Hello all,
I got started with an arduino uno about a year ago, and after a few projects I wanted to try something more challenging. I began designing a motor controller for a 48V, series wound golf cart, and it's turned out to be a bit more challenging than I thought. I've got most of the details sorted out - it's about 90% complete. I wanted a second set of (more experienced eyes) to take a look at it and see what you all thought. My design specs are:
Target = 48V, 400A
Batteries = 6, 8V golf cart batteries wired in series with 4awg wire
Motor = stock 1988 series wound culb car motor
Power side:
Half H bridge
6x IRLB4030PBF (100V, 4.3mOhm) per side, so 12 total (http://www.digikey.com/product-detail/en/IRLB4030PBF/IRLB4030PBF-ND/2096639)
15x Electrolytic bus caps (100V, 680uF, .027Ohm ESR) (http://www.digikey.com/product-detail/en/100ZLJ680M16X40/1189-1047-ND/3133975)
1x L01Z400S05 Current Sensor (http://www.digikey.com/product-search/en?vendor=0&keywords=L01Z400S05)
2x 80-90V TVS Diode of some sort... haven't picked one out yet
15V Zeners on the gates (MOSFET VGD max is 16v)
Control Side:
Arduino Pro Micro will do all the computing
Gate Drive - IR21844PBF (http://www.digikey.com/product-search/en?vendor=0&keywords=IR21844PBF)
Gate resistors to match the max current of the driver - Req = ~12ohm
Linear regulators to get 5V and 15V
The power board will be stacked on top of the control board and individual wires will be run from the power board down to male headers that will plug into the control board. Two massive heatsinks will line each side of the power board and form two sides of the chassis. Vertical buss bars pulled from an old curtis controller will provide attachment for the batteries\motor (see picture below). I've also attached my EAGLE files, PCB will be 4oz copper from myropcb.com
View attachment 2
Any comments\concerns with this design? This is my first attempt, so be nice if I did something stupid
I got started with an arduino uno about a year ago, and after a few projects I wanted to try something more challenging. I began designing a motor controller for a 48V, series wound golf cart, and it's turned out to be a bit more challenging than I thought. I've got most of the details sorted out - it's about 90% complete. I wanted a second set of (more experienced eyes) to take a look at it and see what you all thought. My design specs are:
Target = 48V, 400A
Batteries = 6, 8V golf cart batteries wired in series with 4awg wire
Motor = stock 1988 series wound culb car motor
Power side:
Half H bridge
6x IRLB4030PBF (100V, 4.3mOhm) per side, so 12 total (http://www.digikey.com/product-detail/en/IRLB4030PBF/IRLB4030PBF-ND/2096639)
15x Electrolytic bus caps (100V, 680uF, .027Ohm ESR) (http://www.digikey.com/product-detail/en/100ZLJ680M16X40/1189-1047-ND/3133975)
1x L01Z400S05 Current Sensor (http://www.digikey.com/product-search/en?vendor=0&keywords=L01Z400S05)
2x 80-90V TVS Diode of some sort... haven't picked one out yet
15V Zeners on the gates (MOSFET VGD max is 16v)
Control Side:
Arduino Pro Micro will do all the computing
Gate Drive - IR21844PBF (http://www.digikey.com/product-search/en?vendor=0&keywords=IR21844PBF)
Gate resistors to match the max current of the driver - Req = ~12ohm
Linear regulators to get 5V and 15V
The power board will be stacked on top of the control board and individual wires will be run from the power board down to male headers that will plug into the control board. Two massive heatsinks will line each side of the power board and form two sides of the chassis. Vertical buss bars pulled from an old curtis controller will provide attachment for the batteries\motor (see picture below). I've also attached my EAGLE files, PCB will be 4oz copper from myropcb.com
View attachment 2
Any comments\concerns with this design? This is my first attempt, so be nice if I did something stupid