Paul & Sabrina's cheap DIY 144v motor controller

[mrbigh]

Originally Posted by ga2500ev

I'll keep this short this time. My last post timed out.

Would anyone have an objection to a new first principles post about now? I finally have my stuff together:

3x 1200V x 400A IGBT
4x 100V x 200A schottky diodes
1 500A kilovac contactor
4x 9A IGBT drivers
a double handful of PIC chips.
Advanced DC 8" motor.

All going into a '92 Geo metro.

I plan to build/program my own board and have a bolt together power section.

I'd be happy to write up and post my understanding. I'm still trying to wrap my head around ESR and ripple current for the capacitor bank.

Thoughts?

ga2500ev

Hi ga2500ev, I'm planning to take almost the same approach; Final IGBT stage with the split power supply Open Revolt controller.
In order to not interfere with this one, you can open a new thread for your project. Do not forget to include a reference to your thread so people can fallow you and contribute.

[Weisheimer]

Originally Posted by peja1971

On this pdf file, schematics have regen, can you explain me basics? How it's work?

WBR, Peja

Peja,

I'm sorry to be so late in replying, but my job sometimes takes
me out of town, so this past week I have had spotty internet access.
Here is a link that may answer your question.

Cafe Electric llc

The Curtis did not have regen as it was built, it was a modification
and this link is the source of that info.
Your choice of this PIC PWM generator will work, but it will not
have some of the safety features that you will want in a vehicle
controller. The Revolt controller would be a better alternative.
Do you have a deadline to meet or are you trying to keep the cost
low? The Revolt control board and parts are low cost
and you can get the micro-controller already programmed by Paul.

Perhaps E-bay would be a source for the freewheel diodes.
There are frequently sources of ultra fast soft recovery modules that
have been removed from scrap industrial welders or motor controls.
Search for:

IXYS Fast Recovery Epitaxial Diode DSEI 2x 61-12B

to see a sample. You would need 10 or so for your
controller. These mount to bus bars quite nicely.


Cheers
Mark

[peja1971]

Thanx, yes I have dead-time, I need to finish and test car untill 20.april to present my car on environment fair.
There is too much work to do but first on my to-do list is controller. I'll bye some diodes in to247 case, I plan 24 of them, for now I have 5 diode I think sb30?40 (something similar) from some power suplay.
Yes, my pic have'nt safety feature (but I consider to use some circuit to limit max power which will interrupt pwm signal betwen pic and mosfet driver) and it's just temp solution. for second version I will build other control board with all safety features.

I'll check tomorrow my supplier for diodes.

Which voltage is the best to drive gate of my IRFP260N mosfets? (40 of them)

Thanx again

[ludiagsm]

today i have some success controlling starter motor with mine controller i am using four igbt-s BUP314 here is video w w w.youtubeDOTcom/watch?v=6KQjIMPGA8E

[Weisheimer]

Originally Posted by peja1971

Which voltage is the best to drive gate of my IRFP260N mosfets? (40 of them)

Thanx again

Peja,

I sent you a PM response.
You can also use the IRFP260 Mosfets as diodes.
Tie the gate to the source to do that.

I still recommend that you consider the Revolt control board.

You could convert to it later and keep the power section that
you are building now.

Cheers
Mark

[ludiagsm]

Originally Posted by Weisheimer

Peja,

I sent you a PM response.
You can also use the IRFP260 Mosfets as diodes.
Tie the gate to the source to do that.

I still recommend that you consider the Revolt control board.

You could convert to it later and keep the power section that
you are building now.

Cheers
Mark

Hey Mark can you tell me what diodes i can use for mine controller for now i use IRF540N mosfets for diodes (they have internal like IRFP260) because i don't know what must be used i know that they must be super fast and 200volts or more. I want to build one stable and powerfull controller for 12 volts one for 48volts and who knows maybe one for 144volts if you know what diodes must i use please tell me

[MPaulHolmes]

As far as diodes are concerned:
using 10 of STTH6002C (200v diodes) will be good for 144v 500amp.
using 10 of RURG8060 (600v diodes I think?) will be good for like 300v 600amp.
using 10 of APT100S20B (200v diodes) will be good for like 144v 700amp.

They are all in the TO-247 package.

[ludiagsm]

Originally Posted by MPaulHolmes

As far as diodes are concerned:
using 10 of STTH6002C (200v diodes) will be good for 144v 500amp.
using 10 of RURG8060 (600v diodes I think?) will be good for like 300v 600amp.
using 10 of APT100S20B (200v diodes) will be good for like 144v 700amp.

They are all in the TO-247 package.

Hi Paul and thank you

[Weisheimer]

Originally Posted by ludiagsm

Hey Mark can you tell me what diodes i can use for mine controller for now i use IRF540N mosfets for diodes (they have internal like IRFP260) because i don't know what must be used i know that they must be super fast and 200volts or more. I want to build one stable and powerfull controller for 12 volts one for 48volts and who knows maybe one for 144volts if you know what diodes must i use please tell me

Ludiagsm,

Paul has taken care of the reply, but I did want to say
Way to Go! I watched your video and it sounded nice
and smooth! Keep up the good efforts and you will be catching
up to JackBauer soon.

Cheers
Mark

[jackbauer]

So the Bauermobile got its first real run today. 3.3 miles of round town driving with some hill climbs in second. 96v of odysssey pc2150 agm batts ,80v compound wound 11" forklift motor , 72v constant shunt field supply. Graph attached. Heatsink peaked at 35c. Motor runs to about 3200rpm under load and 3500rpm no load.