How to Plot Current vs. Time for a 2.2 kΩ Precharge Resistor?

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Discussion Overview

The discussion revolves around plotting the current versus time for a precharge resistor of 2.2 kΩ used in an electric vehicle application. Participants explore the theoretical underpinnings of the circuit, including time constants, voltage equations, and practical implications for motor controller operation.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Mathematical reasoning

Main Points Raised

  • One participant calculated the time constant using the formula 5T=R*C, resulting in 2.97 seconds, but expressed confusion over the resulting linear graph when plotting voltage versus time.
  • Another participant questioned the formula used for the time constant and provided an alternative calculation, suggesting that 5 time constants represent settling time, which would be significantly longer than the initial calculation.
  • Concerns were raised about the practicality of waiting for the calculated settling time in an electric vehicle application, with one participant expressing apprehension about the implications of a long precharge time.
  • A suggestion was made regarding the number of time constants needed to reach a certain percentage of full battery voltage, indicating that 3 time constants could achieve 95% of the voltage and proposing alternatives to reduce precharge time.
  • Another participant emphasized the importance of defining acceptable in-rush current to the capacitors at the end of the precharge cycle and suggested consulting contactor specifications for guidance.
  • There was a proposal to reconsider the required settling time and precharge current, indicating that the initial assumption of 5 time constants might be excessive.

Areas of Agreement / Disagreement

Participants do not appear to reach a consensus on the appropriate time constant or precharge strategy, with multiple competing views on the necessity and implications of the calculated settling time.

Contextual Notes

Limitations include potential misunderstandings of the time constant formulas, dependencies on specific circuit parameters, and the practical constraints of the electric vehicle application that may not align with theoretical calculations.

nikita
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please help me with plotting of graph between "current versus time" for precharge resistor- 2.2 kΩ 20W.
this is placed across a contactor,which is linked to a motor controller with capacitors of value:6768μF.
closing time of resistor is calculated as 2.97 sec!
 
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hi nikita! welcome to pf! :wink:

show us how far you've got, and then we'll know how to help! :smile:
 
i have calculated time constant using formula 5T=R*C, and it is coming 2.97 sec! but when i am plotting the graph of voltage versus time using formula v= 1-e^(-t/rc) graph is coming linear instead of exponential. where m i going wrong?
i have also used the formula v=e0(1-e^(-t/rc)), from this graph is coming exponential but time constant is coming very large. around 150 it is showing steady state!
battery voltage is i.e e0 =148v
r=2200 ohm,c=6768μF

i m really confused.what to do?
i have attached the graph which i have got.
 

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Last edited:
T = RC == 14.88. 5 time constants represents settling time, which gives 74.45 seconds.

Where did you get 5T=R*C
 
meBigGuy said:
T = RC == 14.88. 5 time constants represents settling time, which gives 74.45 seconds.

Where did you get 5T=R*C
5T is the time for current to reduce to a manageable value.
and you are saying correct that it will come 74.45 sec,but since our application is electric vehicle,it is practicaly impossible to wait for that much time before vehicle can start.so, I am apprehensive about it.
 
For the precharge circuit - the number of Time Constants needed is to get to within ??% of the full battery voltage, and then allow the main contactor to close. 3 TC = 95% of the voltage... with 2.2K Resistor ~ 3*TC=45S, double up the resistor ( parallel) ~23 Sec, or 2 TC = 85% of the Full voltage. --
This issue is not to get the current down to a manageable value during precharge, it is how much current in-rush to the capacitors can you accept at the end of the precharge cycle - when the main contactor closes? Look at the contactor specs - it may provide some info on number of operations at Current = I -
The better you can define what you need to do ( with real numbers) the better you can find the best technical solution.
 
How much time do you want to spend to precharge to 5T? If the answer is 3 sec, then tau= 0.6 so R must be 0.6/6768uF = 88 ohms.

You need to decide:
1. How much settling do you need. Perhaps 5T is overkill (as Windadct said)
2. How large a precharge current you want to deal with (not sure what the limitation is here).
 

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