November 2010

Tonight I finally got this system debugged. Turns out it had a bad transformer on phase A. Runs smooth as glass now. I left it outside since it’s so cold here now. This will cold soak the Dolphin and help to test if it’s prone to classic dropouts or not. Cold and humid weather pushes any marginal board right into classic dropout mode. Clunk clunk!

Got another customers board today from Hawaii. It needs the dropout mod and also I’ve been requested to add the 70kw upgrade. Busy weekend.

I have have gathered up all of my individual schematics of the Dolphin system and am drawing them up to make a master schematic.

Since I’ve been hammering away at debugging this east coast system, I built up another system to help me. So now I have another completely assembled system that runs.

I’ve been working like a dog on making an electric vehicle system for a guy on the east coast. It’s been assembled for days. Runs too. But it has this kind of miss to it. Almost like it’s got one bad spark plug wire. It just runs rough. I’ve not seen that kind of problem before with an AC electric vehicle system.

Also have the spot welder nearly assembled. It just needs some finishing. I hope to create a process to spot weld braided flat cable to lithium battery cells. The cable allows flexing without breakage. Mostly for our combat robot buddies. For automotive use it’s not really necessary. But it will be a great process to have under my belt.

After this system gets shipped, I have gathered all of my hand drawn individual schematics, and will create one large schematic for the entire Dolphin main board. I have almost every square inch documented. Just a little remains. But even a mostly completed schematic will be helpful in debugging. I’m still deciding what cad package to use.

Today it was time to get the Dolphin chargers that are not running back into running condition. The first step was to remove all of the bad parts. Most get thrown away, but the T1 transformer gets rewound. Four of them were rewound today.

I’m building a super charger for a customer. It runs cooler and does a much more reliable job at charging the battery pack.

The control board and the fet boards are nearly done. The fet board is probably going to get some modification. There are no gate drive resistors installed. I think this is a bad idea. Also another fellow added ferrite beads to his gate drives and it really quieted the ringing he saw on his scope. I’m not sure about using ferrite beads like he did. I am more inclined to use a diode like the OSMC design has on it. Not sure what the diode does. Fairly sure it’s for shutting off the gate quickly. I need to send a few emails to find out. Once this mod is finished I can then add the 18 fets.

The chassis I have for mounting all of the spot welder hardware is a bit small. So I think the initial power up will be done on a piece of plywood the same footprint as the chassis. That may help me to layout all of the components.