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...
New controller prototype
Hybrid Mode
