Paul & Sabrina's cheap DIY 144v motor controller - Page 195 - Fuel Economy, Hypermiling, EcoModding News and Forum

mcudogs · 07-08-2009, 06:57 AM

Has anyone done a PCB layout for the power section yet? I would be willing to create the layout if it hasn't been done yet. I use Altium Designer 6 so I can output in a number of different formats if required.

If we do a bulk buy of these PCB's we should be able to get them made for under $10 a board.

MPaulHolmes · 07-08-2009, 09:06 PM

No one has done that that I know of. It was changed into GCode for etching it on Adam's CNC mill. Does that count? Altium costs $10,000. When you are done with it, can I have it?

blowncurtice · 07-09-2009, 12:47 AM

Attached is my latest parts list Mouser in AU$ and DigiKey in both US$ and AU$.
The caps on the power board are 470 on page 180 Paul talks of using 820 uf could anyone give me a part No for this.

MPaulHolmes · 07-09-2009, 02:02 AM

Hello Blown Curtis! I used 24 of the 470uF caps on the first prototype, and now there's a different power section that fits well with 16 of the 820uF caps:

Digi-Key - P11622-ND (Panasonic - ECG - EET-ED2D821CA)

I finally updated the wiki a couple days ago to account for the new capacitors. On the 3 versions that are going out to Ben, Joe, and Adrian, I used 3 polypropylene caps to help snub any spikes in the power section that may occur. This allows it to run safer at higher voltages.

Digi-Key - PF2475-ND (Panasonic - ECG - ECW-F2475JB)

That needs to be added to the wiki too. I'll try it, but I don't know what I'm doing. EDIT: try??? nay! I did it! ya!

I need to write up a full assembly. A few things are sort of tricky (at least how I do it), and there are some subtle detals to know that will dramatically simplify the assembly.

mcudogs · 07-09-2009, 04:39 AM

Quote:

Originally Posted by MPaulHolmes

No one has done that that I know of. It was changed into GCode for etching it on Adam's CNC mill. Does that count? Altium costs $10,000. When you are done with it, can I have it?

I don't know of any way to convert from .ngc to a pcb format. I have a viewer for .ngc files if you could point me to the file. I can't see it on the Wiki site.

The other option is to scan a blank completed PCB. I can then recreate it if the overall dimensions of the board are specified along with hole sizes.

I will leave you a copy of Altium in my will.

blowncurtice · 07-09-2009, 04:47 AM

Thanks Paul
I try not to trouble you as I think you have a lot to think about and you realy should spend more time with Sabrina and the bub, having said that I realy appreciate being able to get the information off the Wiki. I could not work out how to post to the Wiki so if anyone would like to take my parts list and Post it that may be of help to others.

blowncurtice · 07-09-2009, 08:49 AM

This is the updated parts list with new power board (16 820uf caps)

TheSGC · 07-09-2009, 11:55 AM

So what is the current cost per controller kit?

Is there a waiting list for beta testing other than these three controllers?

roverT · 07-09-2009, 01:52 PM

Quote:

Originally Posted by blowncurtice

This is the updated parts list with new power board (16 820uf caps)

I posted your bom to the wiki for the controller portion with the USD and AUD prices for the 2C board.

take a look, and hopefully I didn't make any mistkes....feel free to change it.

I also have the BOM in Excel now.....I could post that too.

chapper · 07-09-2009, 02:12 PM

Paul
Since the controller design seems to be in the midst of a milestone, how about a (brief) synopsis of the features incorporated in the software, up to this point.

Next question would be: What features are at the front of the line for Stage 2?

As we used to say in the day... nice goin'.
John