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Old 05-24-2011, 01:13 PM   #4791 (permalink)
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Controller Assembly progress

So this weekend I started the assembly process.

I drilled out all the holes necessary - tinsel fun time, my wife loved it.

I then attached the M bus bar to the power board. Now I decided to be adventurous. The instructions mention using silver epoxy.
I decided to go with what I had in the garage which was a bunch of solder, a propane torch and some spring loaded clamps.

I wet the copper with the solder (heating the copper from the underside to melt the solder using the copper bar itself-not the torch)

I then used the 230 watt heat gun to wet the power board areas for the solder.

Smooth everything off- then line the copper bar on the holes with all the solder facing each other. Used the spirng clamps.

Went over the entire length of the bar with the propane torch.

Let it cool and the whole thing seems solid.

What do you guys think? I don't believe anything burned or caught fire (the board didn't smoke i wanted to be careful)

As far as all the bus bars, as i mentioned in an earlier post I would like to face them all the same way... i believe I saw someones controller like that...is there stuff i should be aware of (i'm pretty sure i'm missing something)

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Old 05-24-2011, 01:46 PM   #4792 (permalink)
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JackBauer - what size are your copper bus bars?

I started soldering my control board finally! Now I just need time to FINISH soldering it...

Paul, what revision are we calling this board? 3? Square root of 5?
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Old 05-24-2011, 01:49 PM   #4793 (permalink)
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You can call this board whatever you want. Just don't call it late for dinner.

Yo, Voltmatic Automation, Awesome!!! I don't think there's any downside to soldering those buggers right to the power board, if you are able to do it. And I don't think there's a problem with having the bars all out the same direction either. At least in practice it seems to work just fine.
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Last edited by MPaulHolmes; 05-24-2011 at 01:57 PM..
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Old 05-24-2011, 03:22 PM   #4794 (permalink)
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The bus bar is 20mm x 10mm.
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Now, Cole, when you shift the gear and that little needle on the ammeter goes into the red and reads 2000 Amps, that's bad.
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Old 05-25-2011, 12:28 PM   #4795 (permalink)
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Quote:
Originally Posted by jackbauer View Post
The bus bar is 20mm x 10mm.
Crazy 'Mericans....*grumble* *math noises*

0.394" x 0.787" bars. Call it 3/8" x 3/4", I guess. That was the size we were hunting anyway.

Thanks, JackBauer.
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Old 05-25-2011, 02:09 PM   #4796 (permalink)
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Quote:
Originally Posted by Nevyn View Post
Crazy 'Mericans....*grumble* *math noises*

0.394" x 0.787" bars. Call it 3/8" x 3/4", I guess. That was the size we were hunting anyway.

Thanks, JackBauer.
Yea, 3/4 x 3/8 is what I use too
good for about 450Amp at DC level if my math is not wrong.



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Old 05-25-2011, 02:46 PM   #4797 (permalink)
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okokokok (Leo Getz) , who's trying to upstage me with the igbts and caps ??
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Now, Cole, when you shift the gear and that little needle on the ammeter goes into the red and reads 2000 Amps, that's bad.
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Old 05-25-2011, 05:24 PM   #4798 (permalink)
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okokokok (Leo Getz) , who's trying to upstage me with the igbts and caps ??
It's got to be meee!!!!
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Old 05-27-2011, 02:54 AM   #4799 (permalink)
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Very nice looking, MrBigh.

Are we going to have a little photo competition for the best looking controller?

Dawid

Last edited by DawidvC; 05-27-2011 at 02:56 AM.. Reason: Humour
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Old 05-27-2011, 05:11 AM   #4800 (permalink)
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Kp & Ki

Can some one please explain the relationship between Kp & Ki in the controller settings & how do the different settings make the controller behave.
For example (for all examples use a 144V pack, the same motor & a 100Ah LiFePo battery pack):

If Kp is 2, what is the difference between having Ki at 20 or having Ki at 100.

What would the likely results be with the following different settings:
Kp 2 Ki 20
Kp 6 Ki 50
Kp 1 Ki 160

The wiki description does not really explain how the 2 interact together & what effect on the controller the differing settings actually make.

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