Description
AEM VCU200 Complete Programmable Control for Single-Motor EV Street Conversion and Motorsports Vehicles
Part: 30-8000
AEM EV Vehicle Control Units (VCUs) are the missing link for high-performance EV street-conversion motorsports applications. They allow the calibrator to create customized torque management strategies applicable to a wide range of EV systems and component combinations. They integrate EV systems and unify the tuning experience providing motorsports- and conversion-ready features presented in a high feature, modern and customizable interface. Be In Control with AEM EV.
AEM EV’s VCU200 is built on OEM hardware and features OEM quality strategies. Combined, these provide the highest level of reliability, and more importantly, safety for both the programmer and end-user.
The VCU200 in default configuration can manage a single inverter/motor system, communicate with four independent CAN bus networks, and it can be used on direct-drive and indirect-drive EV setups. Multiple motor control systems may be possible depending on the application (contact us). Please refer to the Supported Applications Tab for supported Motors, Inverters, Battery Management Systems (BMS) and other EV devices.
Primary functions of the AEM VCU200 include:
-
- Input characterization including accelerator pedal, brake switch, PRND switches and other driver/vehicle inputs
- Redundancy and arbitration features for all safety-critical inputs
- Startup and shutdown sequencing of high voltage components, including independent contactor control
- CAN message translation for BMS, inverter, PDUs, and other CAN accessories
- Motor torque management dependent on vehicle operating states and other driver-selectable modes
- Closed-loop motor speed regulation for indirect drive transmission applications
- Dynamic torque limits that maximize safety and optimize performance
- Accessory control of cooling pumps, cooling fans, lights and more
- Diagnostics and fault detection including CAN message timeouts, thermal limits, contactor, and inverter enable cross-checks
| VCU200 | VCU300 | |
| General | ||
| AEM Part Number | 30-8000 | 30-8100 |
| User Interface | AEMcal | AEMcal |
| Pin Count | 80 | 196 |
| Clock Speed | 64 MHz | 200/260 MHz |
| Motor Control | 1* | 4 |
| Inverter Control | 1* | 4 |
| CAN Buses | 4 | 3 |
| Inputs** | ||
| Analog Inputs | 13 | 31 |
| Digital Inputs | 15 | 8 |
| Frequency Inputs | 4 | 5 |
| Outputs** | ||
| Low Side Outputs | 12 | 39 |
| High Side Drivers | 6 | 2 |
| H-Bridges | N/A | 3 |
| 1/2 Bridges*** | 4 LS PWM or 4 HS Drivers | N/A |
| Main Power Relay Driver | N/A | 1 |
| Environmental | ||
| Enclosure Rating | IP6K7 (Waterproof) | IP6K9K (Waterproof) |
| Enclosure Material | Aluminum | Aluminum |
| Operating Voltage | 9-16V DC | 9-16V DC |
| Overvoltage Protection | 16V DC | 16V DC |
| Dimensions | 210 x 137.5 x 37.2mm | 181 x 231 x 50mm |
| Weight | 1.2 lbs (.06kg) | 2.2 lbs (1.1kg) |
| Operating Temp Range | -40c to +105c | -40c to +105c |
* Multiple motor control systems may be possible depending on the application. Contact us for more information.
** Input and Output count listed is based on hardware capability. Actual I/O counts are model dependent. For information or model development contact
*** With shunt resistors.
Features:
The AEM EV VCU200 features a waterproof aluminum enclosure (IP67K, -40C – 105C) and has an 80 pin connector. It is built on OEM hardware with OEM control strategies and uses proprietary AEMcal software for programming (learn more about AEMcal software).
Complete Control, Maximum Performance and Safety for EV Conversions
- AEM VCU200 provides complete control of supported Inverter(s)/Motor(s) in an EV conversion or EV motorsports vehicle
- AEMcal software for the VCU200 simplifies the calibration process by putting all of your controls in one suite. AEMcal is free and fully enabled (no fee to unlock features)
- Motor torque management (programmable torque curves) dependent on vehicle operating states and other driver-selectable modes
- Programmable accelerator pedal, brake switch, PRND switches, and other driver/vehicle inputs
- Seamless data visualization and data logging with addition of CD Carbon Digital Dash Display
- Accessory control of cooling pumps, cooling fans, lights and more through VCU200 with addition of PDU-8 power distribution unit
- Redundancy and arbitration features for all safety-critical inputs
- Startup and shutdown sequencing of high voltage components, including independent contactor control
- CAN message translation for BMS, inverter, PDUs, and other CAN accessories
- Diagnostics and fault detection including CAN message timeouts, thermal limits, contactor, and inverter enable cross-checks
The VCU200 can control one electric motor/inverter and link 4 independent controller area networks (CAN bus). A general set of hardware features is shown below. Actual features are application dependent (contact us).
