Paul & Sabrina's cheap DIY 144v motor controller - Page 295 - Fuel Economy, Hypermiling, EcoModding News and Forum

dave koller · 02-07-2010, 02:43 AM

Yep - up to page 102 - gotta get some zzzzzz's - the controller is great but the humor is even better

Dave

MPaulHolmes · 02-07-2010, 03:25 AM

I'm going to put together a 1000 amp kit really really soon. I'll first need a prototype to make sure it doesn't blow up. Maybe a super small version of the power section, since that's sort of expensive. My stupid motor will probably blow up above 500 amps, so I'm not 100% sure what to do about that. With SR, it should be pretty efficient at lower current, and at higher current, the freewheel mosfets will have a larger voltage drop like regular diodes. That's OK though, because people don't draw 1000 amps for a long time usually I think. For the LEM, I'm going to use a surface mount lem that just has to be calibrated by spacing it away from the bus bar just right. Then it picks up the magnetic field of the bus bar. My friend that did the layout for the controller is going the surface mount LEM route, and it's working really really well for him. It's nice to have such creative friends!

jackbauer · 02-07-2010, 05:49 AM

Paul will this board have an option to fit the standard lem? Me and my igbts

edown · 02-07-2010, 09:41 AM

Paul, I don't think you can pull more than 800 amps out of your batteries with out damaging them.. Even for a few seconds.. I'm I wrong??
Evan

MPaulHolmes · 02-07-2010, 12:02 PM

The surface mount lem and the standard lem have the same Vref, 5v, gnd, and output, so they are intechangeable. how convenient!

edown, I think 800amp out of lead acid batteries would be really really bad. The 1000amp would be motor amps though, so it would just mean lots and lots of torque off the line. It's conservation of power. motorAmps*duty*packVoltage = batteryAmps*packVoltage. So if duty is small, but lots of motor amps, you have relatively small batteryAmps, and low power, but a lots of torque. Once you speed up, the duty goes up, but then the motor amps usually go down

regmeister · 02-07-2010, 12:22 PM

Paul. If you build a smaller SR power section that would handle 300A, I would buy it off you after your testing. If you need some up front help (cash) for the components, let me know with a note.

Good Luck, Richard

jackbauer · 02-07-2010, 12:25 PM

My odyssey PC2150s can pump out 1000amps for 1 minute! MUhahahahahahah

jyanof · 02-07-2010, 04:52 PM

Mileage update: ticked over 3000 mi on the controller last week!

MPaulHolmes · 02-09-2010, 03:03 AM

I ordered 24 of those new fancy TO-264 230amp 200v mosfets today.
Fancy Mosfets!

The sixteen 1000uF capacitors and new LEM (8 pin surface mount) will ship on the 14th. I'm torn between 2 drivers or 1 for each of the high and low side. I think 1 driver would be OK if I lowered the gate resistance just a bit. It's a 12amp driver, and I've only been using like

I also just won a Fluke 337 amp meter so calibrating the new LEM will be easier. I think I'm going to try Darin's metal coat hanger method of drawing like 50 amps from a battery to calibrate it.

MPaulHolmes · 02-09-2010, 03:03 AM

I ordered 24 of those new fancy TO-264 230amp 200v mosfets today.
Fancy Mosfets!

The sixteen 1000uF capacitors and new LEM (8 pin surface mount) will ship on the 14th. I'm torn between 2 drivers or 1 for each of the high and low side. I think 1 driver would be OK if I lowered the gate resistance just a bit. It's a 12amp driver, and I've only been using like 6 amps peak I think.

I also just won a Fluke 337 amp meter so calibrating the new LEM will be easier. I think I'm going to try Darin's metal coat hanger method of drawing like 50 amps from a battery to calibrate it.