AC Controller Survey

AC, DC, amps, volts and kilowatt. It's all discussed in here
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Shirker
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AC Controller Survey

Post by Shirker » Tue, 26 Feb 2013, 00:49

So what AC Controllers are out there? What are you using, what have you seen used? Would you recommend it? DIY, commercial, re-purposed VFDs...

Sure, the AC controller has to match the motor (in my case a Siemens 1PV5315: 300VDC, 400A peak), but with your help, I'd like to collate the knowledge of the forum on this topic to make it easier to research...

Here's what I have so far (hosted at google docs) - please comment, and I'll update it as we go.

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jonescg
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AC Controller Survey

Post by jonescg » Tue, 26 Feb 2013, 01:28

I'll be using the PM150DZ from Rinehart Motion Systems. I haven't tried it out yet, but given the three fastest electric race bikes in the world use Rineharts, I'd guess they're pretty good.
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coulomb
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AC Controller Survey

Post by coulomb » Tue, 26 Feb 2013, 02:40

Shirker wrote: Here's what I have so far (hosted at google docs) - please comment...

You have the Tritium Wavesculptor 200 listed as 75 kVA peak, but it's actually 165 kVA (450 / sqrt(2) * 300 * sqrt(3)).

That's what Weber and I are using in the MX-5, and we hope to get almost 100 kVA electrical from it (assuming sag and losses to 2.5 VPC), so maybe 75 kW mechanical. However, in the 720 V configuration with the 900 V version of this controller, we hope to get closer to 100 kW mechanical, but it depends on the current rating of the higher voltage IGBTs, thermal modelling, and so on.

The original design was for just over 100 kW mechanical, but we've since lost 10 cells of 218, or 4.6%, and it might jut be enough to put us under the psychologically important 100 kW mechanical figure.
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Stiive
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AC Controller Survey

Post by Stiive » Tue, 26 Feb 2013, 14:31

Shirker wrote: So what AC Controllers are out there? What are you using, what have you seen used? Would you recommend it? DIY, commercial, re-purposed VFDs...

Sure, the AC controller has to match the motor (in my case a Siemens 1PV5315: 300VDC, 400A peak), but with your help, I'd like to collate the knowledge of the forum on this topic to make it easier to research...

Here's what I have so far (hosted at google docs) - please comment, and I'll update it as we go.


Lol, I see mine is listed there Image ... I'll put some details in for you, and add in details of V2.0 which is currently being developed
Rgds,
Stiive

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AC Controller Survey

Post by Stiive » Tue, 26 Feb 2013, 14:57

Ah, non editable. Here's the details of the current version

Electronic
Cont. Power (kVA): ? Dyno testing TBA
Peak Power (kVA): ~200kVA
Min Voltage (VDC): Programmable (50V?)
Max Voltage (VDC): 450VDC
Cont. Current (A rms): ? Dyno testing TBA
Max Current (A rms): ~400A RMS
Features
Control: True torque control or speed PID loop
Algorithm: DTC (FOC addition planned)
CANbus: Yes
Regen: Yes
Programmability: Planned open source
Physical
IP rating: ? (custom casing)
Weight (kg): ~10kg depending on casing
Cooling: Air / Liquid
Size:
Commercial
Documentation: TBA
Support: TBA
Price ($AU): About $1,500-$2,000 in parts


And here's V2.0 in the making. You don't have to add it in though :)

Electronic
Cont. Power (kVA): ?
Peak Power (kVA): ~350kVA
Min Voltage (VDC): Programmable
Max Voltage (VDC): 450VDC (alt ~700VDC)
Cont. Current (A rms): ? Testing TBA
Max Current (A rms): ~650A RMS+ (alt 400A RMS)
Features
Control: True torque control or speed PID loop
Algorithm: DTC
CANbus: Yes
Regen: Yes
Programmability: Planned open source
Physical
IP rating: IP65
Weight (kg): ~10kg
Cooling: Liquid
Size: 290mm*215mm*125mm
Commercial
Documentation: Yes
Support: Yes
Price ($AU): TBA
ETA: July 2013


Need my coupling to the Siemens 1PV5 motor to test V1.0 to the limits on the dyno.
Didn't you buy a DMOC shirker?
Rgds,
Stiive

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AC Controller Survey

Post by Stiive » Tue, 26 Feb 2013, 15:04

Also, the Tritium's use FOC and word from James is the WS200 could be capable of 400A RMS peak with 'extensive testing' - But best to assume is 300A for the moment.

A 400ARMS WS200 would suit the Siemens motor perfectly and get the full 100kW out of it.
Rgds,
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Shirker
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AC Controller Survey

Post by Shirker » Tue, 26 Feb 2013, 15:58

Thanks guys - incorporated all your input.

Also added links to build pages, would be good to get some more examples.

jonescg: The Rinehart PM-series is a bit mysterious - did you go factory-direct, or through a distributor? I can't find a datasheet for details... (I've listed the PM150DX instead of DZ, since it's specs are in a similar range to the others)

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jonescg
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Post by jonescg » Tue, 26 Feb 2013, 20:28

I will email you one when I get home, Matt. I got it from the factory. Sutho is able to supply them here in Oz. 700 V baby!
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Stiive
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Post by Stiive » Tue, 26 Feb 2013, 20:32

Ah sorry Matt, didn't realise it was you.
Forgot your AEVA forum name
Rgds,
Stiive

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AC Controller Survey

Post by Stiive » Tue, 26 Feb 2013, 21:20

Oh and BTW, some people seem to have the DMOC working quite well.

Check out this guys channel
http://www.youtube.com/user/wolftronixa ... ture=watch
Rgds,
Stiive

Shirker
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AC Controller Survey

Post by Shirker » Tue, 26 Feb 2013, 23:39

Stiive wrote:
Didn't you buy a DMOC shirker?

Not me - once it was clear there's no means to update its firmware, I couldn't see the point!
Stiive wrote:
some people seem to have the DMOC working quite well.

Yes. There seem to be two groups who have managed to spit out the couple of CAN messages it requires (Rickard's eventual delivery of a CANbus log helped a bit!)... Certainly generated A lot of celebration in EVTV-land, together with lots of catchpraises like "stallions" and "object oriented" Image

And much humour ensues as successive praise receivers eventually disappoint and get their Rickard-slam published globally!

What I'm still keen on is the BorgWarner eGearDrive... But I digress...

Where are all our VFD fans? What does it take to get a COTS VFD to drive a car?

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