INPUTS:
- 13 Analog inputs
- 15 Digital Inputs
- 4 Frequency inputs
OUTPUTS:
- 12 Low-side drivers
- 6 High-side drivers
- 4 Half Bridges with shunt resistors which provide – 4 low side drivers (PWM) or 4 High Side Drivers
Compatibility:
BMS Integration
The VCU200 with a supported BMS provides users with the ability to request torque deratings based on battery pack discharge, pack high temp, pack low temp, cell voltage min, cell voltage max, pack state of charge % (SOC) and overall pack voltage. BMS integration also allows for inverter pre-charge using measured battery pack voltage as a reference. The VCU200 currently supports the Orion BMS and AEM EV BMS, which is slated for release in early Q4.
Start Safe and Drive Mode Safety Features
Fundamental safety features are integrated. Start Safe is a series of safety checks performed by the VCU before a drive mode is selected. Should a fault occur, this can be identified via a CAN message to a CD Carbon dash display.
To prohibit runaway, the VCU will not allow a Drive Mode to be selected unless the brake pedal is engaged, or if a charge plug is connected to the charge port.
Programmable Creep and Reverse Modes
The VCU200 has a user-selectable creep mode that allows the vehicle to “creep” forward slowly after releasing the brake from a stop without applying the accelerator pedal, similar to how an ICE vehicle with an automatic transmission operates. Reverse mode is also programmable for delivering the perfect pedal feel and response when backing up.
Programmable Regenerative Braking
Do you like aggressive regen and never touching the brakes on decel, or do you want to regen but don’t want to feel the motor ‘dragging’ the speed down? With the VCU200, users can custom tailor this feature to achieve the perfect balance of feel and regen. A dedicated map for regenerative braking is included in AEMcal software for the VCU200.
Customized Torque Delivery
An electric motor’s capability to make large amounts of torque in less than one motor shaft revolution can result in undesired roughness on acceleration. To combat this, the VCU has a user-adjustable torque request rate of change limiters for both increasing and decreasing torque requests. This allows for fine-tuning of the torque delivery rate and ensures the torque management provides a smooth driving feel.
Selectable Performance Levels
The VCU provides calibrators with up to four different performance levels. For street conversions, users can set levels based on who will be driving the vehicle, and for motorsports applications, it delivers on-the-fly adjustments to ensure maximum traction for varying track conditions.
Motor Rev Limiting
The VCU200 includes a rev limiter to prevent the motor from over-speeding and/or to limit the speed of a vehicle.
Inverter Current Limiting
Multiple levels of current limiting are available. From simple ramp limits that engage when the inverter current exceeds a predefined limit to fully modeled power limiting that considers everything from individual cell voltages to total pack resistance to motor and inverter efficiency.
Cooling System Controls
The VCU200 supports 3 different main thermal management configurations with options for different types of coolant pumps and cooling fan controls. Pumps and fans may be powered by VCU triggered relays, or optionally with AEM PDU-8s. The VCU will support single-coolant pump/drive system cooling, single-coolant pump, drive and battery system cooling, and dual coolant pumps with independent drive system and battery cooling loops.
Video:
Supported Apps:
SUPPORTED COMPONENTS
The following are some of the tractive system components that have been validated to work with the VCU200. For a larger list of components please visit the FAQs section on our website. Please contact sales@aemev.com for more information or to request component support. AEM EV is working hard to expand its supported components list. Check AEMEV.com often for updates to our list of validated EV components.
Inverter Controllers
- The VCU200 currently supports all Cascadia Motion PM Series inverters and compatible motors. A full list of supported inverters and motors can be found here.
Battery Management Systems
- The Orion BMS2 battery management system CAN data is integrated into the VCU200.
- The Isabellenhuett IVT-S Series Smart Shunt is validated to work with the VCU200 for battery management and as an integrated current, voltage and temperature sensor in conjunction with a BMS.
Water Pumps
- The VCU200 has the ability to control the EMP WP32 water pump through the CAN bus.
Contactors
- We have validated Gigavac contactors to work with the VCU200.
Resistors
Switched Controls
- Switched control for fans, pumps, lights, etc., can be controlled by the VCU200 using AEM EV’s PDU-8 Power Distribution Unit(s). Eight units can be used for a total of up to 64 channels. The VCU200 currently supports up to 2 PDU-8 units.
Vehicle Operation Controls
- Vehicle power, drive activation (PRND) and map switching can be controlled using AEM EV’s 8-Button CAN Keypad.
Display & Logging
- Display and logging capability for all channels on the CAN network can be performed by AEM CD Carbon Digital Dash Displays.
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