[Coulomb]

Originally Posted by mizlplix

The single largest cost in the construction of an EV is the battery pack.
In both systems, you use the same cell capacity in the pack (which is set by your daily driving needs.) BUT, in the high voltage system, you need additional cells in series to gain that higher system rating, adding significantly to your build cost and car room to put them.

Not true. For the same power, a higher voltage system (AC or DC) uses less current, so you use lower capacity cells, but more of them. Lithium Iron Phosphate cells are basically sold per Ah of one cell, so the cost of the actual cells is the same for low or high voltage.

There are plenty of other costs when you go higher voltage, but cell cost is not one of them.

The other costs include cell interconnects and the labor to install them, BMS cost (if used), fuses are more expensive, you may want to use many more contactors to break up the pack into ELV segments (120 V or less), and above 600 VDC it starts getting hard to find components that withstand the higher voltage for long periods of time. Chargers and DC/DC converters above about 417 V (Elcon / TC Charger and MeanWell) are difficult to find, so you may need two chargers and/or DC/DCs.

There are benefits to the higher voltage of course; thinner cables, smaller cells are easier to fit into awkward spaces, and so on.

[mizlplix]

Have you driven a vehicle with an industrial controller? Have you ever driven a vehicle without torque control? I have, they will make the vehicle move, but they lack the smooth, nice feeling a vehicle duty controller does.

Just be aware that not all AC controllers are suited for vehicles.

Miz

[PStechPaul]

Most modern VFDs seem to have control settings and "hooks" that should allow whatever "feel" you want. Here is the manual for a controller very similar to mine:
http://igor.chudov.com/manuals/GE-Fu...VFD-Manual.pdf
and the exact model I have (which is a 2HP 240V version):
http://www.geindustrial.com/publibra...H-6643|generic

The main control input is essentially a speed control, but there are ways to tune the actual performance using torque boost, torque limiting, and acceleration and deceleration time. You can also program an analog output to read the torque, and you can implement a PID loop which can essentially control the torque from throttle position by setting the frequency (speed) appropriately.

[E30_Dave]

This tine in the right place !

It would be great to see a section on Permanent Magnet Synchronous, BLDC, Axial Flux, and most of all, Hybrid Permanent Magnet motors.