And yet you haven't made something bullet proof. You've just added enough overkill so it won't be the weakest link, nothing else. The lack of self regulation and limitations will probably play out in either of two sceraios:
- Since the controller doesn't have any built in limitation it will just continue to provide current until something else gives in. My guess; the battery pack. Sure, the controller will survive but the 5 digit dollar battery pack will be toast. Horray.
- Batteries are continuously improved and especially racers continue to push the bar. Sooner or later someone's gonna add enough motors and use powerful enough cells for your overkill to be overkilled. BAM goes the controller.
Once more, that's because you went with overkill instead of style. It's "Get a bigger hammer"-approach. The problem with that approach is that sooner or later you'll find a nail that's too tough and that's when your hammer isn't good enough anymore.
No, the power stage isn't the problem (or at least not for the reason you claim). The problem is that Logisystems, like your controller, doesn't handle power limitation in any way. Oh, and their hammer were a lot smaller too...
That's because it's also totally absurd.
A controller for an electrical vehicle MUST have current limitation to protect itself, otherwise it will blow up. So you've thrown more transistors on the problem? Good, that means that it will survive longer by sheer brute force. You might even be able to handle that 4000 pound car thanks to overkill, but will the controller also survive it when the car's fully loaded with stuff in the trunk and is going uphill so the power consumption's multiplied a few times? How about hot days when the sun's shining and the temperature gets so high under the hood that your 400 Amps IGBTs should be derated to, say, 300-350 Amps instead?
Sooner or later you'll manage to stress the transistors more than they can handle and that's why a good controller must protect itself. If your controller is too weak for the task it should behave like this:
And not like this:
We've learned that (or rather, verified that) the hard way on the dyno. Seems you guys skipped that class, eh?