Ev Projects

23 Mar 2015 | Author: | Comments Off on Ev Projects
Hyundai Excel

Revised BatPack EV Power Controller.

Overall schematic of the BatPack EV power controller.

Bryan Foster has persuaded me to revisit the BatPack controller. There have been great strides in the cost and performance of power MOSFETs in the years since I made my first controller. Bryan wants me to redo the cost calculations and further describe the operation of the circuits.

I will keep my old page as the second half of this page so one can see how I got to this stage in the design.

Back in the summer of 1997 or so it didn’t seem to us, Virgil Vinz and me, there was not a lot of interest in high power EV controllers. Apart from my Hyundai, his Avenger kit car, and an electric lawn tractor we didn’t pursue this much further.

We determined a patent for the basic concept couldn’t be obtained as there was prior art in the form of a mechanical switch patented in about 1969 that operated in the same way. OK, there were elements that could have been patented such as:

1. Even discharge of BatPacks with differing capacities.

2. Intermingling BatPacks of differing voltages, battery types, and capacities.

3. Dynamic regenerative breaking.

4. Even charging methods by modulating the bypass switches.

We still couldn’t justify a patent for these things as the costs for defending the patent, at least $250,000us would make no sense in the absence of sizable sales. So we just didn’t do it.

Anyway, we went to other pursuits. Solar trackers for me and building CNC machine tools for Virgil. This was probably a good choice for both of us.

Hyundai Excel

The advantages of the BatPack controller are still relevant today. The cost of MOSFETs in this power class has come down drastically. The BatPack advantage where lower breakdown MOSFETs were much cheaper than high voltage types has been largely negated, although still somewhat true.

However, the other advantages are still valid.

The second schematic shows the simple addition to drive a 3 phase motor. calculationsnew

Let’s do some Calculations.

I will use the 125 volt controller as a reference and calculate both a 250 Volt switcher and a 250 Volt BatPack. I will be using generalities in these calculation. I think they are close to reality.

If in the future there are improvements in the cost and performance of MOSFETs the equations could be adjusted for those conditions.

One of the most important requirements when selecting transistors for power controllers. Is the total current carrying capacity. The current carrying capacity of a transistor is primarily inversely proportional to the on resistance.

There is a secondary limiting factor caused by the current carrying capacity of the internal conductors of the transistors.

Comparison of Transistor Relative Characteristics, Quantities, and Costs.

Assuming a rating of 250A for a 125V and 500A for a 250V controller.

Hyundai Excel
Hyundai Excel
Hyundai Excel

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