Paul & Sabrina's cheap DIY 144v motor controller

[MPaulHolmes]

Thanks Ben, it is nice to have everyone be so encouraging!

RedRod, you didn't miss anything. I added some features like current and thermal limiting without adding it to the schematic. I need to update that to account for the car's version. I've worked on it some today. I added the new 2 throttle input to the schematic. I've also been reading up on implementing the bigger 400 or 500 amp Hall effect current limiters. I'll add that to the schematic soon. AND, I'll add the hardware current limiting to the schematic. This thing is sort of growing bigger. The new schematic will be larger, so I'll try to compartmentalize everything to make it still understandable. Once it's ready, I'll upload it.

P.S.: I was informed that there is a little present from my family on the way. hehe. My brother must have just got his Tax return or something. Maybe because I named our son's middle name after him (Caleb)? Why would someone be so kind? I promised myself I wouldn't cry... Tear!

There is a 600 amp current sensor that needed a smaller aperture. Oh dear! I need a way to "mill" the copper narrower to use it though! What to do?! Well, you can officially shave off about $13 from that $313 price tag, if THIS is purchased in packs of 10.

It's shipping right as I speak. The driver is probably in montana right now, bringing that MILL to me!!!!!!!!! Come to me, sweet mama!!!!! Now adapter plates can be done too! Heavy PCB copper etching with +/- 0.001 inch accuracy! Hold me back! Hold me back!

That's right everyone! A beautiful mill coming to live with us forever! A Geared Head Milling Drilling Machine! 1.5 HP. 625 pounds! Gangsta!

Goodbye $500 adapter plates. Goodbye etching with a dremel! Hello MILL!

[lumberjack_jeff]

That's awesome as-can-be! Hopefully my brother will read this and get the hint.

Speaking of which, he lives just down the road in Olympia. Someday when I'm in the area for the monthly Costco binge I'd love to come check out your bug and this cool controller.

Thanks for the awesome build logs!

[MPaulHolmes]

Come any time! Hey, I grew up in Montesano. I used to go to C&T and play video games. And go up to Lake Sylvia every morning to go swimming in the summer. Do you know Pat Papack? (I don't know how to spell Papeck) I went to Simpson The Superstars grade school, not Beacon the Stinkin'!

How about Darin Bees? He was going to give me a compound bow, but he saw me and David Tate shooting a homemade bow and arrow at each other to see of we could dodge the arrows. He told my mom and I got in really big trouble. I lived at 112 S. 7th street.

-Paul

[lumberjack_jeff]

Wow, small world!

I don't know Pat, but I know Phil and Pete Papac... Relations?

Now the kiddos go to Beacon until grade 3 then on to Simpson so they've lost some of that esprit d' corps.

LOL @ the games of dodge-arrow. At least Patches O'Houlihan only trained with wrenches.



Thanks for the invite, I will definitely take you up on it sometime this spring.

[MPaulHolmes]

Patches O'Houlihan? haha!
Anyone remember like 9 months ago or so, when I bought a shop crane engine hoist thing on sale at Harbor Freight? Well, I finally put it together today. It was truly horrible. Why the sudden decision to put it together? Well, the MILL IS ARRIVING AT HARBOR FREIGHT ON TUESDAY!

A student in one of my weenie math 99 classes (x + 1 = 5. Find x.) has volunteered to drive his truck to HF and pick up the mill. Then He'll back into the garage, and we'll get out the old engine hoist, and lift it out of there! It's like 625 pounds! Why the crap is a dang glorified drill press 625 pounds? Whatever. It's all good. My engine hoist can hoist 2000 pounds. So, if Oprah... Nevermind.

Hey, I can remove engines now! Well, I can lift the engine out once all the right stuff is unbolted, which I don't think I know how to do. I'm going to re-watch the video of the new fancy coupler for Ben Nelson. It's so simple and beautiful and awesome! I need to understand that. I might need to some day pick up a lathe, unless it can be done with a mill. I think that was the video when the guys were getting uncomfortably close to Ben...

Calling all MazdaMatt's! So, I understand the principle of PI loops, but I don't know how to measure the step response, because I don't know how to capture a single transient response on the oscilloscope. Maybe I should send a PM to MazdaMatt. That would make more sense. Blah blah. Why am I still writing? I have nothing much to say anymore! by! I have to enter stupid decroded piece of crap grades into the computer now. Whoever invented working was a stupid idiot. I have a Karate Chop sandwich with extra mayonnaise, and Dijon mustard too with their name on it.

[MetroMPG]

Mill. Mmmm.

(Mmm? Must be all the talk about sandwiches.)

[MPaulHolmes]

Originally Posted by MetroMPG

Mill. Mmmm.

(Mmm? Must be all the talk about sandwiches.)

You eat mills for breakfast! haha! General Mills Cereal! Specifically, raisin bran?

[MetroMPG]

Or Apple Cinnamon Cheerios. Drat. Now I need to eat some.

[motor_control]

Originally Posted by MPaulHolmes

either the datasheet was wrong about those lm317's or the lm317's I ordered from Ebay are a different type.

Datasheet is OK ! Check your design.

================

Try free simulator for AVR - VMLAB - 4 Mb only - great soft - IDE/debugger for the AVR microcontroller with WinAVR support

See screenshot -
Not only AVR simulated, but some popular part too.

More - VMLAB User Components ‎(ThVortex‎)

[motor_control]

Originally Posted by MPaulHolmes

There is a 600 amp current sensor that needed a smaller aperture. Oh dear! I need a way to "mill" the copper narrower to use it though! What to do ?!

Use mosfet itself like current sensors. See page 17.

Or hall current sensor that mounted over current condactor.

Have you calculate pricise for ONE power mosfet modul (Mitsubishi or Ixys, Hitachi) instead of set of mosfets ?

Power mosfet modul Mitsubishi has biltin proper driver and fully protected (HARWARE) for overcurrent and overtherm.

You can use 6 MOSFET 200 V module - it's very cheap ! - and control 3 up and 3 bottom mosfet togeter in parallel.