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Old 04-19-2014, 06:05 PM   #6476 (permalink)
MPaulHolmes
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Join Date: Feb 2008
Location: Maricopa, AZ (sort of. Actually outside of town)
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Michael's Electric Beetle - '71 Volkswagen Superbeetle 500000
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I found a really nice thing that lets you connect wires through an enclosure, and it was only 50 cents each. Each piece lets 5 wires pass through, so the controller will need 2 of them. I should have taken a picture of it, since they all arrived already. Oh well, here are some other pictures:
https://www.dropbox.com/s/90xm29bsju...2011.32.01.jpg
Female spade connectors soldered into control board, push onto the male spade connectors on the IGBTs (I didn't push all the way down, since it goes on really solidly):
https://www.dropbox.com/s/au2noihb23...2011.52.26.jpg

Besides the spade connection points, there are 4 #8 screw holes, and nylon 1/2" wide standoffs (at least I think the standoffs were 0.5" wide. Oh they could have been 3/8").

Capacitor mounts to igbts and enclosure (I didn't actually have the capacitor mounted to the enclosure for the picture. it's just sitting on the igbts. Heck, it's not even screwed into the IGBTs at the moment either! haha. But there are no screws that are difficult to access. It all goes together really pretty easy.):
https://www.dropbox.com/s/bo1gjy0019...2011.36.04.jpg

Notice that the nice and calm control section (left half of the control board) is physically far far away from the very naughty, noisy, high current section! And it's a 4 layer board, with almost no exposed area to allow for interference to sneak in.
https://www.dropbox.com/s/xkwb6a88xy...2011.52.59.jpg

It's using 3.3Ohm gate resistors. I"m waiting for the npn and pnp current buffers (15 amp peak) to arrive, probably by monday. Those are the open, silvery spots in the TO-220 package laying down.
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