Go Back   EcoModder Forum > EcoModding > Fossil Fuel Free > Open ReVolt: open source DC motor controller
Register Now
 Register Now
 

Reply  Post New Thread
 
Submit Tools LinkBack Thread Tools
Old 02-16-2011, 12:29 PM   #1 (permalink)
EV Builder
 
Freyguy's Avatar
 
Join Date: Nov 2010
Location: Macungie, PA
Posts: 157
Thanks: 15
Thanked 63 Times in 39 Posts
LCD Instrumentation for Cougar Controller

For those Cougar controller owners (or owners to be) interested in a simple LCD instrumentation interface for the Cougar, I’d like to give you an option.
Originally this was designed for my own EV conversion, but I made it flexible enough to support options I didn’t need but foresaw other might (metric units for instance).
My intent is to get all the information on operation, BOM, fab files, source code, etc onto the OpenRevolt Wiki page so others can use as they wish (with Paul & company’s approval of course!)

Design Overview:
The display is 2 line x 16 character backlit LCD with oversized characters, controlled by a PIC18F2480 microcontroller. It displays both readings taken with local A/D and information transmitted serially from the Cougar. Displayed info includes:
- pack voltage (isolated circuitry) 0-204V range
- battery amps (Tamura hall sensor input or Cougar’s output) 0-511A range
- motor amps (Cougar output)
- accessory battery voltage
- motor temp in C or F (via thermistor)
- controller temp in C or F (Cougar output)
- pack temp in C or F (via thermistor)
Other features:
- calculation & display of SOC based on battery amp usage (peukert is factored in). Battery amp draw is subtracted from battery capacity every second with remaining capacity written to EEPROM every minute.
- calculation & display of MTE (Miles to empty) based on %SOC per mile/km
- momentary switch to toggle between 2 profiles transmitted to controller
- “Mode” LED to indicate when controller runs with alternate profile
- “Overtemp” LED based on independent thresholds for the 3 measured temps
- Alarm output (NPN sinking)
- PWM output of SOC to interface to existing analog fuel gauge
- Canbus and RS232 interfaces (E-Can controller is integrated in the PIC)

Below are links to demonstration videos (part 1&2) of the system breadboarded running preliminary code.





The schematic is also attached.

As of this writing, I have the final fab’ed PCB populated and mostly tested in my car.
I’ll post a few pics of the completed unit later tonight.
I may revise the board since I found minor issues (header pin hole size, part clearance) but I don’t plan on turning this into a development thread. 13 hour work days and family commitments make it hard enough just getting to my conversion (after 2 years I really need to wrap it up & get it on the road!)

Attached Files
File Type: zip Cougar LCD Instrumentation Schematic.zip (38.3 KB, 209 views)
  Reply With Quote
The Following 3 Users Say Thank You to Freyguy For This Useful Post:
deodeo (04-25-2012), ianbartie (04-30-2011), Nevyn (02-17-2011)
Alt Today
Popular topics

Other popular topics in this forum...

   
Old 02-16-2011, 12:55 PM   #2 (permalink)
EV test pilot
 
bennelson's Avatar
 
Join Date: Jan 2008
Location: Oconomowoc, WI, USA
Posts: 4,356

Electric Cycle - '81 Kawasaki KZ440
90 day: 334.6 mpg (US)

S10 - '95 Chevy S10
90 day: 30.48 mpg (US)

Electro-Metro - '96 Ben Nelson's "Electro-Metro"
90 day: 129.81 mpg (US)

The Wife's Car - Plug-in Prius - '04 Toyota Prius
90 day: 78.16 mpg (US)
Thanks: 12
Thanked 551 Times in 332 Posts
OOh! Very cool!

Yet one more project for me to make......
__________________


300mpg.org Learn how to BUILD YOUR OWN ELECTRIC CAR CHEAP
My YouTube Videos
  Reply With Quote
Old 02-16-2011, 01:08 PM   #3 (permalink)
AC-DC enthusiast
 
mrbigh's Avatar
 
Join Date: Nov 2009
Location: Long Island, NY
Posts: 281

Dual-PWR PHEV - '04 Toyota Prius

Kopper - '79 Bradley Bradley GT-II
Thanks: 121
Thanked 50 Times in 35 Posts
I love it, I want to be able to use it real soon.
I like the idea of different "driving profilez" parameters, maybe 3 or 4?
Is the display legible and bright at a 3' average driver's distance?
Could RTD explorer be used in parallel connection?
Count me in..............
__________________
. .. .. . .......
Prius Absolutum Dominium . ..........KOPPER
PHEV conversion since Dec 2006.. . .... .Future EV
. . . . . . . .CALCars # 27. . . . . . . . . . ..on the works now !!
. . . . . . . . . . . . . . . . .. . ........
  Reply With Quote
Old 02-16-2011, 03:46 PM   #4 (permalink)
EcoModding Lurker
 
Join Date: Sep 2009
Location: Western NY
Posts: 27
Thanks: 5
Thanked 1 Time in 1 Post
This is a good project. I will have analog gauges for battery volts and motor current and aux battery volts but there is definitely a need for this. Thanks for the good presentation and I can't wait to hear more.
  Reply With Quote
Old 02-16-2011, 04:17 PM   #5 (permalink)
Custom EV Builder...
 
