Paul & Sabrina's cheap DIY 144v motor controller

[GrahamMc]

Jam-on-ee, Jam-on-ee

[MazdaMatt]

Right on. Looking forward to seeing v2 start pushing electrons.

[adamj12b]

Paul, Great work, I just finally finished reading through the whole thread. I cannot wait till the new site is up.

As for CNC. I have built 2 cnc milling machine so far and have started a third. For future power stages, I am offering to mill the boards for free. just send me the copper boards and I will send them back done. As long as they will fit in a 7.25x19 inch area there shouldn't be any problems.

Also, that bit you've been using should be spun closer to 15,000 rpm's the higher the better. if you could do 30k you would be great.


On to the control board. I happen to have a good friend that owns a production shop built for assembling circuit boards. I could get a great deal on getting the boards built. His machines can place 50k parts per hour!!! All you would need to do is make the board surface mount instead of through hole. Were talking panels of like 9 boards assembled and soldered in about 90 seconds. then you just snap them apart and finish the few things that need to be done by hand, like the DC-DC converter and any IC sockets.


-Adam

[MPaulHolmes]

Um, OK! hahaha! I don't know what to say. Maybe we can get people a finished high voltage controller for much cheaper than I ever thought possible.

Man, this is awesome. A group of dedicated people, committed to a cause can make a real difference. I'm going to cry! Cut it out! You guys!

The files still need to be uploaded to the website. Sabrina is going to add those files tonight I think. I ordered the parts for the 3 control boards that will undergo testing, and had them shipped to the engineer that's been helping with the control board schematic.

I've been working on the code for testing the extra features of the new control section. Let's see, there's now an RS-232 com port, an ISP port, an IDLE LED, a POWER LED, undervoltage lockout (so Ben's controller failure can't happen), optical isolation between the control section and the power section, a relay fo rthe controller to control the main contactor, there's a watchdog timer, variable hardware current limit, the screetching has been dealt with, so that it's true cycle by cycle current limiting, schottkey diodes to prevent voltage spikes on the current A/D channel from latching up the microcontroller (which has been a problem with the first version too). It has a 16 MHz crystal, NOT FROM EBAY ANYMORE!

I'll let you know of I think of anything else major. Next time there will be other features, like maybe battery pack current control, rpm control, I can't think of what else right now.

For the next version, we can convert that stuff to surface mount without much of a problem I bet.

http://www.paulandsabrinasevstuff.com

[Thalass]

Awesome! Next step: Three phase induction motor VFD with vector control and capable of controlling multiple motors!

:P

[MPaulHolmes]

uh...... sure.... no problem!

[Thalass]

hahaha Can't blame me for trying!

[taffy]

Be scared if the price gets too low i might buy 2 lots of parts. No then.

Awesome work, i am hanging out to see how version 2 comes along.

[Joe_Bloe]

Originally Posted by GrahamMc

Jam-on-ee, Jam-on-ee

Newcleus in the hizzy!

[jeffd94]

Originally Posted by MPaulHolmes

Um, OK! hahaha! I don't know what to say. Maybe we can get people a finished high voltage controller for much cheaper than I ever thought possible.

Man, this is awesome. A group of dedicated people, committed to a cause can make a real difference. I'm going to cry! Cut it out! You guys!

The files still need to be uploaded to the website. Sabrina is going to add those files tonight I think. I ordered the parts for the 3 control boards that will undergo testing, and had them shipped to the engineer that's been helping with the control board schematic.

I've been working on the code for testing the extra features of the new control section. Let's see, there's now an RS-232 com port, an ISP port, an IDLE LED, a POWER LED, undervoltage lockout (so Ben's controller failure can't happen), optical isolation between the control section and the power section, a relay fo rthe controller to control the main contactor, there's a watchdog timer, variable hardware current limit, the screetching has been dealt with, so that it's true cycle by cycle current limiting, schottkey diodes to prevent voltage spikes on the current A/D channel from latching up the microcontroller (which has been a problem with the first version too). It has a 16 MHz crystal, NOT FROM EBAY ANYMORE!

I'll let you know of I think of anything else major. Next time there will be other features, like maybe battery pack current control, rpm control, I can't think of what else right now.

For the next version, we can convert that stuff to surface mount without much of a problem I bet.

Welcome to PaulandSabrinasEVstuff.com

Hi Paul

I've been reading this forum for some time now, your efforts have been fantastic. I've been to your wife's website and she has done a grand job.
I have signed up on the database as well.

I look forward with the final result.

All the best

Jeff