Paul & Sabrina's cheap DIY 144v motor controller

[evimarn]

To Jackbauer,

nice work there and explanation,still assimilating your input.Impressive.Cannot afford all the r&d but I am sure and rely on the fantastic work done here on this forum.You guys sure know a lot.Once again Thanks.

[isaac_alaska]

Originally Posted by sawickm

Hi Paul,

I put together an assembly drawing of what you posted.

I added the sensor assembly drawing into the revolt wiki: Open ReVolt/PCB Schematics - EcoModder

- Mark

Figured out this is the current sensor board i have, but i need to get the caps and the actual IC for it. i looked on mouser and digikey, and did a google search for it, but i can't seem to find the little tiny chip. any ideas?

thanks!

[Freyguy]

isaac_alaska,
The actual part number should be MLX91205KDC-HB.
Both Digi-key and Future Electronics show stock.

Digi-Key - MLX91205KDC-HB-ND (Manufacturer - MLX91205KDC-HB)

MELEXIS | MLX91205KDC-HB-TU | MLX91205 Series 4.5 to 5.5 V Surface Mount IMC Current Sensor - SOIC-8 - Future Electronics


Qty 1 price from Future is only $4.85 compared to $10.13 from Digi-Key

[isaac_alaska]

Originally Posted by Freyguy

isaac_alaska,
The actual part number should be MLX91205KDC-HB.
Both Digi-key and Future Electronics show stock.

Digi-Key - MLX91205KDC-HB-ND (Manufacturer - MLX91205KDC-HB)

MELEXIS | MLX91205KDC-HB-TU | MLX91205 Series 4.5 to 5.5 V Surface Mount IMC Current Sensor - SOIC-8 - Future Electronics


Qty 1 price from Future is only $4.85 compared to $10.13 from Digi-Key

THANKS! i would have had a super hard time finding that myself. i think now the only thing i have left to do is figure out how to program the rest of the board. can the 1ka cougar board be programmed with just the serial link? or does the microcontroller have to be programmed off the board first?

[Nevyn]

Sorry I've been missing for so long! With the SBE ring cap - You only need ONE to do the whole shebang??

[isaac_alaska]

Originally Posted by Nevyn

Sorry I've been missing for so long! With the SBE ring cap - You only need ONE to do the whole shebang??

according to the data sheet, it looks like each one is good for 500 amps rms. 1000uF is more than enough capacitance to supply the current needed during the conduction phase of the power stage. if i remmeber correctly, according to my calculations, at 50% PWM duty and 1000 amps and 170 volts, the capacitor must supply about 5.5 watt seconds of energy. at 100% PWM duty, it doubles to about 11 watt seconds. 1000uF at 170 volts is good for about 35 watt seconds. so even at MAXIMUM power draw, the capacitor never dips below 1/3 depleted. the data sheet also says it can handle 10,000 amps fault current.
However, it lists 500 amps RMS at 20 khz as the maximum. So i think for most applications, you would only need one, but if you're pulling the full 1000 amps for an extended period of time, you need two of them.

can someone else confirm this?

[adamj12b]

The Soliton 1 controller uses only 1 of these caps and its rated at 1000A Continuous.

Also, you will very rarely pull even close to 1000A at 100% duty cycle. The morot would have to be stalled or close to it when the throttle is stomped.

-Adam

[isaac_alaska]

Adam, are these the 600v 1000uF caps? That's the only ones I was able to find a data sheet for.

*edit*
i found a bunch of other data sheets on SBE's website, but i don't see any that say they are rated for for over 500A RMS. it's very possible they aren't advertising this one though, or the soliton controller is just using them above their rms rating. (which it appears would still be really safe; several of their caps can handle a 100,000 amp spike)

[vamp200]

this is one long thread. 519pages. Couldn't read all of them. Mindboggling. I'm still trying to figure out what all those parts do. I definitely need the controller and for sure help to put it together. Gotta save a bit more money still.
c ya all later.

[MPaulHolmes]

hahaha. ya it's long. Isaac, I can confirm that you can't just program the micro through the serial port until the initial programming has happened. I use a programmer from digikey that was $35 I think.

Digi-Key - ATAVRISP2-ND (Manufacturer - ATAVRISP2)