Paul & Sabrina's cheap DIY 144v motor controller

[GrahamMc]

Originally Posted by MPaulHolmes

Ya, but there were a few patent issues, since Hazen patented his controller. It is a really good idea though.

I don't think it is a violation of patent law if you are not selling the product. You can build your own 747 if you want, just dont try to sell it. Still a free country and all. Maybe you could design one and call it "Blazin' Hazen" as a tribute.

[jackbauer]

First test drive today with the igbt controller at 24v. I'd like to thank everyone especially paul for all the help freely given. Without the work of everyone on this project i wouldn't have had so much fun today. Enjoy!

http://www.youtube.com/watch?v=uYVgbfTtG0o

http://www.youtube.com/watch?v=2CBrDa4iZnQ

[MPaulHolmes]

That is awesome!!!!! Nice enclosure too! An actual real life controller without the need for special machining equipment! Great Job! You know that one guy in Braveheart that said Ireland was his island? Ireland is your island!

[jackbauer]

Thanks Paul Its running with the 8mhz crystal , 8khz switching. Only a little noise at low current. I wouldn't have noticed if I wasn't looking. Heatsink stayed below 24c throughout the whole run and at 24v it would have to draw a lot of amps! I must have a look at getting the v1.1 firmware to run at 8mhz.

[jackbauer]

Did a few more runs today. Drove a total of 0.8 miles! Climbed the hill in third pulling 400 battery amps with 4 people in the car! Heatsink temp peaked at 28c. According to the pc program rtd explorer i consumed 7.8ah for the whole journey. Very impressed with the rtd program as i could actually see the motor amps graph climb as the hill got steeper. Despite running the controller at 8khz there is no noticeable noise. Only a tiny whine at low speed. Nothing like the curtis. I even managed an upshift from first to second. No problems.

All in a great test and proves its a viable vehicle. Next step 48v

[MPaulHolmes]

That is freaking awesome! 400 battery amps??!! The motor amps were higher then. Are you using 2 IGBTs in parallel? What were their ratings again? I forgot!

P.S.: Oh no! 28 degC! hahahaha Talk about a safety margin!

-Paul

[jackbauer]

I'm using 2 igbts. One as the switch one as the freewheel with its gate - emitter tied together. they are rated at 1000amps 1200volts. That rating drops to 800amps at a tj of 125c. I drew about 300 ish amps for the climb and a peak at 400 amps at the very top where the hill is steepest. I'd guess if i had more voltage the current would have been less. I was amazed really. 4 people in the car and a boot full of tools! Nothing i tried would stop that motor! Slow it down yes but stop it no chance and that was with only 36v on the shunt field. It can take 80.

[steiner]

Jack,

What motor are you using?

Congrats on the sucess!!!!

Rick

[squiggles]

Great stuff Jack, you should have your own TV show it would be a lot more entertaining than Oprah!!

Had to laugh, you want a heater, it was 43 deg C here yesterday. I will send a can of it over for you.

[jackbauer]

I do have my own show its called 24! Motor is a 11.5" diameter 80v compound wound beast from a mitsubishi 4 ton forklift Torque city!