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Old 06-06-2011, 10:22 PM   #4851 (permalink)
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Hey, come on, I "tested 'til failure" the very first Cougar controller.

I also once smoked the Alltrax on my cycle, I know a bit about smoking controllers!

I like to say that I have broken more electric cars than most people have ever ridden in.

(In all seriousness though, I do have fire extinguishers in all my vehicles. Especially the gasoline ones! )

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Old 06-06-2011, 10:24 PM   #4852 (permalink)
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The controller fought it battle up to the last second and died as a champion!!!
The new breed of electronics will be replacing it taking upon his name.
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Old 06-07-2011, 05:18 PM   #4853 (permalink)
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Quote:
Originally Posted by ianbartie View Post
Harlequin2
Would would mind detailing how you got the motor amps up t0 625?
Here's a bit more detail on increasing the current:

VR1 adjusts the current trip level for the hardware overcurrent protection circuit only. The AVR micro sees the output from the HASS sensor directly without any scaling.

You have two options. One is to replace the HASS 300 sensor with an HASS 500. That will give you 500/300 = 1.66 * 500A = 833A. That is without any software change.

The other is to modify the software and keep the HASS 300 with VR1 turned to max for 775A. This will allow you maybe 700A as the PI loop that controls current does not work correctly if there is not some margin between the current it regulates and the hardware overcurrent trip point. The software modification is quite easy.

For the firmware cougar-v1.11b

In cougar.c, line 322 we have:

current_fb = (loc_current_fb * 19) >> 3; // (19/8 is 2.375)

This scales raw counts from the LEM current sensor to amps.
If you simply change the 19 to a 15 you will increase the raw counts required by a factor of 19/15 to achieve the same amps count.
Since the controller now puts out 509A, 509*19/15=644, so 644A.
If you change it to .... *31)>>4 then the current will be 625A

Note that the serial output to RTD Explorer will be wrong, as I mentioned previously.

The thing ought to be able to handle quite a bit more yet as the MOSFETs are rated at 130A each and there are ten of them. The diodes I think from memory are only 50A x 20 = 1000A, so there is a fair bit of safety margin. Might be interesting to take it up to 700A and see.
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Old 06-07-2011, 11:39 PM   #4854 (permalink)
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Actually, they are 30 amps * 2, so rated for 60 amps average if you are using the stth6002.
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Old 06-08-2011, 12:02 AM   #4855 (permalink)
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Yes, quite right, Iav is 60A so 600A is about the safe limit. Minbe's been managing 625Afor a long time now though.
The diodes you used in the 1000Acontroller were higher - probably could stick them in the 500A one to safely uprate it it a bit.
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Old 06-08-2011, 05:23 PM   #4856 (permalink)
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Well we now have a brake signal input on the LCM. Many thanks to Paul for yet another code mod

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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 06-11-2011, 11:23 AM   #4857 (permalink)
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Another AVR programmer

With the amount of flashing many of you do to your chips (especially Paul), this might be really useful for you. The Complete AVR Programmer That Fits in Your Pocket - Hack a Day
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Old 06-11-2011, 05:51 PM   #4858 (permalink)
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Thanks!

Hi All,

I spent the last three weeks reading this thread. What a tremendous resource!
Congratulations to Paul and all the others that have contributed. This documents both how people can come together to do something great, useful, and for the public good. It also documents the how broad system design considerations must be to produce a useful stable product.

Thank you to those that made this development possible.

Dave

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Old 06-11-2011, 05:55 PM   #4859 (permalink)
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PIC Adapter Interest

Quote:
Originally Posted by Camaro View Post
After days of struggling with the AVR and accidentally locking its programming fuse, I've moved on.
I'm now using Paul's board but with a PIC24FJ. ...snip...
I'll post my code, and an eagle PCB schematic and board that can plug right into the AVR socket if anyone is interested.
Hey Camaro,

I'm also a PIC person and interested in your adapter. Let me know what I might due to help get this done.

Dave
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Old 06-11-2011, 06:26 PM   #4860 (permalink)
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For those of you who want to learn how to build a controller in 45 minutes, instead of reading this thread for 3 weeks.....

Please watch the following two videos!





Thanks to Paul for the work he put in to give this presentation!

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