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Old 11-23-2011, 11:44 AM   #1 (permalink)
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NEW! Uprising Control Series (Logic and Driver Boards)

Hello Everyone,

I have put together a design for a new motor control board based on the Revolt design. I will be calling this board the Uprising to keep confusion to a minimum.

I hope to direct traffic about the Uprising board to this thread as to not clutter Paul's already MASSIVE thread!

Thank You.

-Adam


V. 2.0.0



Untitled by AdamBrunette, on Flickr

23 Pin Weatherproof Automotive Connector: One of the biggest things I wanted to include was an easy way to disconnect the controller. I have found an affordable 23 pin weatherproof connector meant for automotive applications.

5 Universal Inputs: Each one of these inputs is capable of accepting a signal from 3.3 to 15v without damage. This means you can feed 5v TTL signals and automotive 12V signals into the controller. Each input is independent of the other so they can be used in any combination. One of these inputs has a special function of accepting a tach input signal.

4 Universal Outputs: Each of these outputs is supplying 12V from the controller, Common to the vehicles 12v system. This means you can easily run indicators that are tied to ground. One of these outputs is wired special for tach output as well.

Ethernet Communication: I have included ethernet communication on the board for easier configuration. Software will provide a web interface that will be accessible from anything device with a web browser (iPhone, Android, ect.)

Built in Pre-Charge: This is done with solid state switching inside the logic board. Just 1 lead to outside the controller, on the live side of the contactor is all thats required.

Bus Voltage Monitoring: The controller measures the voltage inside the controller at the cap. This will be used for pre-charge and for motor and battery voltage limiting.

Universal Driver Output: The output section of the controller took alot of thought. I wanted something flexible, powerful and unlimited. What I came up with I think will fit the bill. The board is capable of driving mosfets directly, indirectly, or driving IGBT driving modules. I think thats everything! Directly, the controller can be connected to 10 or so fets through some simple breakout and everything will work good. Indirectly, There is also the ability to driver remote mosfet drivers at high voltage to resist noise and have alot of drivers. And , IGBT's. The driver chip can be changed out to a non-inverting driver to drive VLA-500 modules, and jumpers reset to provide 5V high current output.

Throttle Options

Single 2 Wire Potentiometer
Dual 2 Wire Potentiometer (Inverted or Normal)
Single 3 Wire Potentiometer
Dual 3 Wire Potentiometer (Inverted or Normal)
Single Hall Effect Sensor
Dual Hall Effect Sensor (Inverted or Normal)

Other Features: I decided to keep serial on the controller because I had room and if people want to poll or tell the controller to do things over simple serial they would still be able to. Throttle section is the same, as well as contactor control, temp sensor, current measurement and under-voltage circuitry.

This controller uses a very different AVR though. I have moved to a Atmega 644p. This provides 32 IO, and I used all but 4!

Now, Some of you will be disappointed in my next decision, but believe me, it was not made lightly.

I have designed the board in all surface mount components, except for optos and the DC-DC.

This brings me to my next statement. After prototyping is complete, I will be offering pre built logic boards. These will be professionally assembled on assembly machines. Once a few boards are made and purchased, I hope to always keep a few controllers on hand ready for shipment. They will be tested and loaded with the latest firmware.


Schematic:
Uprising Rev2 Sch by AdamBrunette, on Flickr

Layout:
Uprising Rev2 by AdamBrunette, on Flickr

Current Revision: 2.0.4

11/23/11
I have finished populating 90% of the prototype of version 2.0.0 . While doing this, I made a video showing the process of hand building an SMD board. Enjoy.

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You can download RTD Explorer for the Cougar controllers at www.EVVette.com

Last edited by adamj12b; 03-20-2012 at 08:49 AM.. Reason: Updated Uprising Picture.
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Old 11-23-2011, 01:05 PM   #2 (permalink)
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Very Nice Layout !

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Old 11-23-2011, 01:11 PM   #3 (permalink)
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Thanks for starting this thread. Your sharing of this process is very valuable. Folks can now feel a lot more confidence in building SMD boards.

Good job!

Can't wait for your next posting.

Congrats.

Eric
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Old 11-23-2011, 04:34 PM   #4 (permalink)
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Nice, I like it already..
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Old 11-23-2011, 07:26 PM   #5 (permalink)
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What are the specs for this board?
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Old 11-24-2011, 10:39 PM   #6 (permalink)
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I'm tagging along this thread
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Old 11-30-2011, 05:42 AM   #7 (permalink)
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Wow I must admit although I am no great fan of smd's I really like this unit, wish I have one.Keep it up Adam.
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Old 12-02-2011, 03:11 PM   #8 (permalink)
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Hi Adam please keep the info flowing can't wait to know more , guess most are getting curious / interested as I am.
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Old 12-02-2011, 03:43 PM   #9 (permalink)
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Quote:
Originally Posted by evimarn View Post
Hi Adam please keep the info flowing can't wait to know more , guess most are getting curious / interested as I am.
HAHA Im glad people are interested.

I have hit a little bit of a road block financially. I have to wait till my birthday rolls around in a couple weeks to order the last parts for the logic board. I still needed dc-dc converts, one of which will take some extra time to get because its special order. I also forgot the optos for the inputs so i cant test those yet.

Ive been working on wiring up a test stand for it and adding wires to the connector.

On monday the driver boards will be here. I was graciously donated the money to build them and plan to get that tested right away. I was hoping I could use the uprising board to do the testing of the driver board, but im going to have to use the old revolt board for pwm signal.

In other news, Ive got most of the 1kA controller built! The water plate is done and the cap and modules are mounted. All I got left is bus bars and install some new washers that came yesterday.

Here are some pics of the controller.


Untitled by AdamBrunette, on Flickr


IMG_1285 by AdamBrunette, on Flickr


-Adam
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You can download RTD Explorer for the Cougar controllers at www.EVVette.com
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Old 12-02-2011, 04:25 PM   #10 (permalink)
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This is awesome!

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