Paul & Sabrina's cheap DIY 144v motor controller

[flores]

So there is no problem?

[MPaulHolmes]

There is a hardware overcurrent protection circuit for each separate IGBT. I'm not doing anything with the other 2 current feedbacks at the moment inside the micro.

[flores]

Okay.. I think the best thing to do is leave the setting at 100A and drive it around.. and monitor it closely.. with separate devices

[jedsmd]

At last the home move is winding down and I can work on my new controller.

Today I got it into the truck and fully connected up


A lot of orange cable going this way and that

Right now the controller is setting above a fan that feeds air through a gap under the controller. I don't know if that will be enough cooling for my around town driving style. I will monitor the plate temperature and add a heatsink if required.


Low voltage end with cover open, note the relay added to the contactor circuit to isolate the 24volt controller from the 12 volt contactor coil.


So when I fire it up absolutely nothing happens

Paul is possible I can get some software?

[MPaulHolmes]

Minor details. I guess it would be good to program it first. I'll send you a hex file tomorrow morning. I probably just had some debug mode code on it at the moment.

[MPaulHolmes]

Oh crap. I forgot that your throttle is inverted. I almost sent you the wrong code. PHEW. I'll try to find some time today to make the modification so it goes 5k = zero throttle and 0k = max throttle. There will be a little dead zone, so as to guarantee that the throttle contactor closes well BEFORE the throttle is considered nonzero. You definitely don't want the throttle to be nonzero, and the poor pwm ramping up to 100% in the vain attempt to see a nonzero current feedback (no current can flow when the contactor is closed).

[flores]

Wouldn't it be a good idea to make that configurable?

[MPaulHolmes]

Well, now that you mention it, yes! That would be good. I had been half-heartedly trying to keep things as similar as possible to the other serial structure, but I've had to depart from it somewhat. So I may as well add that!

[Sunny2]

Originally Posted by xtian999

Yes, it is like a pc fan, only much bigger. About 6" across and 2" thick. I will splice in a plug for it and see what happens. If it causes the controller to fry, then we will know that it was a big fan of irony.

Reading through the whole thread. This one killed me!

You guys are funny guys.

[flores]

btw.. I ordered this RS232 Shield - floris.cc so I can start building that web interface netduino thing.