Join Date: Jul 2009
Location: Ohio
Posts: 57
Thanks: 8
Thanked 1 Time in 1 Post
Quote:
Originally Posted by Freyguy View Post
For those Cougar controller owners (or owners to be) interested in a simple LCD instrumentation interface for the Cougar, I’d like to give you an option.
Originally this was designed for my own EV conversion, but I made it flexible enough to support options I didn’t need but foresaw other might (metric units for instance).
My intent is to get all the information on operation, BOM, fab files, source code, etc onto the OpenRevolt Wiki page so others can use as they wish (with Paul & company’s approval of course!)

Design Overview:
The display is 2 line x 16 character backlit LCD with oversized characters, controlled by a PIC18F2480 microcontroller. It displays both readings taken with local A/D and information transmitted serially from the Cougar. Displayed info includes:
- pack voltage (isolated circuitry) 0-204V range
- battery amps (Tamura hall sensor input or Cougar’s output) 0-511A range
- motor amps (Cougar output)
- accessory battery voltage
- motor temp in C or F (via thermistor)
- controller temp in C or F (Cougar output)
- pack temp in C or F (via thermistor)
Other features:
- calculation & display of SOC based on battery amp usage (peukert is factored in). Battery amp draw is subtracted from battery capacity every second with remaining capacity written to EEPROM every minute.
- calculation & display of MTE (Miles to empty) based on %SOC per mile/km
- momentary switch to toggle between 2 profiles transmitted to controller
- “Mode” LED to indicate when controller runs with alternate profile
- “Overtemp” LED based on independent thresholds for the 3 measured temps
- Alarm output (NPN sinking)
- PWM output of SOC to interface to existing analog fuel gauge
- Canbus and RS232 interfaces (E-Can controller is integrated in the PIC)

Below are links to demonstration videos (part 1&2) of the system breadboarded running preliminary code.





The schematic is also attached.

As of this writing, I have the final fab’ed PCB populated and mostly tested in my car.
I’ll post a few pics of the completed unit later tonight.
I may revise the board since I found minor issues (header pin hole size, part clearance) but I don’t plan on turning this into a development thread. 13 hour work days and family commitments make it hard enough just getting to my conversion (after 2 years I really need to wrap it up & get it on the road!)
OK To cool!! Can it be modified for use with the new high amp controller?
  Reply With Quote
Old 02-16-2011, 04:51 PM   #6 (permalink)
EcoModder
 
Join Date: Mar 2010
Location: New Zealand
Posts: 181
Thanks: 0
Thanked 32 Times in 20 Posts
Very nice, I want one! Looking forward to a circuit board and the s/w asap.
  Reply With Quote
Old 02-16-2011, 05:40 PM   #7 (permalink)
dcb
needs more cowbell
 
dcb's Avatar
 
Join Date: Feb 2008
Location: ˙
Posts: 5,032

pimp mobile - '81 suzuki gs 250 t
90 day: 96.29 mpg (US)

schnitzel - '01 Volkswagen Golf TDI
90 day: 53.56 mpg (US)
Thanks: 156
Thanked 264 Times in 207 Posts
sweet! it would be terribly useful for efficiency tracking if you can squeeze in a speed signal from a vehicles existing speed sensor or an add-on. To track distance/speed and display realtime and trip watts/mile or whatever.

All the pins are used up on that cpu, but maybe you can combine mode and overtemp, or use an internal oscillator or something, wow that thing is loaded up

here is a thread with a couple examples of vehicle speed sensors.
Wanted (Alive): Aftermarket vehicle speed sensor (VSS)
__________________
WINDMILLS DO NOT WORK THAT WAY!!!
  Reply With Quote
Old 02-16-2011, 08:30 PM   #8 (permalink)
EV Builder
 
Freyguy's Avatar
 
Join Date: Nov 2010
Location: Macungie, PA
Posts: 157
Thanks: 15
Thanked 63 Times in 39 Posts
Hey Thanks guys!
Mr Bigh- the display is easily readable at 3'. Reason I chose the oversized character version. It could work in parallel with RTD Explorer only if RTD is used to receive data from the Cougar. Both RTD and the LCD can't transmit unless you incorporate some kind of A/B distribution switch. More than 2 profiles gets complicated and now you need an indicator showing which one you're running with.

Wakinyantanka- As long as the status message sent from the high amp version is formatted the same it should be compatible. If the configuration parameters are different, it shouldn't matter since the user programs in the serial data he wants transmitted as his "profile".
DCB- Yes, every pin is used up. You could drop in a PIC18F2420 which is the same part without the CANbus. The two I/O lines for CAN then become standard I/O.
  Reply With Quote
Old 02-16-2011, 08:42 PM   #9 (permalink)
EV Builder
 
Freyguy's Avatar
 
Join Date: Nov 2010
Location: Macungie, PA
Posts: 157
Thanks: 15
Thanked 63 Times in 39 Posts
Here are some pictures in various stages of assembly











Last picture in the car is with electric heat running (12A batt draw)
Bezel is just 1/8" thk clear acrylic which I masked off and spraypainted black
on the backside.

Last edited by Freyguy; 02-17-2011 at 08:13 AM..
  Reply With Quote
Old 02-17-2011, 02:55 AM   #10 (permalink)
Master EcoModder
 
jackbauer's Avatar
 
Join Date: Sep 2009
Location: Ireland
Posts: 681
Thanks: 24
Thanked 263 Times in 147 Posts
Fantastic piece of work. Well done indeed. Interested to see the code and pcb.

__________________
Now, Cole, when you shift the gear and that little needle on the ammeter goes into the red and reads 2000 Amps, that's bad.
www.evbmw.com
  Reply With Quote
Reply  Post New Thread


Thread Tools




Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.5.2
All content copyright EcoModder.com