Paul & Sabrina's cheap DIY 144v motor controller

[patx]

Originally Posted by MPaulHolmes

It would be really nice if we could get all the parts converted to surface mount, and then have a computer place the parts, and have it soldered with some weird wave soldering machine. Adamjb12 has a friend that works at a place that does that. Adam12bj? Adambj12? hehe. I forgot. I now know him as Adam.

hi Paul,

As I told before, I will have the board made at a chinese factory as soon as you update the files ... where are you at with the gerber ?!? And yes this factory does have a pick and place SMT so if you want to go surface mount this would be even better ...

As for now i work with what I have in hand... (BOM)

Here is an email quote from the chinese factory:

Please note that we can NOT find those parts in china:

>Common Mode Choke, 4mH 600mARN102-0.6-02
>
>Ultra-Fast Rectifier Diode, 200VSTTH2R02QRL
>
>Precision shunt reference, 2.5VLM4040D25ILP
>
>Optocoupler, high speed, high CMHCPL-4504-000E
>
>Isolated 12V-12V DC/DC ConverterEC4A02H

Replacement need to be found...

Also going trough the hole thread I read somewhere that you intend to add a RPM sensor in the future and maybe use RPM reading as triggers... Can I suggest to add a connector (+ solder pads as someone else suggested) with all Atmega I/O, GND & power to make this board upgradable... all future addons could be made on a different PCB...

For example, Right now I am building a generator with a 10hp induction motor.

Induction Motors as Generator

My commute is 50km/day to go to work but my hometown doesn't have much services and I have to go to the nearest city for grocery, Canadian tire, computer store, jiu jitsu class or any other specialised shop once a week or so... this ride is about 120-160km depending on the city chosen.

I want to put a switch for battery or hybrid operation and control the generator from the controller to deliver its power when needed... The connector would be very usefull for me... this way, Instead of building my own controller from yours, I could only add my addon PCB to the wiki and anyone could make their own if they wanted to...

In a short while i bet there would be many boards made to control what ever ppls can think of...

[MPaulHolmes]

blowncurtis: You can make your own from the Rev 2C schematic! I need to upload the new schematic that has a couple fixes like a change in resistor value and a new cap, etc.

Hey patx! That's a good idea. I'm short on time these days, and it will take me a while to finish converting the layout to ExpressPCB, at which time I can add whatever routes and solder pads and stuff like that. In fact, I'm certainly no expert at that. Just because this thread is called Paul & Sabrina's ..., doesn't mean I know anything about anything! hehe. Let's delegate:

If anyone wants to learn ExpressPCB (which is free, has no size limits, and is pretty easy to use), they could convert the layout that is in PDF form to ExpressPCB layout format. Basically, all a person would have to do is look at the picture of the top and bottom layout in the PDF of revision 2C, and copy it to ExpressPCB. The 6 pin thing for serial programming would need to be mirrored (there was an error) but that's no big deal. Then people can add whatever changes people want to add. The software is here:

http://www.expresspcb.com/ExpressPCB...t_software.htm

[jyanof]

Originally Posted by MPaulHolmes

I'm shipping out Adrian's (unassembled) controller tomorrow. Here are a few pictures:

i concur! Looks awesome! I can't wait to get one of these in my car!

[MPaulHolmes]

hey jyanof! I was going to put yours together. I hope you don't mind! haha!

[patx]

Originally Posted by MPaulHolmes

If anyone wants to learn ExpressPCB (which is free, has no size limits, and is pretty easy to use), they could convert the layout that is in PDF form to ExpressPCB layout format. Basically, all a person would have to do is look at the picture of the top and bottom layout in the PDF of revision 2C, and copy it to ExpressPCB. The 6 pin thing for serial programming would need to be mirrored (there was an error) but that's no big deal. Then people can add whatever changes people want to add. The software is here:

ExpressPCB - Free PCB layout software - Low cost circuit boards - Top quality PCB manufacturing

Ok, Downloaded ExpressPCB, I will try to find some time this weekend to go trough all datasheets and get SOIC infos for all components...

Can you please post the fixed (The 6 pin thing) REV 2C schematic here or on the wiki ?!

Is the BOM final ?!?

Thanks

[jyanof]

nope, not at all - was curious when you think it'll be ready? I'll have to start thinking about how to disassemble my current setup...

[slurryguy]

I don't see why someone other than Paul cannot write up the assembly instructions to post on the wiki.

It seems to me that the first few guinea pigs that are building the controller could easily document every step as they build. Maybe have a seperate assembly thread??? Paul will undoubtedly be answering questions as the first few go together anyway. If each initial builder took the time to post each step they take as they go, and snap lots of pictures and video, the first draft of the assembly instructions would take shape quickly. It would simply be a matter of cleaning up the text to post in the wiki.

I have little doubt that as the controller design matures and more people build it, that the assembly instructions will be refined and improved.

No need to make Paul do all that documentation work. Let Paul keep doing what he's doing. (and doing it very well, I might add.) Besides, the instructions might be better if they are written from the perspective of someone seeing the parts and layout for the first time. Fresh eyes will more easily see all the simplistic nitty gritty details that Paul can now do in his sleep. (When else does Paul get the chance to sleep?... Does he sleep???)

Just a thought.

[MPaulHolmes]

hey patx! Well, I'm not allowed to post attachments here (I ran out of space), and I need to either email things to ZeroGasoline to put on his website, which then can be transferred to the wiki, or our website to the wiki or to anyone that wants it to the wiki! ya! Sabrina is just very busy with our baby, and I know nothing. hehe.

Personally, I would maybe wait a while to see if anything blows up with the 3 controllers, but I ain't nobody's pappy (actually I am, but that doesn't count). This is definitely beta testing phase. It's probably fine, but you know.

jyanof: Let's shoot for 2 weeks for assembly, but then there's the issue of programming. hmm...... Well, Fran is going to send me his bootloader. I know DCB was mentioning that it might have reliability issues with a bootloader, so I don't know, but then you could reprogram it yourself from any laptop (free software too!). I'm sure the software will need to be fine tuned. I don't see a way to avoid a bootloader in the early stages?

[MPaulHolmes]

Yo, Slurry! What's up!
I like your idea. There's certain stuff that I'm really not good at, like posting things! hehe. Whether it's SVN, or websites, or who knows what. My all time favorite thing RELATING TO CONTROLLERS!!!!!!!! is to program and try new stuff on the controller. Next is drilling holes and etching, next is figuring out how to assemble stuff. Other than that, I hate doing everything else! hahaha! I always forget to take pictures. I get sort of on a roll.

I forgot, my most favorite thing is going to the store and buying the wrong length of bolt 3 different times for Adrian's controller. What? That's not my favorite part! What am I saying!

In fact, I need to go buy some bolts now. Tacoma Screw has free donuts on Fridays, so I always try to do my purchases then.

EDIT: THANKS, SLURRY! working on controllers is actually way down the list of life enjoyments.

[slurryguy]

Yo Paul,

I'll tell you what's up!

You better go back and edit your last post and put time with Sabrina and your Son as the #1 thing you like to do. You might get your butt kicked if you don't.

(I'm just looking out for your best interests.)

hehe