Paul & Sabrina's cheap DIY 144v motor controller

[adamj12b]

Originally Posted by jackbauer

We're going to need a bigger heatsink!

JACK!!

Those look familiar!!!

What kind of crazy controller are you planing?!?!?!

Each IGBT is good for 400VDC

With the parallel derating recommended by Powerx, You can push 1382A out of that bus you are building!!!

As for heat sinks, I know a place to get some good ones. You know how to get ahold of me.

What are you planning for a current sensor? The standard LEM sensor can only go to 900A....so the 4th module would be wasted. The surface mount sensor can built into a little module and code modified so you can get 1200A out of your controller.

Also, 300A per module is an over cautious derating fo the modules. Thats still 1200A for the 4. Keep them cool, and you will have a controller that can beat a Zilla!!

-Adam

[jackbauer]

Busbars done. I call it the "Bauer-con-1K-LV"

[wakinyantanka]

Originally Posted by adamj12b

JACK!!

Those look familiar!!!

What kind of crazy controller are you planing?!?!?!

Each IGBT is good for 400VDC

With the parallel derating recommended by Powerx, You can push 1382A out of that bus you are building!!!

As for heat sinks, I know a place to get some good ones. You know how to get ahold of me.

What are you planning for a current sensor? The standard LEM sensor can only go to 900A....so the 4th module would be wasted. The surface mount sensor can built into a little module and code modified so you can get 1200A out of your controller.

Also, 300A per module is an over cautious derating fo the modules. Thats still 1200A for the 4. Keep them cool, and you will have a controller that can beat a Zilla!!

-Adam

Long time reader first time poster


OK First you guys are awesome

Second; Hi Adam, I may have asked before in one of our emails but why are you using IGBT's? It is my understanding,(which is limited at best when it comes to controllers), that they are hard to get to work together in parallel. Is this not true? I know the Zilla uses them but they are the TO-247 ones I think. Got to look inside a Zilla a few months back. I guess I'm trying to figure this out as far as which would be the best way to go for the "Orion"
Here is a few pics for those of you who have not seen her.
OK maybe not, ??? apparently I'm missing a security token????????
Contact me if you want to see some pics of my ground up composite build.

[adamj12b]

Originally Posted by wakinyantanka

Long time reader first time poster


OK First you guys are awesome

Second; Hi Adam, I may have asked before in one of our emails but why are you using IGBT's? It is my understanding,(which is limited at best when it comes to controllers), that they are hard to get to work together in parallel. Is this not true? I know the Zilla uses them but they are the TO-247 ones I think. Got to look inside a Zilla a few months back. I guess I'm trying to figure this out as far as which would be the best way to go for the "Orion"
Here is a few pics for those of you who have not seen her.
OK maybe not, ??? apparently I'm missing a security token????????
Contact me if you want to see some pics of my ground up composite build.

A group of us got together and picked up all 28 modules for about $20 a piece in a group. So were working with what we have. lol

These modules will take a little consideration in putting them in parallel because you have to keep them at the same temps. Im planing a copper layer in between the copper and heat sinks to evenly spread the heat.

The nice thing about IGBT's is their high voltage ability. These can handle a battery pack with a nominal voltage of 400V!

-Adam

[jackbauer]

Other major advantage of an igbt is that it gives the ruggedness of a bipolar transistor with the ease of control of a fet.

[dave koller]

Awesome Jack! And Adam - whew!

[wakinyantanka]

Originally Posted by adamj12b

A group of us got together and picked up all 28 modules for about $20 a piece in a group. So were working with what we have. lol

These modules will take a little consideration in putting them in parallel because you have to keep them at the same temps. Im planing a copper layer in between the copper and heat sinks to evenly spread the heat.

The nice thing about IGBT's is their high voltage ability. These can handle a battery pack with a nominal voltage of 400V!

-Adam

So it's a matter of keeping the temp the same on all of the igbt's then. This allows them to flow the same amount of current for each parallel unit. I think I mentioned once that someone told me paralleling igbt's is like trying to get a team of cats to pull in the same direction, conversely a group of mosfets is like a team of Clydesdale horses. It has to be due to temp variations.
I think I'm going to go with the fets because my pack voltage is only 144v. I'm just waiting for Paul to get that SR unit going so I can start my build.

[mrbigh]

As wakinyantanka, I'm also waiting for Paul's "SR" controller to be finish.
Mean while, my power stage parts are awaiting on a green environment for a green cause.
Amazingly, Jack's and I had the same IGBTs configuration idea, mine plus a finned additional heat sink

[bigh]

Originally Posted by adamj12b

A group of us got together and picked up all 28 modules for about $20 a piece in a group. So were working with what we have. lol
-Adam

Wow thats a really good price. I'd be happy to buy 4 at that price! Is there any chance that another group buy is going to be run? or modules available at a decent price - i'd definitely be interested.

[adamj12b]

Yes, I believe that we will be doing another group buy for these. They will be slightly higher price. Maybe $10 more each max. Shipping to Australia wont be cheep though. It was $45 USD to ship them to Jack in Ireland. I would expect the same. I will add you to the list for 4 and give the total needed to be filled tomorrow. I got to got to bed now, I have a pounding headache. Goodnight!

-Adam