Conduction Cooled AC-DC: Make This Electric Scooter/Rickshaw Circuit

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simple electric
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Cooled AC-DC scooter circuit
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design which
can be also Bicycle Projects (6)
modified to Bluetooth (6)
make an
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electric auto-
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rickshaw. The
idea was Cell Phone Projects
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requested by Mr. Steve.
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I was lucky enough to find your blog, really amazing stuff (66)
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Input: SLA (sealed-lead-acid) Battery 12V, which is ~13.5V (35)
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How it Works (17)
Output: 60V DC motor 1000W. IC 4017 (71)
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Have you came across a circuit like that?
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I can image it will be push-pull type, but have no idea of types IC 4047 (10)
of mosfets (give the wattage 80-100A), driving them, then
IC 4060 (47)
the transformer, the core type and then diodes.
IC 555 (20)
Plus the minimum voltage cut off to cap the PWM's duty
cycle. IC 741 (48)
(58)
I have found some more information. The motor is 3 phase
brushless with hall sensors. Induction Heater (9)
There are two ways to approach it, a/ leave the existing Infrared Projects
(15)
controller in place and only do 12V to 60V step up or b/
replace the controller too.
(100)
Laser (8)
There won't be any difference in power efficiency, the
controller simply switches which phase get current based on LED Driver (99)
the hall sensors. Therefore, sticking with plan a. LM 317 (21)
LM 338 (10)
LM 567 (4)
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Today making an electric vehicle is much easier than it used Timer Projects (51)
to be earlier, and this has become possible due to two main
TL 494 (1)
elements in the design, namely the BLDC motors and the Li-
ion or the Li-polymer batteries. Transformerless
Power Supply (25)
Transmitter Circuits
These two ultra efficient members have fundamentally (18)
allowed the concept of electric vehicles to become a reality
Triac Control (9)
and practically feasible.
Tubelight (15)
The BLDC motor or the brushless motor is efficient because Tutorial (93)
it's designed to run with no physical contacts except the ball TV (2)
bearings of the shaft. In BLDC motors the rotor rotates solely
UPS (19)
through magnetic force making the system extremely
USB (11)
efficient, contrary to the earlier brushed motors which had its
rotors attached with the supply source through brushes, Voltage Doubler (4)
causing a lot of friction, sparking and wear and tear in the Voltage Stabilizers
(15)
system.
Water Sensors (43)

On similar lines, with the advent of the much upgraded Li-ion Windmill (3)
batteries and the Lipo batteries today achieving electricity
from batteries is no longer considered an inefficient concept. AdChoices
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Earlier we had only lead acid batteries at our disposal for all
Motor Controller Circuit
the DC back up systems which posed two major drawbacks:
These counterparts needed much time to charge, possessed
restricted rate of discharge, lower life, and were bulky and
heavy, all these only adding to their inefficient nature of
working.
Opposing to this, Li-ion, or Li-po batts are lighter, compact,

quickly chargeable at high current rates and are
dischargeable at any desired high current rate, these have
higher run life, are SMF types, all these features making them
the right candidate for applications such as electric scooters,
electric rickshaws, quadcopter drones etc.
Although BLDC motors are extremely efficient, these require

specialized ICs for driving their stator coils, today we have
many manufacturers producing these exclusive next-
generation IC modules which not only do the basic function
of operating these motors, but are also specified with many
advanced additional features, such as: PWM open loop
control, sensor assisted closed loop control, multiple
foolproof safeguards, motor reverse/forward control, braking
control and a multitude of other state-of-the-art in-built
features.
I have already discussed one such excellent chip in my

previous post, specifically designed for handling high
wattage BLDC motors, it's the MC33035 IC from Motorola.
Let's learn how this module may be effectively implemented

for making an electric scooter or an electric rickshaw, right in
your home.
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The above figure shows a full-fledged high wattage

brushless 3-phase DC motor driver IC MC33035 which
becomes perfectly suitable for the proposed electric scooter
or electric rickshaw application.
The device has all the basic features that may be expected
to be in these vehicles, and if required the IC could be
enhanced with additional advanced features through many
alternative possible configurations.
The advanced features become specifically possible when

the chip is configured in a closed loop mode, however the
discussed application is an open loop configuration which is
a more preferred configuration since it's much
straightforward to configure, and yet is able to fulfill all of the
required features that may be expected in a electric vehicle.
We have already discussed the pinout functions of this chip

