This is a hopefully 156volt 1000amp DC controller. It's a high side buck converter. 6 isolated supplies. The video shows the pictures of the assembly process.
It's a melexis HB ... By: MPaulHolmes. on 13 May 12, 14:38:25 It's a melexis HB that measures the magnetic field around the bar. I'm going to measure noise possibly? not today because it's mothers day! Oops, I better go out and buy some flowers. haha.
The more the better ... By: MPaulHolmes. on 13 May 12, 14:16:25 The more the better. Ideally I would need 500amp of ripple to do 1000amp continuous. But you just can't do that with electrolytics, so you just pile as many in as you can. haha. This has around 150amp ripple rating or? something. I figured it out, and now I forgot. (just woke up)
that looks a? very ... By: lezbriddon. on 13 May 12, 13:35:55 that looks a? very neat design
nice.
have you ... By: DFCad1. on 13 May 12, 12:43:01 nice.
have you actually observed a noise difference between high and low side transistor placement?
what type is the current sensor? using the busbar as a mV shunt? what? chip do you use to measure the shunt voltage?
How do you know how ... By: Chuechco93. on 13 May 12, 11:32:33 How do you know how many capacitors? you need? Are you just testing it out?
You da man!? By: pooey1911. on 13 May 12, 08:54:50 You da man!?
Another thing you ... By: daveharpe. on 03 Jan 12, 04:19:49 Another thing you can do is put one probe on the signal you want to see and the other on the ground point, and set the channels for the same voltage per division. In "alternate" mode, the scope will show both signals on the screen, and you can see how much noise you can ignore? on the line that has the signal you want to see. Not exact, but it will give you an idea what you really have. You are not likely to be looking at frequencies low enough to use "chop" mode.
There are some ... By: daveharpe. on 02 Jan 12, 06:47:22 There are some things you might be able to do. Most scopes have a 3 prong plug, which can cause a ground loop and give you garbage signals. If yours is like that, put a 3 to 2 adapter, from the hardware store, on the plug, and don't ground the tab? on the plug. Be careful not to float the scope to high voltages and get zapped if you do this. A certain amount of noise is inevitable, and you just have to know it's there. Long wires anywhere make it worse.
It is very ... By: MPaulHolmes. on 02 Jan 12, 02:31:13 It is very oscillating and messy just with both probes on? ground. Is there any way to get an accurate signal?
Oops, I forgot to ... By: MPaulHolmes. on 02 Jan 12, 02:18:50 Oops, I forgot to reply to you. Thank you!!!! I'm going to try what? you suggested!
Thanks Dave!!! I'm ... By: MPaulHolmes. on 02 Jan 12, 02:18:20 Thanks Dave!!! I'm going to check what you? suggested.
I would guess that ... By: daveharpe. on 01 Jan 12, 19:42:01 I would guess that most of that ringing is not real. Scopes being used around high power switching pick up a lot of noise. You can see how much of it is just noise by putting your probe tip on the? same point as your probe ground. I saw this a lot on things I used to work on.
I used to do this ... By: daveharpe. on 01 Jan 12, 19:27:24 I used to do this kind? of stuff, but not at these power levels. I made controllers for small aircraft and bicycles. I had a friend in the bay area who was making bigger controllers for electric cars. No shop now. I wish I could still do this.
This shows how you can calibrate the Melexis current sensor, which can be used for sensing thousands of amps. This will be used in a 1000 amp controller prototype.
I compute the watt hours per mile at 18 mph and 35 mph. At 18 mph, it was 223, and at 35 mph, it was about 250. Hurray! That's better than I thought it would be.
Hmmm, I've never ... By: akai454. on 21 May 11, 03:20:05 Hmmm, I've never really thought of batteries in that way before as a finite amount of energy, I've always thought of it as the battery can supply so much current at a point on it's discharge curve, I've always thought of batteries as variable, like if You leave the battery alone after it discharges and then try to pull some current, it will give some current.
But thinking of it in that way gives it? a finite amount of energy / time, that's more convenient, Thank You. Take Care.
Simply take your ... By: evric2008. on 20 May 11, 22:12:11 Simply take your pack size in WHrs (say 20KWHrs pack ? = 20,000WHrs) and divide it by the 250WHrs/mile and this gives the figure of 80 miles to a flat battery pack or 64mile range taking you pack down to 20%.
You da man!!? By: pooey1911. on 15 May 11, 21:20:22 You da man!!?
Ok, smart, I ... By: akai454. on 15 May 11, 03:40:10 Ok, smart, I understand now, it's the amount of power needed to plow through the air ? resistance at a certain speed.
And yeah, You would be able to calculate an estimated range at any moment.
Keep Kickin' Ass Man.
It's a measurement ... By: MPaulHolmes. on 15 May 11, 03:06:48 It's a measurement of the force it takes to keep the car moving at a given speed. From that you can? figure out what the range will be at any given speed.
Thank you!!!? By: MPaulHolmes. on 15 May 11, 03:05:29 Thank you!!!?
Hmm... What voltage ... By: MPaulHolmes. on 15 May 11, 03:04:59 Hmm... What voltage range is it? 72 to 120? That's weird! ? How heavy is your car?
Yes! I'm going to ... By: MPaulHolmes. on 15 May 11, 03:03:57 Yes! I'm going to find a good area that's flat and figure out the energy usage per mile at every speed. ?
Will you be making ... By: 20RoyalSuperKing. on 14 May 11, 22:31:52 Will you be making a nice? graph with power curves etc, this is getting really interesting. thanks for all the vids.
I need some? advice ... By: waynesb. on 14 May 11, 20:19:14 I need some? advice. My '73 Bug has a 90v pack and Curtis 1221C controller. It doesn't send enough power to the motor to even start on a fairly gentle slope. How do I find my problem, and what instrumentation should I get?
