Paul & Sabrina's cheap DIY 144v motor controller - Page 560 - Fuel Economy, Hypermiling, EcoModding News and Forum

jackbauer · 03-19-2012, 03:02 PM

Woohoo! When can I get one?

MPaulHolmes · 03-19-2012, 03:14 PM

It's a 4 layer board since they can be like 10 times as noise immune, and there's so many tracks that it just made it easier, so the lead time is 18 days instead of 12, but I'm trying to prioritize what to send in first. If I get a sale, I can send it in right away.

jackbauer · 03-19-2012, 03:24 PM

You've got a sale!

MPaulHolmes · 03-19-2012, 03:54 PM

lol. I'll order it this week. Lots of it is very similar to the most recent control board that I just finished debugging last night, but it's a dsPIC microcontroller (since that has 6 pwm outputs), so there are some differences. 2 current sensor inputs instead of just 1. If there are errors, they should be very minor.

isaac_alaska · 03-20-2012, 04:35 AM

Quote:

Originally Posted by MPaulHolmes

I've got a sample 400v diode but it only has one really wide leg and I don't know how to put slots in the board. I wouldn't mind figuring that out. That would let me up the voltage some, since good mosfets can be had up to 300v.

just stack three or four though-holes on top of each other, offset slightly. i'm pretty sure that's what adam did on the IGBT driver board that's in my motor controller. the driver board fits over the tabs on the IGBT's really nicely, and i think the holes are even plated all the way through. it's not a perfect slot but it works well

adamj12b · 03-20-2012, 08:41 AM

Quote:

Originally Posted by isaac_alaska

just stack three or four though-holes on top of each other, offset slightly. i'm pretty sure that's what adam did on the IGBT driver board that's in my motor controller. the driver board fits over the tabs on the IGBT's really nicely, and i think the holes are even plated all the way through. it's not a perfect slot but it works well

That's Exactly what I did! Only thing to watch out for is the hole size. Most shops wont do overlapping drill hits without them being a minimum size. For Advanced Circuits, I believe its 0.064".

Here's a pic of it.

Untitled by AdamBrunette, on Flickr

-Adam

MPaulHolmes · 03-20-2012, 08:58 AM

well heck, that's good enough for gubment work..

okie00 · 03-20-2012, 12:17 PM

Quote:

Originally Posted by MPaulHolmes

I've got a sample 400v diode but it only has one really wide leg and I don't know how to put slots in the board. I wouldn't mind figuring that out. That would let me up the voltage some, since good mosfets can be had up to 300v.

edit: forgot bus bars- 1" x 0.25" x 14" I think bus bars. Not sure about length at the moment. 13" or 14". and B- is 3/4" x 3/8" x LENGTH, where length is "I forgot" haha

Thanks

the 300v sounds good I'm wanting to stay below 300v but was thinking around 220 - 240 would be good and that would have room to upgrade if needed

How many diodes would it take?

isaac_alaska · 03-20-2012, 09:40 PM

i found this chip, for doing PFC on things like chargers

Digi-Key - LT1249CN8#PBF-ND (Manufacturer - LT1249CN8#PBF)

thought i would share it. it looks really simple to use. i'll let you know how it goes, i'm planning to use it in my charger

AviatorBJP · 03-21-2012, 12:40 AM

Hi everyone,

I was wondering how the new controller design is coming? It is hard to get a summary by looking back through the posts.

I was planning on building an open revolt controller over the next few months. If the 1000 amp design is nearing completion, I would love to build one, especially if it helps you guys out in any way.

-Brad