Hardware


Some prototyping netted 91kw of output from my truck recently. The acceleration was unbelievable. That’s still an 80% improvement. The pack is sagging more than normal right now. So I’m correcting that as of now. I suspect that would be worth a few more kw. Looking forward to 100kw soon as the pack gets updated and the R & D progresses.

The data sheets say the factory igbt’s are rated at 400 amps. Almost there now. If I can keep the pack above 250vdc at 400 amps, then I’ll be at 100kw.

I have had an igbt/hv buss redesign going. Might have to put more priority into that since the factory igbt’s are nearly at their max current rating. Although for maybe only 10-15 seconds at a time, 400 amps may not be a threat to their longevity.

With the A123 prototype modules doing fine, a full pack would have such low impedance that 100kw would be easy to hit. Maybe too easy. Going to build about 12 more A123 modules soon.

I found on the Endless Sphere forum a BMS that matches my needs and philosophy of being simple, but with a processor. Here is the link. He talks about his design as he builds it in other threads. I just don’t see anything since late 2009 on the progress of the design. I’ve emailed him. We’ll see.

Here you can see his prototype layed out. It communicates using infrared leds. That helps get around the EMI issue.

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.

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