Paul & Sabrina's cheap DIY 144v motor controller

[MPaulHolmes]

Originally Posted by Wherewolf

Paul, I've been working on getting you 2 each of the 4oz boards - I hope to have confirmation on Monday - I'll buy them and get them shipped directly to you as quickly as possible.

How can I be da man, when you da man?

Originally Posted by Wherewolf

I also have a small supply of copper buss bars that I could send you - I'll need to dig them out of the barn - as I recall they are 19" long, 1/4 inch thick, and 3/4 wide? Some might have holes in them, but you can probably cut them up to the sizes you need.

That's the exact dimensions I have been using (well, not 19" though, more like 13" or something. I forgot. hehe.)

Originally Posted by Wherewolf

When we are sure the heavier copper boards are what we want, I can proceed with ordering the full sheet of 6oz. I am wondering if you think the design is at a point where we could just have the board maker mill and drill the patterns we need for the power section?

The power section is still in a bit of flux right now, as the inductance issues get sorted out. I'm so thankful for your help!

To the curious: 6 ounce copper implies AT LEAST 900 amp controller possible.

By the way, there have now been 10 donations since yesterday! I love setbacks! This next version is going to be much better!

-Paul

[bennelson]

Hey Paul,

The controller is on the way back to you. I'll e-mail you the tracking number.

Should be there in about a week.

[MPaulHolmes]

Thanks, Ben! No need for careful packaging this time! hahaha!

[Wherewolf]

Parts Ordering: It's going to take someone to coordinate bulk purchases so we can get the best possible price per component. Someone could always go out on their own and purchase parts, but it would be better for everyone to work together on this.
It could mean the difference of many dollars in both purchases and shipping.

It would be IDEAL (eventually) if someone or a few folks who live(s) in Louisville, KY, or Memphis, TN could be the receiver of all ordered parts, and put together the kits and send them back out. It would save a great deal on shipping/reshipping and timing. Let me know if there is anyone out there who is willing to work for the cause....

It will take time, patience, and committment. I have a great deal of resources, and some flexible time, and am willing to try.

I have some ideas on how to coordinate this, but I will need some help from others with web support etc... when the time comes....

Go Version 2!

Wherewolf

[MPaulHolmes]

I had an idea about naming, and I figure I'd run it up the flag pole, to see if anyone salutes it:

It will be very easy to make different power versions of the controller. Some people with a motor cycle may only want a 200 amp version. The pack voltage input is flexible from 0v to 144v, so that doesn't matter. Others may want a 400 amp, 500, up to maybe 1000. In principal, there's VERY LITTLE DIFFERENCE ON THE INSIDE. Couldn't it be the Open Revolt motor controller project, and the various variations on the directions/kit/whatever could have a name?

Maybe the 144v 400amp model could be Little Miss Mosfet?
144v 500amp could be Cougar, etc...

[esoneson]

Paul,

Contribution has been made for a couple of K-9 mosfet replacements.

Chopper and Gypsy.

I have one request. Can you put them closer to the middle of the array this time?
Give them a fighting chance.

Thanks,

Eric

[MPaulHolmes]

The middle is the most dangerous spot!!! They get turned on first!!! I don't think it was an overcurrent event that killed the mosfets, but an overvoltage spike, due to inductance issues, either from outside the controller or from the inside. Plus, It WAS ben's and Darin's that were killed. Hahahaha! Your doggies are still OK.

Thank you so much, Eric!

Opto-isolation this time! I can't wait to show you guys the new board layout. Much more professional!

-Paul

[GrahamMc]

So the web-site is OpenSorcery.com

And the First project is the Open Revolt Motor Controller Family

And under that 'Make' there are the 'models?'

100 Amp Little Miss Mosfet
200 Amp Oprah
500 Amp Cougar

Sounds like a plan, of course, I am pretty easy to please.

[bennelson]

Oh come on! An OPRAH must be bigger than a Cougar, but not nearly as fast.

Paul, I stopped over at Brian's house today. After working on a new feature for my car, I quizzed him on a few things about his controller.

He has a Zilla controller in his S10. I got to drive it a week or two ago. One thing I remembered is that you turn on the manual disconnect, turn the key to on, then you have to push in the clutch and turn the key to the START position to activate the main contactor.

Apparently, the Zilla controller is what actually turns the main contactor on.

If you controller had a bit of circuitry in it to control the main contactor, the issue of what order you turn things on could be almost moot. Just put the controller in charge of it all.

[Intrigued]

Originally Posted by MPaulHolmes

...To the curious: 6 ounce copper implies AT LEAST 900 amp controller possible... Paul

Oooohhh, I can't wait! Man, I should have doubled up on classes for this summer so I could get out and get a job quicker!

144 Volts and 900 amps!!! I can hardly stand it!!! Zilla isn't gonna have anything on you, Paul! You have had such good help!

Come on, graduation!

Come on, job!!!