Paul & Sabrina's cheap DIY 144v motor controller

[mora]

Originally Posted by ianbartie

There are hardware kits for the motor controller available here http://www.digitalhometech.net.au/in...roducts_id=193.
They have all the fiddly fixings, clips & stuff. They also have a very nice case with a machined heat sink & twin fans.

Looks good, but does the controller already support precharge resistor control? Have I missed something?

This is quoted from pre-charge resistor for cougar controller page:
The controller can turn on the pre-charge relay & the power resistor will allow the capacitors to charge gradually (less than 2 seconds).

[drbobwoolery]

This shows up as a dead link to me. No harm as I am just a spectator at the moment.

[wjdennis]

Is this the correct link?

COUGAR Motor Controller Parts : Digital Home Technology!

Bill

[ianbartie]

Here is the correct link
COUGAR Motor Controller Parts : Digital Home Technology!
Did a typo last time.

[ianbartie]

Hi Mora
The Australian version is a little bit different. It has more outputs & can turn a pre-charge relay on automatically.

[MPaulHolmes]

Awesome! That enclosure is a piece of art. I'm a tiny bit worried about the heat spreader. The mosfet clamp holes looked a tiny bit too far down, but maybe not. There's room and flexibility for it. I use 0.2" below the top to drill the holes. Also, are the mosfet clamps the right kind of metal? So that they will keep their springiness? It's really really really important to make sure the mosfets are clamped firmly against the heat spreader. One time I clamped 9 mosfets really hard, and left one "gently clamped" on accident, and I blew that one mosfet up. It was pretty easy to take apart and remove and add a new one, but still it was scary.

That's a really really good idea to have an exchange for copper so the person can drill stuff and send it out. Awesome job!

[MPaulHolmes]

Version 2D! I can't wait to hear how it works out. I'm working on adding voltage monitoring on mine too. That is not only important for pre-charging, but you can add code so that batteries won't sag too low. I finally got Protel 99SE working in my garage. I'm so happy! ya!

I hope this turns into an arms race! hahaha. By some time next year, this group will have a $200 zilla!

Here's my DC holy grail, which will take a little time:
Learn the dsPIC30F2010, which has programmable dead times between pwm outputs (and has 6 pwm channels). Use it to drive maybe 12 of the new 200v 230amp 7.5Ohm RdsOn gigaMos mosfets, and 12 freewheel "mosfets" (same ones), which will easily be a 1000 amp controller. It will use a total of 6 drivers. 3 for the mosfets, and 3 for the "freewheel mosfets". (syncronous rectification). It will need something other than the LEM current sensor since that only goes to 900 amps. Bob sent some current shunts that I think will be perfect for that. ya! Thanks Bob!

[watt-a-mezz]

Paul, glad to see the bag of parts is back! Makes the control board some easier to assemble. Was looking at HF website, and they have a 180w soldering gun with extra tips for 12.99. Would that work on this? If so I will get one. Looks like your project has taken on a life of its own. Hope to see more posts on how they work. Watt.

[MPaulHolmes]

Hey Watt! A 180 watt gun would probably work fine. I know for sure that a 230 watt gun works well, so I can't say for absolute certain.

[watt-a-mezz]

Was wondering if you were still ordering from McMaster-Carr. They are still listing their copper bus bars for 8.96. I know that is in undrilled and untinned condition, but not bad just for bars. Watt.