbs) 8 AWG FIGURE 12. KBL1xxx Side View and Dimensions M4 FIGURE 13.