in the previous chapter, let's summarize the same and also
understand how exactly the above IC may be required to be
implemented for achieving the various operations involved in
an electric vehicle.
The green shaded section is the MC 33035 IC itself which

shows all the built-in sophisticated circuitry embedded inside
the chip and what makes it so advanced with its
performance.
The yellow shaded portion is the motor, which includes a 
3-phase stator indicated by the three coils in the "Delta"

configuration, the circular rotor indicated with the N/S poled
magnets and three Hall effect sensors on the top.
The signals from the three Hall effect sensors are fed to the
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pin nos 4, 5, 6 of the IC for internal processing and
generating the corresponding output switching sequence
across the connected output power devices.
Pinouts 2, 1 and 24 control the externally configured upper

power devices while the pins 19, 20, 21 are assigned to
control the complementing lower series power devices.
which together control the connected BLDC automotive
motor as per the various fed commands.
Since the IC is configured in an open loop mode, it's

supposed to be activated and controlled using external PWM
signals, whose duty cycle is supposed to determine the
speed of the motor.
However this smart IC does not require an external circuit for

generating the PWMs, rather it's handled by an in-built
oscillator and a couple of error amp circuitry.
The Rt, and Ct components are appropriately selected for

generating the frequency (20 to 30 kHz) for the PWMs, which
is fed to pin#10 of the IC for further processing.
The above is done through a 5V supply voltage generated by

the IC itself at pin#8, this supply is simultaneous used for
feeding the Hall effect devices, it seems everything is
precisely done here....nothing is wasted.
The portion shaded in red forms the speed control section of

the configuration, as can be seen it's simply made using a
single ordinary potentiometer....pushing it upwards increases 
the speed and vice versa. This is in turn made possible

through the correspondingly varying PWM duty cycles across
the pin#10, 11, 12, 13.
The potentiometer could be converted into an LDR/LED

Search Here... 
assembly circuit, for achieving a friction-less pedal speed
control in the vehicle.
Pin#3 is for determining the forward, reverse direction of the

motor rotation, or rather the scooter or the rickshaw
direction. It implies that now your electric scooter or your
electric rickshaw will have the facility of reversing back....just
imagine a two-wheeler with a reverse facility, .....interesting?
Pin#3 can be seen with a switch, closing this switch renders

the pin#3 to ground enabling a "forward" motion to the
motor, while opening it causes the motor to spin in the
opposite direction (pin3 has an internal pull up resistor, so
opening the switch does not cause anything detrimental to
the IC).
Identically, pin#22 switch selects the phase-shift signal

response of the connected motor, this switch needs to be
appropriately switched ON or OFF with reference to the
motor specs, if a 60 degree phased motor is used then the
switch needs to stay closed, and open for a 120 degree
phased motor.
Pin#16 is the ground pin of the IC and needs to be connected

with the battery negative line and/or the common ground line
associated with the system.
Pin#17 is the Vcc, or the positive input pin, this pin needs to
be connected to a supply voltage between 10V and 30V, 10V
being the minimum value and 30V the maximum breakdown
limit for the IC. 

Pin#17 may be integrated with the "Vm" or the motor supply
line if the motor supply specs matches the IC Vcc specs,
otherwise pin17 could be supplied from a separate step
down regulator stage.
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Pin#7 is the "enable" pinout of the IC, this pin can be seen
terminated to ground via a switch, for so long as it is
switched ON and the pin#7 remains grounded, the motor is
allowed to stay activated, when switched OFF, the motor is
disabled resulting the motor to coast until finally it comes to
a halt. The coasting mode may quickly come to a halt if the
motor or the vehicle is under some load.
Pin#23 is assigned with the "braking" ability, and causes the

motor to stop and halt almost instantly when the associated
switch is opened. The motor is allowed to run normally as
long as this switch is kept closed and the pin#7 is held
grounded.
I would recommended to Gang-up the switch at pin#7

