[Arlo]

Very cool I think Im going to try to build one of theses.

[z_power]

What is your opinion on using 24V starter motor with removed armature as resistive/inductive test load? Isolation is rated a bit on low side but keeping it cool in water bucket should let it last longer.
I'm asking because I can't find big enough inductor for low $ but I have a few starters in ~3 kW range with damaged rotors. Don't know about saturation issues, can you give me a word of advice? Would be great to see waveforms at ~150V 500A without "real" motor test stand.

Mike

[valerun]

Originally Posted by z_power

What is your opinion on using 24V starter motor with removed armature as resistive/inductive test load? Isolation is rated a bit on low side but keeping it cool in water bucket should let it last longer.
I'm asking because I can't find big enough inductor for low $ but I have a few starters in ~3 kW range with damaged rotors. Don't know about saturation issues, can you give me a word of advice? Would be great to see waveforms at ~150V 500A without "real" motor test stand.

Mike

Hi Mike - 150V 500A will be tough regardless. With a stationary inductor, there is no back EMF so all the voltage rise will have to be purely resistive. Maybe if you wind a big inductor (see some of my earlier posts in this thread for example of my test inductor) with heating wire (high-resistance nickel-chromium alloys usually) and put into water?...

but IMO you don't need full 'motor' voltage to test your controller design. Voltage spikes on transistors will be mostly determined by I^2 and battery voltage. The only problem you won't catch this way is thermal management on the switch. But if you are using half-bridge and diode is integrated in the package, even this error will be small.

just my 2 cents.

Guys - sorry the controller project got put a bit on hold to focus on perfecting our charger (http://www.diyelectriccar.com/forums...-59210p47.html, http://www.emotorwerks.com/cgi-bin/compkits.pl) and Android EV Dashboard (http://www.emotorwerks.com/emw3/prod...basic-edition/).

Now that this is largely done, will spend a bit more time on this.

Stay tuned.

V

[z_power]

Thanks Val for your answer, I missed the battery/mot amps difference.

How would it affect thermal management if I used two single igbts with one of them as a diode? (a'la your charger setup or jack's first version of power section) With no parallel current trough silicone there shouldn't rather be any problems, am I right?

I keep watching your charger thread too, the amount of knowledge possible to gain from threads like that one is amazing; thank you!

Mike

[valerun]

Originally Posted by z_power

Thanks Val for your answer, I missed the battery/mot amps difference.

How would it affect thermal management if I used two single igbts with one of them as a diode? (a'la your charger setup or jack's first version of power section) With no parallel current trough silicone there shouldn't rather be any problems, am I right?

I keep watching your charger thread too, the amount of knowledge possible to gain from threads like that one is amazing; thank you!

Mike

As long as the freewheeling device and switching device are in the same package, it should give a relatively ok approximation.

[SomeOne9032]

Originally Posted by valerun

Guys - sorry the controller project got put a bit on hold to focus on perfecting our charger (http://www.diyelectriccar.com/forums...-59210p47.html, http://www.emotorwerks.com/cgi-bin/compkits.pl) and Android EV Dashboard (http://www.emotorwerks.com/emw3/prod...basic-edition/).

Now that this is largely done, will spend a bit more time on this.

Stay tuned.

Very interesting project. Do you have any news for it?

I'm looking for cheap controller to DIY EV Drag Bike and this looks very nice

[valerun]

long time for no update. we were keeping busy with the charger and EV Dashboard upgrades (http://www.diyelectriccar.com/forums...-59210p44.html, http://www.diyelectriccar.com/forums...age-82629.html, and http://www.diyelectriccar.com/forums...-63265p13.html)

finally something to show - a couple of properly constructed DIY controllers.

1. DC 1000A. 1200V device and 600V caps so should be good up to ~500VDC battery voltage.

2. BLDC 100A, up to 400V.

Pics attached.

Now trying to understand how much interest in open-source DIY kits around these.

PM or post here with your thoughts.

Thanks,
Valery.

[Duncan]

Hi
I'm running an OpenRevolt at the moment but I expect to want to upgrade at some point so I would be interested in the DC controller - or if there is a more powerful OpenRevolt kit available

[atelierve]

Mr. Valery,
Very interesting and I'm interested in your DIY Controller.
Actually, I'm building my own bms based on diy, next month charger from emw and after the controller (dc motor).

what do you think about sharing some component between controller and charger, ex: arduino, ...?

Gaet

[tylerwatts]

Hi Valerun. Any chance of a higher power BLDC controller? At least 100kVA? And is there a reason you call it BLDC? How programmable would it be and could it be reprogrammed for different AC motor types?
Thanks!