[Tesseract]

The controller enclosure being machined:



Next is the topside view (mostly-assembled, coolant passages not yet milled). We aren't 100% thrilled with the fans but the internal copper heat-spreader for the IGBT module(s) does increase the effectiveness of the heatsink, and the calculated volume of air required to limit the temperature rise of the heatsink to 25C with 1000W dissipated is only 45cfm; those two rinky-dink fans each move 44cfm so with an allowance for backpressure they will technically work fine (and 1000W is pretty much the worst case scenario).




Next is a view of the laminated bus structure made from two pieces of 0.090" thick copper plate and 10mil mylar for insulation. Notice in the lower left hand corner there are two EV200 contactors installed (for a two-module controller - only one will be used for the one-module version). This allows the microcontroller to supervise pre-charging the film capacitor (hidden under the bus plates) as well as protect against hooking up the battery pack backwards, exceeding the allowed input voltage or catching on fire should the output section blow up...




Finally, a close-up of the interface section, showing the industrial ethernet jack (the matching housing for the plug can be installed "in the field" without any special tools), LEDs for power/status and error codes, and sealed barrier strips for 12V power, throttle, contactor interrupt ("E-Stop"), coolant pump, tachometer, etc...




Now I just need to finish designing the new pc boards for this beast...

[ga2500ev]

Impressive!

ga2500ev

[dimitri]

I am drooling on the keyboard as I type this

There is an empty spot in my EV that wants to be filled by this baby

[TheSGC]

Just WOW. Can't wait to see that thing in action. Let us know if you need any 3rd party testing, I bet this thing will be amazing compared to my 96 volt Kelly.

[ClintK]

Very beautiful! You're like the Steve Jobs of motor controllers (meant as a compliment).

[Qer]

Originally Posted by ClintK

Very beautiful! You're like the Steve Jobs of motor controllers (meant as a compliment).

As long as you don't call us the Windows Vista of motor controllers...

[dimitri]

Speaking of calling names ... have you come up with the product name yet? Or shall we call it "new controller" ?

Do we need a name contest? Don't look at me, I suck at creative tasks...

[bblocher]

Very cool! Can't wait to see what all the specs are on it and pricing.
Best of luck guys.

[Qer]

Originally Posted by bblocher

Very cool! Can't wait to see what all the specs are on it and pricing.

Specs so far is 750 Ampere peak and 500 Ampere continuously (provided it's properly cooled) for the "small" one and 1500/1000 for the next step. Voltage is, uh, to quote Tesseract "North of 200 Volt" or however he put it. Not sure if he's finally made up his mind about HOW much north of 200 Volts...

Most stuff is controlled by a microcontroller (some panic stuff is made in hardware just for added safety/reliability) and all user settings will be done through an ordinary browser (yeah, the serial port got scrapped). Price is not decided yet, but expect it to be at Zilla levels rather than Nice Price.

[bblocher]

Originally Posted by Qer

Specs so far is 750 Ampere peak and 500 Ampere continuously (provided it's properly cooled) for the "small" one and 1500/1000 for the next step. Voltage is, uh, to quote Tesseract "North of 200 Volt" or however he put it. Not sure if he's finally made up his mind about HOW much north of 200 Volts...

Most stuff is controlled by a microcontroller (some panic stuff is made in hardware just for added safety/reliability) and all user settings will be done through an ordinary browser (yeah, the serial port got scrapped). Price is not decided yet, but expect it to be at Zilla levels rather than Nice Price.

Nice, I'll have to keep my eye on it then. I have no idea what Zilla pricing used to be or what Nice Price is Either way, keep us posted when all the specs become final and pricing is decided.