Sunday, September 28, 2008
Saturday, September 27, 2008
So I have decided to start to save up for a 96 volt controller that will meet my needs until my homemade controller is complete. I need about $600 for a Kelly KDH096400 96 Volt 400 AMP controller, so I am hoping anyone out there willing to spare a few bucks will.
I am also long overdue for come pictures of the rear battery rack and the front motor mount, so I will try and take some if the rain ever stops.
Friday, September 26, 2008
As for my own controller design, I have my current sensors arriving today and I am still working out a few problems in my design. The design itself looks fine, but the 15 volt source I need doesn't. I was going to use a LM317T adjustable voltage regulator, but it is only 1.5 AMPs max and my math says I need at least 4.5 AMPS for the IGBT driver.
I have a computer gig to do this afternoon, so hopefully that will pay for the temporary controller.
Sunday, September 21, 2008
The second generation controller has many new features and fixes, such as a microprocessor, 16KHz freguency, IGBT driver, Hall Effect current sensor and a large freewheel diode. Eventually I will hook up an LCD display to it and add some more feaures. This controller is still early in it's development, with parts being ordered this week. I have lots of work to do on this software for it, creating IDLE control, Performance/Range settings and what ever else I can thing of. I have gone through this particular design a few times, and showed to some professionals and it should work perfectly fine. Ideally I would want to make this as customizable as possible, and maybe make a small side business in the EV controller market, but that is probably a few years off.
Thursday, September 18, 2008
But the car did move under it's own power! Tomorrow I am going to make sure nothing happend to the coupling because there were some loud sounds from that area when I jammed the car into park and shutdown the motor.
The second gen controller has a true IGBT driver, and should be ready to test this weekend. It will be getting a go over from a few professors and IGBT experts tomorrow.
Tuesday, September 16, 2008
So there I am, camera rolling, everything connected. I start up the car, contactors close, cooling fan comes on, put it into reverse and hit the pedal. NOTHING HAPPENS.
After 5 minutes of taking measurements, it hits me. I modified the current limiting wrong, so it forced on, prevent the car from moving. (Well at least that worked!)
It gets better. So I go to remove the controller, shut everything off, flick the breaker and proceed to remove the controller. In an act of complete stupidity, I drop the wrench across the B- and M- terminals, and it sparks blowing the logic board away. The capacitors were still charged, and found their way to there desitnation by toasting the controller.
I had breakers and fuses for every other part of the system except dropping a fraking wrench across the terminals. Now I have to repair it, which should be as simple as replacing the three chips and some bench testing. I also am almost done laying out the microprocessor controller and hope to have that is some sort of a testing phase in the next week or so. I just have to order a hall effect current sensor and plan on having it completed before it gets cold out. (It's water cooled, and that will provide my heat for the cabin.)
Friday, September 12, 2008
The rear battery rack has both coats of paint on it and is all dry and ready to be installed. I also made a test cable yesterday, and will make the rest up today. Before I mount the rear battery rack, I am going to do a test fit to make sure all 5 batteries fit.
I also have to adjust my controller battery current limiting from 500 amps to 250 amps for many reasons, but one is that if I don't, the controller can be called the EgoBuster. Set at 500 amps and you step on the pedal, the 250 amp breaker would blow before the current limiting kicked in, and that would make anyone's ego bust up. I can just picture going for my test run and stepping on the throttle to see what my controller can do, and blowing the breaker before I go anywhere!
So what's left:
-Install motor mount
-Install Rear Battery tray
-design and install front battery tray
-Make one last modification to my controller
Drive it. If I can get the front motor mount welded today, I can wire up the rear batteries and do a 60 volt street test!
Tuesday, September 9, 2008
Today is a wasted day because 1)- It's raining and 2)- I am in classes until 9:00 tonight.
Tomorrow I plan on painting the rear rack, buy the materials for the front motor mount, and mount two 12 volt fans to the controller. During my test, it got warm to the touch pulling 25-45 AMPs, so more cooling would be nice.
And on the topic of controllers, my second gen microproccessor controller is in the works with so many nice features. I have an IGBT driver on the way that is compatible with it, and I also am going to order an isolated current sensor. And I have also solve my heat problem in the EV. I have a water cooling system for my IGBT, and I am going to use it on the second gen controller, and route the water through the exsiting heating system. It should be up in the 90-150F range, so plenty of warmth for defrosting the windows. I also am trying to integrate the status display into this edition of the controller.
My hope is that I can build a successful, powerful controller that I could put into production in a few years, after gathering data and abusing it to the best of my ability. My hope is to eventually have a controller that can be programmed for specific motors and battery sizes, as to maximize range and performance.
Monday, September 8, 2008
Friday, September 5, 2008
Thursday, September 4, 2008
As the plates go, I should have the spacer plate cut out and cleaned up tonight! I hope to have the motor and transmission assembled tonight and make the last cut outs for the drive shaft and the engine mounts because the plate covers them at the moment.