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Old 04-10-2009, 07:27 PM   #851 (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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EDIT: WELL, MAYBE IT WAS THE CAPACITORS! HAHA!

Well, it sounds like it was the mosfets. Now, does everyone want to hear a secret??? I did a really bad job making sure the mosfets were really flat against the copper heat spreader when they were soldered. The clamps were clamping some much harder than others. I thought that might turn out to be a problem, but I wasn't sure. I've fixed that issue in the version 2 power section, but I'm still not sure that was the problem.

There is lots of good news, though! A bona-fide professional expert electrical engineer fixed up the schematic, using opto-isolation to separate various sections of the board, and did other stuff too. I believe A HUGE source of the problem with the current sensor was the fact that the power section ground was being shared with the weenie control section ground, causing terrible EMI issues. Even if all the mosfets are bad, there is a lot on that sucker that can be salvaged!

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