Paul and Sabrina's Cheap 3 Phase Inverter (AC Controller) with Field Oriented Control

[dave koller]

Search around a bit on the forum as Adam has some pictures of liquid cooling... busy right now or would find them and plant some URL's... ADAM? (adamj12b)

[bennelson]

You can even use a thick piece of aluminum and just drill some holes through it the long way and hook some radiator hoses up to it.

I've also seen where somebody uses a router to carve into a block of aluminum, and puts some sealant on it and puts a thin aluminum plate over the top of that.

Either making something or buying something that's already designed for it, either way, it's pretty straight-forward to take a home-built controller and make it into a liquid cooled one.

Just to note, I've NEVER had a heating issue on my 500 amp DC controller, using just the stock aluminum plate heat sink.

[MPaulHolmes]

The baseplate will have no holes where the bus bars are clamped to it, so it would be very to do like Ben described and mill channels in it and add a thin plate to cover the channels. That would chill the bus bars directly that the IGBTs are soldered to.

[bggale]

Cool (pun intended). Thanks everyone for the tips. My motor is liquid cooled, so it seems to make sense to do the same with the inverter if I'm going to already have the pump, reservoir and radiator.

[TadhBijou]

Originally Posted by MPaulHolmes

The boards will be here around the 16th of this month. Hurray!

So the 16th is here... HURAY!

[MPaulHolmes]

Oh heck ya!!!!!

[MPaulHolmes]

My boards arrived today for the 200ampRMS (hopefully) controller. And I ordered the parts for populating the boards too. The BOM is ready to be posted to the ecomodder wiki too. Parts are in the $500 range, and the software is of course free, since it's just a bunch of 0's and 1's. Well, it helps living in my mother-in-laws basement. haha. It stacks as follows:

Power board. Notice the 6 large boxes across the top. Each box is a 50mm tall 100uF film capacitor, so 600uF total.


The 24 igbts are going to be these. $7.93 each isn't too bad (for 25):
IRGP4066D-EPBF International Rectifier IGBT Transistors

The power section capacitors are 6 of these:
Digi-Key - 399-5945-ND (Manufacturer - C4AEGBW6100H3NJ)

Power board then Low side Driver Board. 3 isolated supplies. -8.2v up to 15v for turning the igbts on and off Of course, there will be spacers. haha:


Power board, then low side driver board, then high side driver board. 3 isolated supplies. :


Power board, then low side driver board, then high side driver board, then control board:


Close-ups of control board:


Notice the 6 pwm outputs:


The right hand side. haha. 5 friggen nand gates for lots of hardware disabling of the pmw signals. Well, what it does is any trip turns off the 3 high side optocouplers so the poor little pwm signals never make it to granny's house:

[nlc]

Good job !! Can we have a look to the entire bottom side of power board ? Can't see where will be the 3 power phase output

[TadhBijou]

YEAHA!!! Very very nice job! I am impressed. I've just wanted to ask you when the Wiki will be updated and you just answered this in previous post... (Mind reader?)

Well, thank you very much for your work and contribution to the community here. This is awsome!

[TadhBijou]

Ok. I couldn't post links yet, so I have to write another post and not to edit previous...
[EDIT]
This is link to film capacitors on Mauser. The price is higher, tho, but shipping to DE or AT is free.
C4AEGBW6100H3NJ Kemet DC Link Film Capacitors

1: 26,75 €
5: 25,41 €
10: 24,20 €
[/EDIT]