(enable) and pin#23 (brake) together so that these are
switched with a dual action and together, this would probably
help to "kill" the motor rotation effectively and collectively
and also enable the motor to run with a combined signal
from the two pnouts.
"Rs" forms the sense resistor responsible for checking the

overload or over current conditions for the motor, under such
situations. the "fault" condition is instantly triggered
switching off the motor immediately and the IC going into a
lock-out mode internally. The condition stays in this mode
until the fault is corrected and normalcy is restored.
This concludes the detailed explanation regarding the

various pinouts of the proposed electric scooter/rickshaw 
control module pinouts. It just needs to be correctly

implemented as per the shown connection info in the
diagram for successfully and safely implementing the
vehicle operations.
Search Here... 
Additionally, the IC MC33035 also includes a couple of in-
built protection features such as under-volatge lockout which
ensures that the vehicle is switched off if in case the IC is
inhibited from the required minimum supply voltage, and
also a thermal overload protection ensuring that the IC never
works with over temperatures.
How to Connect the Battery (Power Supply)
As per the request, the electric vehicle is specified to work

with a 60V input and the user requests for a boost converter
for acquiring this higher level of voltage from a smaller 12V
or a 24V battery.
However, adding a boost converter could unnecessarily

make the circuit more complex and might add to a possible
inefficiency. The better idea is to use 5nos of 12V batteries
in series. For sufficient back up time and current for the 1000
watt motor, each battery could be rated at 25AH or more.
The wiring of the batteries may be implemented by referring

to the following connection details:
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27 comments:
pro October 20, 2015 at 3:22 PM

sir, i will like to generater at list [12V---50V] DC from a
coil and magnet
please ,sir help me out. 
Reply
Replies
HOME SOLAR BATTERY CHARGER
Swagatam INVERTER
Majumdar LEDOctober
ARDUINO
20, FREE ENERGY
2015 at 6:01 PM
pro, you can achieve this by using any Search Here... 
standard "555 boost circuit", but please
do not anticipate any kind of free energy
generation from the result...the output V
x I result will be always less than the
input V x I

ok,sir

look like you know what i wanted to use
it for ,
i am having eletricity problem,i have got
an inverter that run on 9-12V, that is why
i am looking for a way to have a stable
DC that i can connect to my inverter ,and
my eletricity problem will be over
Swagatam Majumdar October 20,

2015 at 9:37 PM
If you are looking for free electricity then
you can install panels or wind generator
set up....
Reply
Sachin October 24, 2015 at 7:12 PM

Swagatam,
You bring out nice things.... !
1) I want to understand what is top drive and bottom

drive. Could you elaborate on this?
2) I looked into the datasheet of MC33035. It says that 
Top Drive Voltage max is 40V.

Top Drive Voltage (Pins 1, 2, 24) VCE(top) 40 V
HOME SOLAR
Can it BATTERY
be usedCHARGER INVERTER
to drive motor LED
of 48v? ARDUINO
When FREE ENERGY
batteries
are fully charged, the 48v battery voltage readings are
around 56v... If I connect 56v to pin14 (Vm), would it
Search Here... 
work or would it blast the IC? IC is costly, Rs.425 on
RSdelivers website.. I dont want to burn it :)
3) I am planning to build a controller around this for Yo

EXL which is 1300w continuous and 1800w peak. Is
this controller IC is usable?
4) Looked into TIP147 datasheet, It has max voltage of

100v. I assume this is fine for driving 48v/60v motor.
Right?
5) Collector current of TIP147 is 10A continuous, 15A

peak. For driving 1300W continuous/1800w peak
motor with 48v battery, the current required is around
27A continuous/37A peak. That would require 3
MOSFETs per phase(connected in series or
parallel???). I am a new bee here. Please offer your
suggestions on this.
Thanks
Sachin
Reply
Replies

2015 at 11:30 AM
Thanks Sachin,
for driving 3-phase motors we require

high side and low side driver
configuration to supply the required
3-phase signal to the motor at the
specified shift angle.....it's a kind of
H-bridge configuration designed for
operating 3-phase loads correctly.
yes, the upper drive transistors are rated 
at 40V...so in order to drive higher

Electronic Circuitvoltage
Projects
motors we could use opto
coupler such 4n35 with pins1, 2, 24, this
would effectively solve the issue and
allow us to INVERTER LED
use virtually ARDUINO
all kinds ofFREE ENERGY
motors regardless of their

voltage/current specs.
Search Here... 
according to me, this IC (with the opto-
couplers) could become universally
suitable for all types of BLDC motors,
provided the output devices are
dimensioned accordingly.
you could replace the TI147 with a

Darlington combination of TIP127 and
TIP36...this would allow you to drive the
mentioned high wattage motors with
ease.
for the mosfet you could probably use

single IRF540 on each channel
(adequately heatsinked) these are rated
to handle 33amps at 100V

2015 at 11:40 AM
....sorry 4n35 won't work, it's too rated at
30V...you could try H11G1M
Sachin November 21, 2015 at 8:27 AM

Swagatam,
I got the Mc33035 ic in hand.
The data sheet talks about using

optocoupler MOC8204 for driving
motors of high voltage/wattage.
Could you please provide the wiring

diagram for optocoupler connectivity for
all upper and lower MOSFETs?
Also, how to calculate the resistor value

for overcurrent protection?

