trialspower2
100 W
- Joined
- Dec 31, 2016
- Messages
- 108
I am in the process of trying to design a speed controller to run a 25kW brushless motor (http://alienpowersystem.com/shop/brushless-motors/120100sw-sensored-outrunner-brushless-motor-50kv-25000w-water-cooled) I have already had a previous attempt which did not go very well, while it did run the motor I had various issues. I therefore went back to the drawing board and did some research. I game across arlo's game changer speed controller on this forum and liked the design. But as the controller has to fit on a bike it needed to be more compact. So I have put together my own version which has a water cooled core.
I have not done the PCB layouts as yet, but it will be a dspic controller with three UCC21520 Ti FET drivers (4A source, 6A sink) with isolated power supplies for the high side rather than a bootstrap. I will be using 36 x IPP110N20N3 88A FET's which have a low gate charge and reverse transfer capacitance. I am looking at switch at a minimum of 100KHz and run upto 100 volts.
The main hub section which bolts onto the zero volts plate to form a hollow section for the water to pass through in the middle
Hub section in place on the zero volts plate
Low size PCB board with 18 FET's, gate leg will hopefully reach to the control PCB which is at the other side of the zero volts plate. The PCB is bolted against the zero volt plate for the FET source.
Phase plates, split into three sections for each phase. These are bolted to the hub using a layer of heat conducting insulation and plastic screws. The FET heatsink (Drain) bolts directly onto these.
View attachment 6
Next we have the high side PCB, this is bolted onto the three phase plates for the FET source. The gate leg is connected to the control PCB via an extra link.
View attachment 5
Next we have the positive plate bolted to the hub again on insulation with plastic screws. The FET drains are bolted onto the rear of this plate.
View attachment 12
Finally we have the capacitor end showing the connection point for the +Volt lead in on the centre plate at the left (between the caps) and the -volt lead to the right hand side of the centre. This PCB connects to the end of the hub (zero volts) and to the Positive plate on spacers.
On the underside of this capacitor PCB I have allowed for 9 x 12 uf polymer capacitors, as I believe these have a very low ESR which might help things? With 50mm high capacitors I think I can fit around 36000uF.
Hopefully I have explained this well and would be interested to hear any comments/ suggestions. I want to try and get things right this time from the start.
Thanks
Danny
I have not done the PCB layouts as yet, but it will be a dspic controller with three UCC21520 Ti FET drivers (4A source, 6A sink) with isolated power supplies for the high side rather than a bootstrap. I will be using 36 x IPP110N20N3 88A FET's which have a low gate charge and reverse transfer capacitance. I am looking at switch at a minimum of 100KHz and run upto 100 volts.
The main hub section which bolts onto the zero volts plate to form a hollow section for the water to pass through in the middle
Hub section in place on the zero volts plate
Low size PCB board with 18 FET's, gate leg will hopefully reach to the control PCB which is at the other side of the zero volts plate. The PCB is bolted against the zero volt plate for the FET source.
Phase plates, split into three sections for each phase. These are bolted to the hub using a layer of heat conducting insulation and plastic screws. The FET heatsink (Drain) bolts directly onto these.
View attachment 6
Next we have the high side PCB, this is bolted onto the three phase plates for the FET source. The gate leg is connected to the control PCB via an extra link.
View attachment 5
Next we have the positive plate bolted to the hub again on insulation with plastic screws. The FET drains are bolted onto the rear of this plate.
View attachment 12
Finally we have the capacitor end showing the connection point for the +Volt lead in on the centre plate at the left (between the caps) and the -volt lead to the right hand side of the centre. This PCB connects to the end of the hub (zero volts) and to the Positive plate on spacers.
On the underside of this capacitor PCB I have allowed for 9 x 12 uf polymer capacitors, as I believe these have a very low ESR which might help things? With 50mm high capacitors I think I can fit around 36000uF.
Hopefully I have explained this well and would be interested to hear any comments/ suggestions. I want to try and get things right this time from the start.
Thanks
Danny