Paul & Sabrina's cheap DIY 144v motor controller

[jyanof]

Originally Posted by dave koller

I just do something stupid -- and switch a resistor in the throttle circuit....

this would effectively tell the controller a smaller throttle position but not change the control loop speed. it wouldn't help the loop instability at low speeds when the loop is tuned for high acceleration rates.

[dave koller]

Originally Posted by jyanof

this would effectively tell the controller a smaller throttle position but not change the control loop speed. it wouldn't help the loop instability at low speeds when the loop is tuned for high acceleration rates.

Yep... Note the word "Stupid" --
Forgot to mention it is not a REVOLT...

[Nevyn]

Something like a 3-position toggle switch that the controller checks the position of. Switch is polled for which position its in, and controller changes kp/ki values depending on position that is read. Have a "safety loop" so that it only changes modes when speed=0.

Position 1: "crawler" setup
Position 2: "normal" setup
Position 3: "I'm-feeling-evil-and-want-to-show-ricer-boy-next-to-me-at-this-light-a-thing-or-two" setup

How's that sound?

[isaac_alaska]

hi again!

what's the lead time on the 144V, 500 amp dc controller kit?

thanks (:

-isaac

[Frxdy]

Good day! Is there a place where I can download the "open revolt" decal vector? I'd like to engrave my control box when the time comes. I can make a vector from the photos of it, but if there was one ready it'd save me an hour or so. More and more people have or have access to a CNC machine so perhaps if there is no vector I'll make one and post it on the Wiki....if I figure out how to do that.

[bennelson]

I've got the vector here somewhere.....

Let me find it for you. Give me a few minutes...

OK, I have it, not sure what's the best way to get it to you. I have both an .AI and an .EPS - both are about 1MB. that's too big for me to post on my blog.

Can somebody help me get it Wiki'd up?

[Georgia Tech]

Originally Posted by pamcmills

In response to electricstorm, I'm also using a forklift motor in my S-10. It's a GE motor a little over 11 inch and in the 200 pound range. Except for the spline shafts and different bolt pattern on the output side, It looks exactly like the NetGain Warp 11 motor. The motor was rated 13 hp @ 48 volts, 150 amps, 1800 rpm, class H insulation. Class H insulation is good for up to 356 deg. F and 600 volts or so. Generally the type of brushes in that motor are only good for about 78 volts. But I have been running 144 plus volts for 10000 miles and have noticed no abnormal brush ware. I did set my brush timing to 6 deg advanced to reduce brush arcing which works for my motor with the load it's under. Hope this was helpful.

I have a motor simmilar to this as well. So you say yours ahs been working really well? I plan to drive mine with the 1000 amp controller when it is done.

[Frxdy]

Drat! I was just looking.... EPS & Ai files are not allowed! It says "Permitted file types: png, gif, jpg, jpeg." *sigh* I'm hoping to maybe expand on the decal...perhaps add "EV Controller" or something to tell a bit more of what it is, what it does. Even I make a vector from a photo, it would be nice to be able to post it some place for the public to use.

[isaac_alaska]

i'm at EVS26 for one more day! never thought i would see so many different types of batteries, motor controllers, chargers, and charging stations in one place at one time.

[Nevyn]

Ahoy, folks! It's been a while since I've posted here in this thread, but I've been re-charged to get working on stuff and have a question that I'm hoping you folks can help with.

I have just about everything ready for my Open Revolt based controller. The control board is completed (needs programmed), and my IGBT driver board is also completed. I have IGBTs and heat sinks.

I want to assemble it as a "low-power" controller first, and test/debug it on the go-kart we have before we doll it up all pretty and re-assemble it as a road-capable version.

I have 2x (matched pair) of 600V 75A IGBTs I was planning on using together to get 150A:




My question for you folks is this: What size/type of capacitor layout would I need to handle 48V 150A max? How would I connect it up properly to IGBTs?