Joined
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Long Post, you have been warned.....
Some of you might remember this thread and for some back round it might be helpful to look over it briefly:
http://www.diyelectriccar.com/forums/showthread.php/diy-ac-motor-controller-super-size-30075.html
Others no doubt are aware of my own personal issues with the BLDC motor controller for my car which has died a second time roughly 2000 km after I brought it back to life from a mild internal fire last winter. See my build thread for details on that saga......
So far I can't quite figure out what is wrong with it this time and I am beginning to wonder if its worth bothering to fix it a second time even if I could. Options I am exploring right now are to try and replace the logic/driver board with an evaluation board but I am not quite sure which one to use.
The biggest stumbling block is finding one that I am sure can control an external driver since most appear to be intended for powering fractional horsepower inverters and are fully integrated with their own built in power stage - which is naturally way too small to push a 3000lb car up to highway speed. I'm wondering if they could be modified to run an external power stage but I'm not sure if it's worth doing this. Opinions wanted!
Of some of the things I found in the process, this was fairly interesting:
http://www.eefocus.com/设计我最赞/blog/08-09/155607_39e2c.html
The ideas in that link could solve my problem for how to drive my existing IGBTs since I *think* the powerex BG2B-5015 units can run the IGBTs I already have. Some reorganizing inside the controller would be needed to physically fit them though. At roughly $100 each, they aren't cheap but it would get me running again and digikey does carry them.
Problem is I would still need a logic board to control the inverter. They show that too in the link, but they also had to modify an existing MCU developer board a few times before they could settle on something......I'm not sure if I could pull something like that off yet.
This board seems to have most of what I'm after since they claim it can run an external power stage, but finding a source proved challenging:
http://www.fujitsu.com/ca/en/servic...microcontrollers/datalib/devtools/91f267.html
And again, I'm still not sure if other boards that come with low power integrated power stage can be modified to drive an external power stage. Gaps in my knowledge are rather annoying in that area.
I stumbled over these during my research when a link showed up on an ecomodder discussion that google found for me:
http://www.ehitex.de/p_info.php?products_id=544&xID=574668e34207918b45cdf663e9e9cd2b
It's extremely unlikely that I am going to dish out that kind of money at this point but I did find the price to be fairly reasonable considering the 80kw power rating. I have looked over the PDF file here:
http://www.infineon.com/dgdl/AN+Hyb...47094&fileId=db3a30432239cccd01225a7cfb166c8a
and its not exactly plug & play, but all the major hardware is there. Most of the work appears to be in setting up the software to run the motor safely. I have to admire the compact and clean package layout (water cooled).
A smaller 30kw version is available here:
http://www.ehitex.de/p_info.php?products_id=543&xID=574668e34207918b45cdf663e9e9cd2b
The HybridKIT1 and 2 are built on the idea of an integrated single piece 3 phase IGBT power stage, and if you looked more closely in the AC motor thread I posted at the top, Technologic found a similar setup offered by Fuji. It would be nice, but I'm not particularly picky at this point.
Applied Power Systems in the USA does offer an impressive IGBT half and full bridge driver board that is rated for IGBTs up to 1700 amps. Not that I need that much but there seems to be a wide gap in the products I have been able to find with most being under rated for what I need.
http://www.appliedps.com/drivercircuits.htm
No, I haven't called and asked for a price yet, but I probably don't want to know anyway. Besides, that would still be only half the battle and I would still need a motor control logic board.
The general idea I am working on at the moment is to get a basic control setup together that could get the car running again but that could also be reused in the future if I decide to upgrade the power stage.
I haven't quite given up 100% on repairing the current setup, but after the second failure I felt compelled to try putting together a backup.
Some of you might remember this thread and for some back round it might be helpful to look over it briefly:
http://www.diyelectriccar.com/forums/showthread.php/diy-ac-motor-controller-super-size-30075.html
Others no doubt are aware of my own personal issues with the BLDC motor controller for my car which has died a second time roughly 2000 km after I brought it back to life from a mild internal fire last winter. See my build thread for details on that saga......
So far I can't quite figure out what is wrong with it this time and I am beginning to wonder if its worth bothering to fix it a second time even if I could. Options I am exploring right now are to try and replace the logic/driver board with an evaluation board but I am not quite sure which one to use.
The biggest stumbling block is finding one that I am sure can control an external driver since most appear to be intended for powering fractional horsepower inverters and are fully integrated with their own built in power stage - which is naturally way too small to push a 3000lb car up to highway speed. I'm wondering if they could be modified to run an external power stage but I'm not sure if it's worth doing this. Opinions wanted!
Of some of the things I found in the process, this was fairly interesting:
http://www.eefocus.com/设计我最赞/blog/08-09/155607_39e2c.html

The ideas in that link could solve my problem for how to drive my existing IGBTs since I *think* the powerex BG2B-5015 units can run the IGBTs I already have. Some reorganizing inside the controller would be needed to physically fit them though. At roughly $100 each, they aren't cheap but it would get me running again and digikey does carry them.
Problem is I would still need a logic board to control the inverter. They show that too in the link, but they also had to modify an existing MCU developer board a few times before they could settle on something......I'm not sure if I could pull something like that off yet.
This board seems to have most of what I'm after since they claim it can run an external power stage, but finding a source proved challenging:
http://www.fujitsu.com/ca/en/servic...microcontrollers/datalib/devtools/91f267.html
And again, I'm still not sure if other boards that come with low power integrated power stage can be modified to drive an external power stage. Gaps in my knowledge are rather annoying in that area.
I stumbled over these during my research when a link showed up on an ecomodder discussion that google found for me:
http://www.ehitex.de/p_info.php?products_id=544&xID=574668e34207918b45cdf663e9e9cd2b
It's extremely unlikely that I am going to dish out that kind of money at this point but I did find the price to be fairly reasonable considering the 80kw power rating. I have looked over the PDF file here:
http://www.infineon.com/dgdl/AN+Hyb...47094&fileId=db3a30432239cccd01225a7cfb166c8a
and its not exactly plug & play, but all the major hardware is there. Most of the work appears to be in setting up the software to run the motor safely. I have to admire the compact and clean package layout (water cooled).
A smaller 30kw version is available here:
http://www.ehitex.de/p_info.php?products_id=543&xID=574668e34207918b45cdf663e9e9cd2b
The HybridKIT1 and 2 are built on the idea of an integrated single piece 3 phase IGBT power stage, and if you looked more closely in the AC motor thread I posted at the top, Technologic found a similar setup offered by Fuji. It would be nice, but I'm not particularly picky at this point.
Applied Power Systems in the USA does offer an impressive IGBT half and full bridge driver board that is rated for IGBTs up to 1700 amps. Not that I need that much but there seems to be a wide gap in the products I have been able to find with most being under rated for what I need.
http://www.appliedps.com/drivercircuits.htm
No, I haven't called and asked for a price yet, but I probably don't want to know anyway. Besides, that would still be only half the battle and I would still need a motor control logic board.
The general idea I am working on at the moment is to get a basic control setup together that could get the car running again but that could also be reused in the future if I decide to upgrade the power stage.
I haven't quite given up 100% on repairing the current setup, but after the second failure I felt compelled to try putting together a backup.