And how to calculate Rt and Ct for

Electronic Circuitrequired
Projectsmax rpm?
With these info, I can immediately start

testing.
Thanks,
Search Here... 
Sachin.
Swagatam Majumdar November 21,

2015 at 10:21 AM
Sachin,
the complete wiring detail is alerady

provided in the particular diagram, in the
datasheet.
you can find how the transistor leads of

the opto is connected with the 1M, 4k7
and the zener diode and the fet...the LED
of the opto can be seen connected a
with a 1K resistor.
so this needs to be applied for all the

upper three outputs for implementing
the intended high voltage operation.

2015 at 10:26 AM
select the current sensing resistor Rs
such that a 100mV appears across it for
the desired over current
value.....meaning if suppose you select
10amp as the over current limit then Rs
value must be selected such that a
100mV voltage is developed across it at
10amp current

2015 at 10:28 AM
Rs = 0.001/Max current
Sachin November 21, 2015 at 12:37 PM


You mean that it is one optocoupler for

Electronic Circuitone
Projects
mosfet pair Atop:Abottom. Right?
What is Vboost connected to pin 5 of

optocoupler?INVERTER LED
What should beARDUINO
its value? FREE ENERGY
What is the formula for calculating Rt

Search Here... 
and Ct for a preferred maximum speed
of vehicle?
In your earlier response, you asked me to

use Darlington pair of TIP126 and TIP36.
Could you please tell me how the
connection should be?
I am troubling you a lot, and you are the

source of help for me. I can do work, but
i just need some right directions. Please
bear with me....
Thanks
Sachin

2015 at 7:08 PM
opto coupler will be required only for the
top pinouts 2, 1, and 24.
the formula for calculating Rt/Ct could

be somewhere in the datasheet, you can
check it out, by the way the values
furnished in the above article would be
generate around 20kHz frequency which
you can easily alter by practically varying
the Rt value and confirming the same
with a frequency meter.
Darlington pair will not be required if you

are using an optocoupler, as these
would be replaced with FETs....for
reference you can check the following
article to learn how Darlington transistor
are connected:
http://www.homemade-
circuits.com/2014/11/48-v-inverter-
circuit.html 
Electronic CircuitSachin
Projects
November 23, 2015 at 5:13 PM
Some Vboost is required for pin 5 on the
HOME SOLAR
optocoupler.INVERTER
BATTERY CHARGER
There isLEDalsoARDUINO
a circuit
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given in ds, fig 30. I searched for the ic
given there which is MC1555. Did not
find it. Search Here... 
Any alternatives for it?
In the h bridge, is it the top set of fets

that drive forwards, or the bottom fets?
For backward movement, can same

mosets be used?
-sachin

2015 at 8:55 PM
I think Vboost = Vm + 12V
I too am not sure about MC1555
the upper and the lower fets together

operate the motor as per the complex
sets of signals delivered by the IC.
Reply
Sachin November 27, 2015 at 12:00 PM

Swagatam,
I opened up the controller to see arrangements of

MOSFETS.
The mosfets used are IRFB4310 which are 130A,

100V.
There are total of 15 mosfets for 3 phases! 5 for each

phase !
I want to understand why 5 mosfets when one alone is

sufficient to drive the motor? 
Electronic Circuit
I have Projects
uploaded the connection image here -
http://postimg.org/image/as3cb8vet/
HOME SOLAR
ThanksBATTERY CHARGER INVERTER LED ARDUINO FREE ENERGY
Sachin
Reply Search Here... 
Replies

2015 at 9:31 AM
Sachin, looks like the upper two mosfets
are in parallel, and the lower three are in
parallel with each other.
And where is the load connected?
.....the parallel connections could be for

tackling the switch ON high current
consumption by the motor.
Reply
Unknown March 18, 2016 at 1:26 PM

Hi sir
can i use this from this plan for casual bicyle and what
is Speed set in plan.
thanks
Reply
Replies
Swagatam Majumdar March 19,

2016 at 10:30 AM
yes you can. speed will depend on
motor specs and battery specs.
Reply
Taibani Imran March 23, 2016 at 8:02 AM


Sir, can you help me for pwm circuit of 0 to 5A & 0 to

Electronic
30ACircuit Projects
for hho generator.
Reply
Replies
Swagatam Majumdar March 23, Search Here... 

