Fuel Economy, Hypermiling, EcoModding News and Forum - EcoModder.com - View Single Post - Paul & Sabrina's cheap 144v motor controller

MPaulHolmes · 12-13-2008, 05:25 AM

There are 3 basic parts to an electric car:

Motor Controller
Batteries
Motor

Freeway capable EVs are more expensive than slow EVs because you need more batteries (sometimes: could use buddy pairs at lower voltage) and a high voltage controller. The same motor can often still be used, just by advancing the brushes, and maybe adding a blower to keep it cool.

So, it seems to me that the best place to focus efforts to making freeway capable EVs more affordable (under $1500?), is to focus on the controller. About $1200 or so can be shaved off the cost of a new controller.

So, here's my plan:
First, I'll make a smaller controller. I plan on it being 72v 40amp. Then, I'll try to scale it up. I'll test the smaller controller on my ebike, which has a brushed dc motor.

Today, I ordered most of the components and tools needed to make the bike controller. As they come, I'll take pictures of the things and the process. I'll try to get the bike controller done before school starts in January.

Some of the more important parts I ordered include:

50 MHz two channel oscilloscope
Ten IRFB4110 mosfets
IXDD414PI mosfet gate driver
Five STTH6002CW freewheel diodes
Atmel STK500
ATMega8 microcontroller
7.5 to 76V in, 5V out DC-DC
7.5 to 76v in, 12v out DC-DC
Twelve TS-ED 200v 470uF Panasonic Capacitors

12-13-2008, 05:25 AM	This thread is in the EcoModder Project Library \| #1 (permalink)
MPaulHolmes PaulH Join Date: Feb 2008 Location: Seattle, WA Posts: 1,393 Michael's Electric Beetle - '71 Superbeetle 500000 Thanks: 14 Thanked 12 Times in 8 Posts	Paul & Sabrina's cheap 144v motor controller There are 3 basic parts to an electric car: Motor Controller Batteries Motor Freeway capable EVs are more expensive than slow EVs because you need more batteries (sometimes: could use buddy pairs at lower voltage) and a high voltage controller. The same motor can often still be used, just by advancing the brushes, and maybe adding a blower to keep it cool. So, it seems to me that the best place to focus efforts to making freeway capable EVs more affordable (under $1500?), is to focus on the controller. About $1200 or so can be shaved off the cost of a new controller. So, here's my plan: First, I'll make a smaller controller. I plan on it being 72v 40amp. Then, I'll try to scale it up. I'll test the smaller controller on my ebike, which has a brushed dc motor. Today, I ordered most of the components and tools needed to make the bike controller. As they come, I'll take pictures of the things and the process. I'll try to get the bike controller done before school starts in January. Some of the more important parts I ordered include: 50 MHz two channel oscilloscope Ten IRFB4110 mosfets IXDD414PI mosfet gate driver Five STTH6002CW freewheel diodes Atmel STK500 ATMega8 microcontroller 7.5 to 76V in, 5V out DC-DC 7.5 to 76v in, 12v out DC-DC Twelve TS-ED 200v 470uF Panasonic Capacitors (Support Ecomodder.com & get rid of these annoying ads!) __________________ As I watch the old man walk on the sidewalk below my window, I think "Some day old man, I will be like you. So why not give me your coat?" Then I go downstairs to get his coat, but he's gone. Hey, maybe he was Zorro. website! Last edited by MPaulHolmes; 03-06-2009 at 02:58 AM..