Fuel Economy, Hypermiling, EcoModding News and Forum - EcoModder.com - View Single Post - Paul and Sabrina's Cheap 3 Phase Inverter (AC Controller) with Field Oriented Control

thingstodo · 01-16-2016, 11:31 PM

Jan 13 update continued

My conclusions from this test:
- the AC controller works fine up to Id = 330 amps
- the mechanical rpm measurement works fine
- recording video makes it a lot easier to synchronize the readings

A few things I learned:
- I should not panic when I smell electrical varnish. George Hamstra had warned me that if the warp 9 motor had not been in a car, had not been subject to load on it for maybe half an hour at a time, the varnish would smell a bit as it finished it's curing
- Regen brakes only regen to a certain speed, based on the torque you command. I was pumping 20 amps at 122V FROM the High voltage pack near the end of the test .. into the AC controller ... to have the AC motor slow down my DC motor. The DC motor was taking 270 amps at a voltage between 20 and 23V at the time. 2440W from the High voltage pack, maybe 5500W from the low voltage pack, ALL going into heating up the controller and the motors.
- the temp was up to 75C at the end of the test, but that was much higher than I got from my handheld thermometer. I got about 17.7C on the large heat sink, 27.0C on the spreader and 49.7C as the hottest that any part of the IGBT surface is. So the toothpaste is OK as thermal paste .. but the internal heat really gets much higher than the surface of the heat spreader shows.

Some things that may not be working on the AC controller:
- the Vd measurement may not be working. It did not seem to change during the test
- the battery amps don't match too well for the high voltage pack. Not sure why. 20 measured versus 32 logged, 4 measured versus 9.5 logged, 30.5 measured versus 43 logged.

01-16-2016, 11:31 PM	#2540 (permalink)
thingstodo Master EcoModder Join Date: Sep 2010 Location: Saskatoon, canada Posts: 1,488 Ford Prefect - '18 Ford F150 XLT XTR Tess - '22 Tesla Y LR Thanks: 746 Thanked 565 Times in 447 Posts	Jan 13 update continued My conclusions from this test: - the AC controller works fine up to Id = 330 amps - the mechanical rpm measurement works fine - recording video makes it a lot easier to synchronize the readings A few things I learned: - I should not panic when I smell electrical varnish. George Hamstra had warned me that if the warp 9 motor had not been in a car, had not been subject to load on it for maybe half an hour at a time, the varnish would smell a bit as it finished it's curing - Regen brakes only regen to a certain speed, based on the torque you command. I was pumping 20 amps at 122V FROM the High voltage pack near the end of the test .. into the AC controller ... to have the AC motor slow down my DC motor. The DC motor was taking 270 amps at a voltage between 20 and 23V at the time. 2440W from the High voltage pack, maybe 5500W from the low voltage pack, ALL going into heating up the controller and the motors. - the temp was up to 75C at the end of the test, but that was much higher than I got from my handheld thermometer. I got about 17.7C on the large heat sink, 27.0C on the spreader and 49.7C as the hottest that any part of the IGBT surface is. So the toothpaste is OK as thermal paste .. but the internal heat really gets much higher than the surface of the heat spreader shows. Some things that may not be working on the AC controller: - the Vd measurement may not be working. It did not seem to change during the test - the battery amps don't match too well for the high voltage pack. Not sure why. 20 measured versus 32 logged, 4 measured versus 9.5 logged, 30.5 measured versus 43 logged.