Paul, you're right about needing to know the pack voltage. What if we use the same voltage test hardware to measure the pack voltage while the controller is pre-charging the caps? We should be able to isolate the same way you isolate the undervoltage lockout. I don't believe we need great resolution, so we build the circuit to measure 0-200V, and if the traction pack is 36V we only have 180bits of resolution instead of 1024. Still enough to easily distinguish slow speed, and overspeed.
Slewing unfortunately doesn't help stop the current from going to 500A if the e-brake is on.
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