2016 at 11:44 AM
you can try this circuit:
circuits.com/2016/01/universal-
variable-power-supply-circuit.html
Reply
Unknown April 19, 2016 at 11:12 AM

Hello sir,thank you for sharing this circuit with us,i had
a couple of doubts,it would be great is you could solve
them:
1.Can we use IRF9540N instead of TIP147

2.Aren't almost all BLDC in star formation instead of
delta,if not how will this circuit have to be modified to
suit a star formation BLDC motor.
It would be great if you answered these ASAP,thank

you again.
Reply
Replies
Swagatam Majumdar April 19, 2016

at 1:11 PM
Hello, In the original datasheet BJTs are
recommended so I doubt if mosfets
could be replaced with them...I think you
should go with BJTs instead of FETs.
for increasing the power you can try

TIP36/2N2907 joined in Darlington
configuration and replace with the
TIP147 transistors
Reply 

Ankith April 21, 2016 at 10:13 AM
HOME
Hi swagatam
SOLAR
thanks forINVERTER
BATTERY CHARGER
the reply,could
LED
you suggest
ARDUINO FREE ENERGY
any other alternatives to the TIP36/2N2907 darlington
configuration that is in single package.
Search Here... 
thank you
Reply
DEVRAJ SINGH January 3, 2017 at 11:40 AM

Sir, here the ic operates on 30v max. but we are using
a pair of batteries which is equal to 48v, so how can
we use that 48v directly to that ic ?
Reply
Replies
Swagatam Majumdar January 3,

2017 at 5:18 PM
Devraj, as mentioned in the article for
48V or higher supplies you may have to
use a voltage regulator circuit for
feeding pin#17 of the IC...you can try a
TL431 based circuit for making the
regulator.
circuits.com/2012/12/explaining-
programmable-shunt-regulator.html
Reply
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Make this Electric Scooter/Rickshaw Circuit - Electronic Circuit Projects pagina 1 van 22

Electronic Circuit Projects

The article Audio Projects (49)

Conduction presents a Automation (6)

Hi Swagatam, Datasheets (37)

that you've managed to design. Emergency Light

Scooter Motor Fish Aquarium (7)

Free Energy Devices

charged Generators (11)

minimum voltage - cut off at ~10.5V Hobby Circuits (53)

Motor Circuits (42)

Power Supply (31)

Sea Energy (2)

Solar Projects (76)

Sport Projects (7)

Water Sensors (43)

Opposing to this, Li-ion, or Li-po batts are lighter, compact,

Although BLDC motors are extremely efficient, these require

I have already discussed one such excellent chip in my

Let's learn how this module may be effectively implemented

Wire thickness and

Parts List Transistor Resistor

Upper power BJTs = TIP147 IC 555 Calculator

The above figure shows a full-fledged high wattage

The advanced features become specifically possible when

We have already discussed the pinout functions of this chip

The green shaded section is the MC 33035 IC itself which

The yellow shaded portion is the motor, which includes a 

3-phase stator indicated by the three coils in the "Delta"

Pinouts 2, 1 and 24 control the externally configured upper

Since the IC is configured in an open loop mode, it's

However this smart IC does not require an external circuit for

The Rt, and Ct components are appropriately selected for

The above is done through a 5V supply voltage generated by

The portion shaded in red forms the speed control section of

the speed and vice versa. This is in turn made possible

The potentiometer could be converted into an LDR/LED

Pin#3 is for determining the forward, reverse direction of the

Pin#3 can be seen with a switch, closing this switch renders

Identically, pin#22 switch selects the phase-shift signal

Pin#16 is the ground pin of the IC and needs to be connected

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Pin#23 is assigned with the "braking" ability, and causes the

I would recommended to Gang-up the switch at pin#7

"Rs" forms the sense resistor responsible for checking the

This concludes the detailed explanation regarding the

control module pinouts. It just needs to be correctly

How to Connect the Battery (Power Supply)

As per the request, the electric vehicle is specified to work

However, adding a boost converter could unnecessarily

The wiring of the batteries may be implemented by referring

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HOME SOLAR BATTERY CHARGER INVERTER LED ARDUINO FREE ENERGY

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pro October 20, 2015 at 3:22 PM

pro October 20, 2015 at 7:06 PM