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Old 12-24-2014, 06:29 AM   #6981 (permalink)
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Merry Christmas Guys,
It's been really hot today - I hope Christmas day is a bit cooler

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Old 01-17-2015, 02:02 PM   #6982 (permalink)
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So I'm BACK!!!

Sorry for the delay friends, I've been busy.
Today I mounted the controller in the beetle.

Set the amps limit to 300 (so that is 1200A) and took it for a spin... it drives really good I must say.. baseplate of the controller doesn't get hot or anything.

So decided to ramp the amps up to 550 (that's 1650A).. and in one word: AWESOME !!
With that much amps the first and second gear become unusable because the rpm limit kicks in very fast.. so I drive it in third.. with very quick acceleration..

In my neighbourhood there are some roundabouts and I can endlessly drift around them.. It feels VERY VERY quick..

Also tried it in fourth, but then when stamping on the gas, one time I guess the hardware limit kicks in.. I thought I broke the whole thing.. but a reset fixed everything..

I will make a video tomorrow and post it here..

Any suggestions on how to stress it more?
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Old 01-17-2015, 03:43 PM   #6983 (permalink)
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hahahaha. Holy cow, um... I wouldn't go higher than that. You are right. It must have been the hardware overcurrent coming on in 4th gear. It was set to 600amp per igbt, so at least one of the IGBTs must have gone over 600amp for an instant. I'm really glad I put 3 independent current sensors (one on each IGBT) on your controller, you mad man! LOL. Oh can I please get a video of this?!

MORE STRESS:

Well, they are 600v IGBTs, and a 600v ring capacitor. So, why not bump it up to 350v? hahaha

It is possible to change a resistor so that the hardware overcurrent would come on higher, like 700amp instead of 600, and then maybe you could set the current per IGBT to 600, but I don't know if that would be wise... I mean, they are rated for 600amp. It would be weird if they blew up just because you ran them for a short time at their actual rating. I would be concerned about how much heat the IGBTs would be putting out though. Also, I don't remember what the state of your software is. I need to make a couple changes, and send them to you guys. I've really improved the serial communications on the AC controller, and need to port that over. And I need to send jedsmd the updated code for throttling back based on temperature. I need to send it to you too.

So, just so I'm clear, jedsmd is Hall Effect. Flores is 5k-0, and duncan is 0-5k. haha. I think that's right.
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Old 01-17-2015, 08:03 PM   #6984 (permalink)
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Flores
Congrats! Sounds like a fun ride.

I know this is a controller thread, but I am really curious what you are using for a battery pack.
Jerald
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Old 01-17-2015, 08:30 PM   #6985 (permalink)
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Quote:
Originally Posted by jedsmd View Post
Flores
Congrats! Sounds like a fun ride.

I know this is a controller thread, but I am really curious what you are using for a battery pack.
Jerald

Me too
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Old 01-19-2015, 03:38 AM   #6986 (permalink)
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Sorry guys, it was raining all day yesterday and since I have no protection whatsoever against water I didn't took the beetle out.

I'm running on 45 thundersky/winston 160Ah lipo's, here are some specs:


Weight (kg) 5.8
Height (mm) 278
Width (mm) 182
Depth (mm) 71
Nominal Voltage (V) 3,2
Capacity (Ah) 160
Max discharge current (A) 1600
Optimal discharge current (A) 80
Max charging current (A) 480
Optimal charging current (A) 80
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Old 01-19-2015, 03:38 AM   #6987 (permalink)
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So.. I guess I can up the voltage to 200V.. that would be nice.
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Old 01-19-2015, 03:40 AM   #6988 (permalink)
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Oh btw.. the controller was still only warm to the touch after all my abuse.

But it was cold outside, could be different in summer.
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Old 01-19-2015, 10:43 AM   #6989 (permalink)
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I find temperature rise to be pretty slow with just a fan for cooling. Paul must of made them pretty efficient

Are you using a fan or heatsink?
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Old 01-19-2015, 10:47 AM   #6990 (permalink)
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Quote:
Originally Posted by flores View Post
Sorry guys, it was raining all day yesterday and since I have no protection whatsoever against water I didn't took the beetle out.

I'm running on 45 thundersky/winston 160Ah lipo's, here are some specs:


Weight (kg) 5.8
Height (mm) 278
Width (mm) 182
Depth (mm) 71
Nominal Voltage (V) 3,2
Capacity (Ah) 160
Max discharge current (A) 1600
Optimal discharge current (A) 80
Max charging current (A) 480
Optimal charging current (A) 80
Nice - Should give you a good range too.

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