Paul & Sabrina's cheap DIY 144v motor controller

[isaac_alaska]

you can use a film capacitor pretty easily with something that small, and make a laminated bus like adam built. with something that size, with only a few holes, it wouldn't be impossible to bend the copper plates yourself in a brake and then drill them with a drill press. the C4de is a pretty easy form factor to work with, and has big heavy terminals on it.
i would think something like this would work well:
C4DEFPQ6260A8TK Kemet DC Link Film Capacitors
but adam or paul would have a better idea of the minimum capacitance needed for the controller you're building.

[isaac_alaska]

also i got some sweet pics. i'll upload them when i'm less lazy and have slept more!

[MPaulHolmes]

The new official controller prototype with the 400v diodes, and 250v mosfets is officially done and ready to test this weekend! It's a high side, and better work, or I'm going to be friggen angry inside. I need to post pictures!

[zsnemeth]

I'm really waiting for the (hopefully very positive) results of the tests.
Soonish, i'd like to order a kit from You and i'd go for this new, higher power version.

Fingers crossed

[evimarn]

Originally Posted by MPaulHolmes

The new official controller prototype with the 400v diodes, and 250v mosfets is officially done and ready to test this weekend! It's a high side, and better work, or I'm going to be friggen angry inside. I need to post pictures!

Cool it Paul, There is somebody praying not preying for you.He (me) needs results.
Good luck mate.

[rayjay]

Originally Posted by MPaulHolmes

The new official controller prototype with the 400v diodes, and 250v mosfets is officially done and ready to test this weekend! It's a high side, and better work, or I'm going to be friggen angry inside. I need to post pictures!

Be very, very careful, take a big breath before throwing the switch, then go for it. HEHEHEHE

Seriously we all have our collective fingers crossed. After all this time it just HAS to be operational.


rayjay

[ChedMpls]

I made my first commute trip with the cougar today and I had a big issue with whining and squealing (yes both). Having read the thread most people have been delighted to NOT have this issue. The W&S was fairly constant at all speeds,gears,and power levels. It seemed to be o.k. at just the right amount of LOW power in a given gear. If you can see the pix you will appreciate that this is a low-budget homemade affair (adapter plate cut with sawzall).
1996 Saturn SL2 running 84v
cougar rev2c 500a
I used slightly larger mosfets and capacitors.
My M- cable is less than 18" but others may be longer.
My LEM sensor is not glued yet (won't fit in case).
I ran a mixed pack of new and old (learned my lesson today...old are history).
Controller heatsink is not isolated from vehicle chassis and it's 12v battery.
Loved the drive, HATED the racket!! Any guesses? Do I need some type of sheilding?

Thanks guys,
Ched

[MPaulHolmes]

whining could mean that the fuse bits aren't set, which means the microcontroller could be running at a lower frequency than 16MHz, which would slow the pwm signal. I think 1MHz is the default, which would mean 1kHz pwm signal, which would be EXTREMELY annoying. The correct fuse bit settings are

extended = F8
High = DC
Low = F7. But if you are using ponyprog or something, then I think you should use extended = 8. Could there be an alignment issue causing the other sound?

[ChedMpls]

are those parameters set in the explorer program? I don't know what a ponyprog is!!!!???? BTW does explorer work using a serial to usb adapter?
ched

[Weisheimer]

Those parameters are set when doing the programming of the microcontroller for the first time before it is installed on the control board.
A Ponyprog is a device used to program the AVR microcontroller.
Did you buy a pre-programmed microcontroller from Paul, or was yours programmed by someone else?

Explorer works fine with a USB to serial adapter.