Paul & Sabrina's cheap DIY 144v motor controller - Page 435 - Fuel Economy, Hypermiling, EcoModding News and Forum

MPaulHolmes · 02-08-2011, 01:42 AM

Absolutely!

Edit: I've been spending an inordinate amount of time on putting that stupid precharge circuit on the control board, and making the board bigger and more expensive, when I realized, there is a perfectly good mounting board directly below the control board that is larger. I can just have the precharge stuff mount right there! Hurray! Now the thru-hole control board is like 6.5x2.5" or so, so it's a lot cheaper. By the way, MR Bigh, that's what the hold up has been for me sending it to you, since i've been changing so much stuff on it.

Nevyn · 02-09-2011, 03:07 PM

Paul - I've sent some monies your way! If you cheat and mark it as a personal gift, then PayPal doesn't take their money-grubbing fees out of it! I'm such a scoundrel, hahaha!

Figured I'd post that for everyone to see that way if they wanted to further the cause they can do the same - so that you get 100% of every dollar sent your way!

DJBecker · 02-09-2011, 04:08 PM

How much are the boards?

Do you have a batch or sample that has flaws? I might get a control board just to make certain that my CAN bus controller code "drops in" the existing system. I wouldn't be populating all of the sections so they wouldn't need to be correct.

MPaulHolmes · 02-09-2011, 06:13 PM

There was one SR board back in August that I messed up on the low voltage cutout for the high side driver (or low side, or something like that). I could send you one of those piles of crap if you want. It's surface mount resistors and capacitors, but through-hole ICs and stuff.

Jeff! with your money, I'm going to order a 3/8"x3/4"x ??? bus bar and test the melexis current sensor. Initial calculations using the equations in an application note showed that it only has to be 1/16" above a 1" wide bus bar, but I'm not going to do a wider bus bar, so I need to do it for a 3/4" wide bar. I figured it's better to keep the inductance down, since the current will be so high.

Nevyn · 02-10-2011, 10:38 AM

Quote:

Originally Posted by MPaulHolmes

There was one SR board back in August that I messed up on the low voltage cutout for the high side driver (or low side, or something like that). I could send you one of those piles of crap if you want. It's surface mount resistors and capacitors, but through-hole ICs and stuff.

Jeff! with your money, I'm going to order a 3/8"x3/4"x ??? bus bar and test the melexis current sensor. Initial calculations using the equations in an application note showed that it only has to be 1/16" above a 1" wide bus bar, but I'm not going to do a wider bus bar, so I need to do it for a 3/4" wide bar. I figured it's better to keep the inductance down, since the current will be so high.

Enjoy!

billhac · 02-10-2011, 11:28 AM

hi Paul, I saw this on the internet, last night when i had nothing better to do, Can you tell me how this compairs to your new IGBT controller, Price wise its about the same area, but operational? I think it requires a logic input, which would mean a second board, but im not to sure.
http://www.pwrx.com/pwrx/docs/bg2b.pdf if you get it from powerex its about 112 bucks.

MPaulHolmes · 02-10-2011, 01:17 PM

Oh I will, Nevyn!

Bill! Thank you too! I think that bg2b datasheet is for switching smaller igbts. IT says it's rated for up to 400amp igbts. I basically copied the driver board for the bg2a, which can switch igbts rated up to 1400amp each. They are probably very similar though.

MPaulHolmes · 02-10-2011, 11:13 PM

My Math 102 class is figuring out the surface area of the heatsink that is going on the 1000 amp controller right at this instant so I don't have to. Hurray!!! All I have to do is type this. They are also finding the volume of the heat spreader after the drilling has been removed.

Nevyn · 02-11-2011, 02:01 PM

Your classes must be crazy fun! If you were closer I'd shake your hand. Did you hear/see that the one place that had VLA's went out of stock? We're all stuck!

MPaulHolmes · 02-12-2011, 03:42 AM

OK, please please please please don't try this at home, but someone who put a controller together decided to run his S10 truck at 192v to extend the range!!! We are talking about the 200v components here. He's gone 300 miles so far without any problems. His commute is about 36-38 miles per day. Around 6-8 miles of stop and go in town driving, and 30 miles at 60 mph. I don't know what to say. Fully charged, it has to be way over 200v. Ok, the capacitors are rated for 250v surges, but what about the mosfets?!