You and your wife ... By: TalksWithDirt. on 14 May 11, 07:42:04 You and your wife are pretty amazing. I? admire your walk.
Yes, I'd love to ... By: akai454. on 14 May 11, 07:40:39 Yes, I'd love to have a rechargeable hybrid, it's good to know these measurements.
You said 250W/Hrs, per mile,? does that mean 250 watts for an hour's worth of driving at that speed? Ok, Thank You, Take Care.
Calibration of the 1000 amp current sensor. I used a Melexis HB sensor, and I wasn't 100% sure the full scale was really 1000 amps. Hurray, it is 1000 amps! Hurray!
hahahahahahaha.? By: MPaulHolmes. on 13 Apr 12, 22:54:42 hahahahahahaha.?
Slow down there,? ... By: neptronix. on 13 Apr 12, 02:06:05 Slow down there,? speedy Gonzales!!
so with e.g. a 220 ... By: Sohave. on 12 May 11, 00:01:02 so with e.g. a 220 ohm pre charge resistor it would be like 0.022 * 5 * 220 = 24 seconds? ?
I have send you an email asking for your recomendations.
It depends on the ... By: MPaulHolmes. on 11 May 11, 16:11:28 It depends on the resistor you are using. You want to wait 0.022? * 5 * resistorValue seconds.
Way cool a 1000A ... By: d3adp001. on 30 Apr 11, 03:18:42 Way cool a 1000A controller, now your talkin, are you going to update the website with it? I sure hpe so. 193HP? controller, heck ya.
nice work. but ... By: preytec. on 29 Apr 11, 12:34:33 nice work. but there is one thing thats missing in these electric cars. when you turn? them on, nothing really happens till you pull off. the enterprise had a cool looking warp core and knight rider had that red light in front bouncing from side to side. i just wish that circuit boards looked cool when they are powered up. maybe if batteries were transparent with mood lighting in them that indicated how much of a charge they had left i'm sure if they looked better more kids would be interested.
AWESOME!
Paul, you ... By: BenjaminNelson. on 28 Apr 11, 22:25:33 AWESOME!
Paul, you need a solid coupler, then you can do burn-outs!
500 amps in my front-wheel? drive car just doesn't look as impressive!
you da? man!!! By: pooey1911. on 27 Apr 11, 18:36:30 you da? man!!!
Awsome! Looking ... By: Sohave. on 27 Apr 11, 10:47:22 Awsome! Looking forward to more info about your new controller. By the way speaking of pre charging how long time should i? give my "old" 500 AMP controller to pre charge?
Go adopt some orphan LOL!
This shows all of the steps of soldering the control board from start to finish. I show how to verify the correct orientation for each of the component types and how to solder to the ground plane.
This describes the process of mounting the control board to the power section of the open source 144v 500amp DC motor controller. It also describes how to attach an aluminum enclosure.
This is the first test of the Open Revolt open source AC controller. The controller was tested on a 230v 1/3 HP 3 phase AC Marathon 3 phase motor. The test was at 60v. Check out www(dot)ecomodder(do t)com(slash)wiki for more information on the project. Ultimately, the goal is to have every part of a DIY electric car to be as cheap and professional as possible.
This is a dramatically improved prototype of a 144v 500amp DC motor controller for an electric car. It is open source, and will soon be available in the form of a kit. It is in the beta testing phase right now. This initial test was done at 72v.
60v 10amp current limit motor controller test. There are now 2 mosfets in parallel. I tested them to see if they were in sync. Actually, while not taping, I zoomed all the way in to about 0.5 micro seconds per division on the oscilloscope and verified that they turn on and off at almost exactly the same time. good!
This is a recent improvement in the software of the motor controller so that the car will start smoothly from 0 rpm. Without this feature, the car would probably start with a jerk. Now the throttle controls PWM duty and current. For example, at 10% throttle, either 10% of maximum current is allowed, or 10% of PWM duty is allowed, whichever is the bigger of the 2.
This is the first test of our homemade 72v 50amp motor controller. This is a baby step toward making a cheap 144v 500amp motor controller so that there can be more freeway capable EV's on the road.
This shows the progress of the development of a 144v 400amp cheap motor controller. This is only the low power section so far. The first version will be used on an e-bike to test it out. Then we will scale things up.
We are on our way back from getting some groceries in our new, home-made electric 1971 Volkswagen Superbeetle. Some dangerous animals are encountered along the way...
In this video, Road Rage makes his response to Street Rage (Road Rage's uncle). Street Rage is Road Rage's chief competitor in the art of Krump Dancing.
Latest comments made on this video:
By: MPaulHolmes. on 13 May 12, 14:38:25
It's a melexis HB that measures the magnetic field around the bar. I'm going to measure noise possibly? not today because it's mothers day! Oops, I better go out and buy some flowers. haha.
By: MPaulHolmes. on 13 May 12, 14:16:25
The more the better. Ideally I would need 500amp of ripple to do 1000amp continuous. But you just can't do that with electrolytics, so you just pile as many in as you can. haha. This has around 150amp ripple rating or? something. I figured it out, and now I forgot. (just woke up)
By: MPaulHolmes. on 13 May 12, 14:13:37
lol?
By: lezbriddon. on 13 May 12, 13:35:55
that looks a? very neat design
By: DFCad1. on 13 May 12, 12:43:01
nice. have you actually observed a noise difference between high and low side transistor placement? what type is the current sensor? using the busbar as a mV shunt? what? chip do you use to measure the shunt voltage?
By: Chuechco93. on 13 May 12, 11:32:33
How do you know how many capacitors? you need? Are you just testing it out?
By: pooey1911. on 13 May 12, 08:54:50
You da man!?