11-30-2011, 02:41 PM
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#5231 (permalink)
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EcoModding Lurker
Join Date: Apr 2009
Location: Mauston, WI
Posts: 20
Thanks: 1
Thanked 8 Times in 7 Posts
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The Cougar worked great for my 94 Toyota pickup! I put it on the road this summer. It's got only 300 miles but I'm really happy with it!
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The Following User Says Thank You to jmcginley For This Useful Post:
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 Today
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Other popular topics in this forum...
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11-30-2011, 07:56 PM
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#5232 (permalink)
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EV test pilot
Join Date: Jan 2008
Location: Oconomowoc, WI, USA
Posts: 4,435
Thanks: 17
Thanked 663 Times in 388 Posts
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Quote:
Originally Posted by BlueBlood
I've been reading from page 1, after about four days of reading i'm only at page 101! ......
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At some point, we are just going to convert this into a best-selling book!  |
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11-30-2011, 08:19 PM
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#5233 (permalink)
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EV DIYer
Join Date: Jun 2009
Location: Vancouver, BC
Posts: 28
Thanks: 8
Thanked 6 Times in 5 Posts
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I drove the car for the first time since installing the Open Revolt/Cougar controller, and it runs beautifully! Smooth starts, great acceleration and power to spare. I had used most of the settings similar to Mike's in the Wiki as he has a similar motor and pack voltage and I don't think I will need to change anything, as it works better than I expected.
My thanks to Paul and Sabrina for making the kit available, as well as everyone else on this thread for their contributions to the project!
Amin
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11-30-2011, 09:10 PM
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#5234 (permalink)
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PaulH
Join Date: Feb 2008
Location: Maricopa, AZ (sort of. Actually outside of town)
Posts: 3,832
Thanks: 1,362
Thanked 1,202 Times in 765 Posts
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HI Ben! If we make it a book, we should cut out the naked North Korean Dictator. I can't remember what page it's on, but that was nasty.
Hi Amin! I'm SOOOOOOOOOOOOOO glad it's working!! I can officially breathe again.
Hey! I'm going to do some thermal tests on some lower end diodes. They are rated for 300v, and 60amp per leg. I'm officially a professional at soldering TO-247 package mosfets/diodes to heavy duty bus bars now. And I don't think the thermal stress is too much. They still work just fine after their backs are soldered to the bar and they aren't at solder temperature for very long. It takes a hammer poundind a flat head screwdriver against it to remove them, and that's only after the outer black plasticky part has been completely destroyed. Seriously about 30 pounds with a hammer really hard before I can break the copper back of the mosfets/diodes from the copper bus bar. Those things aren't going to "wiggle" loose. haha. It took a whole bunch of different approaches to get it just right, and the process keeps getting smoother!
For 1000 amps, I need about 84 motor amps from the cheap diodes, which are rated for 120 amps average. In bulk they are only like $3-$4 each I think.
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11-30-2011, 11:12 PM
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#5235 (permalink)
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EcoModding Lurker
Join Date: Jun 2011
Location: Tennessee
Posts: 16
Thanks: 4
Thanked 1 Time in 1 Post
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I haven't made it entirely through this thread yet... Now with naked dictators... I'm not sure I want to... Laugh...
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12-05-2011, 02:39 PM
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#5236 (permalink)
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Master EcoModder
Join Date: Sep 2009
Location: Ireland
Posts: 734
Thanks: 26
Thanked 304 Times in 171 Posts
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"Interesting" event this morning. Air temp was down near freezing. Controller heatsink temp reported as 0C. Switched on as normal. Into reverse , handbrake off , give it some pedal. Nothing. More pedal. Nothing. Even more pedal. Next thing the right side back tyre lays rubber on my drive and i headbutt the steering wheel. Lifted off the throttle and all back to normal. Car drove perfectly all day. Any ideas? Seemed as if the pwm had ramped up to full but was not getting through to the igbts. Or the igbts were hibernating. Or maybe something like in Lethal Weapon 2 when they froze the toilet bomb ... 
__________________
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.
www.evbmw.com
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12-05-2011, 02:53 PM
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#5237 (permalink)
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PaulH
Join Date: Feb 2008
Location: Maricopa, AZ (sort of. Actually outside of town)
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I think the crystal oscillator is rated for 0-70 degC. But 0C isn't below 0C ... There are a few other components that are also rated for 0C. The VLA driver is rated down to -20C. It does sound like the PWM was ramped up to 100% duty, but the IGBTs weren't getting the memo. So, I think the microcontroller was working like it should. Is it possible that the main contactor didn't close at first? That would make the throttle to ramp up quickly to 100% duty. I added a fix to that that causes a fault until the pedal is released, but I don't think you have that version.
Do you just have 1 contactor? Is there anything else like an inertia switch that is affected by cold weather?
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12-05-2011, 03:00 PM
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#5238 (permalink)
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Master EcoModder
Join Date: Sep 2009
Location: Ireland
Posts: 734
Thanks: 26
Thanked 304 Times in 171 Posts
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Paul , I can confirm the main contactor was closed and the bus caps had full pack voltage. Gonna need to figure this out as temps will be getting below freezing very soon. I'll be more careful in the morning
__________________
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.
www.evbmw.com
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12-05-2011, 03:02 PM
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#5239 (permalink)
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Master EcoModder
Join Date: Sep 2009
Location: Ireland
Posts: 734
Thanks: 26
Thanked 304 Times in 171 Posts
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I actually suspect the lem. Does the software have the ability to ignore negative current readings from the lem? This caused a cold weather problem with the charger that uses a hass 50 a few weeks back.
__________________
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.
www.evbmw.com
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12-05-2011, 03:31 PM
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#5240 (permalink)
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EcoModding Apprentice
Join Date: Feb 2010
Location: Northern Wisconsin
Posts: 137
Thanks: 32
Thanked 39 Times in 23 Posts
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Jack
What throttle are you using? Have you noticed any ice formation on the underside of the motor? I noticed the weirdest ice crystals on temperature drops from damp moisture in the storage air and it seemed to form on some contacts. Bit of dust, ice crystals, resistance ? Not that that is the problem but just another thought - I do not have heat in the Garage-in-a-box !
Lem makes sense - things like this never show up in the warm climates. 
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Dave ...
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