Paul & Sabrina's cheap DIY 144v motor controller

[MPaulHolmes]

It makes me so happy when people are able to put a controller together, and everything works like it should. Benny from Denmark make a very nice how to video of the soldering process.

http://www.youtube.com/watch?v=x5C9f...el_video_title

[wakinyantanka]

Originally Posted by harlequin2

Don't worry about it! The current flows down the busbars at about .4 nanoseconds per metre! And that means there is no measurable difference in which device gets what first. The turn-on and turn off times are orders of magnitude greater and completely swamp any variations in busbar length.

Does current flow effect this at all? Remember my build even heavily derated will do 2000A.


Thanks for all the input guys.

[valerun]

whew! just read the whole thing! Epic thread. jackbauer & Paul - per our email exchange we are really interested in a 1000+A IGBT-based design. Damien - have you been able to test your liquid-cooled 1000A IGBT monster yet? Also, I'd appreciate the contact info for whoever you worked with in SF to get the cold plate done (I actually live 15 miles from San Francisco so would be cool to meet with the guy).

Valery.

[jackbauer]

It just so happens the heatsink turned up today. I quickly fitted the transistors and dummy located the bars and caps. As can be seen from the photos it looks good so far. I will be using the rev2c control board and the vla drivers. I decided to stick with the the 2c as its a proven design with proven software. I will be limited to a mere 900amps with this setup but i'll just have to make do


It will be tested on my test bench which is still a work in progress. Based on the evtv design but with a dc injection braked 11kw 3 phase motor as the load.

I will email the guy who designed the heatsink and , with his permission , send on the contact details or make them available on the forum. It's his call and i don't want to post anything yet without permission. He's a great guy so i'm sure it won't be an issue.

[wakinyantanka]

Originally Posted by jackbauer

It just so happens the heatsink turned up today. I quickly fitted the transistors and dummy located the bars and caps. As can be seen from the photos it looks good so far. I will be using the rev2c control board and the vla drivers. I decided to stick with the the 2c as its a proven design with proven software. I will be limited to a mere 900amps with this setup but i'll just have to make do


It will be tested on my test bench which is still a work in progress. Based on the evtv design but with a dc injection braked 11kw 3 phase motor as the load.

I will email the guy who designed the heatsink and , with his permission , send on the contact details or make them available on the forum. It's his call and i don't want to post anything yet without permission. He's a great guy so i'm sure it won't be an issue.

Man...Those are some big capacitors!!

[jackbauer]

Capacitance. Good.
Inductance. Bad.

They are epcos 400v 105c 4700uf low esr.

[MPaulHolmes]

I tested the first of the 1000amp controllers on the electric bike yesterday. The precharge/contactor control is working properly, and the wheel spun just like it was supposed to. All the code changes seem to be working as they should. I've learned to be really careful when I have to go into linux every time I want to make a software change, send the hex file to my email, and then download it on the laptop before I can transfer the code to the microcontroller. I'll get pictures later after school.

[flores]

Cool.. does that mean they have a case now? Or did you test it without?

[MPaulHolmes]

I tested it without the case. Ziegler's Welding is taking FOREVER!!!!!!!!!!!!!!!!!!!!!! Maybe they are just busy right now, but it's making me look really bad to a couple people that ordered a kit too that are over a week past due when I was supposed to ship them. Usually they are really fast.

[mrbigh]

Paul
Is it there a suitable replacement we can use instead aTLP222GF optocoupler?
Mouser and Digikey are soldout
Thanks