Gav's EV Conversion 13 - The Control Panel

[stonerace19]

Great lipstick trick Gav. I've actually done the same thing in the past using other things.

[mszmarcin]

name of song?

[spokehedz]

4:30 - Yeesh... Get the dang power cable out of your work area. XD

[greenboy623]

My g-d mate, that motor rev sounds beautiful!

[TommeyLeeReed]

Save money, and build your own high power speed controller!

[kc7ekk]

I am building my own controller right now. How did you solve the problem when your power IGBTs/MOSFETS go south and you are stuck with a full on transistor(s) that has no intention of obeying the control of the PWM circuit? What kind of emergency stop circuit do you use?

[TommeyLeeReed]

The best way is to read the ground and m- with a comparator, this can read when the mosfet/ibgt are open all the way when the volts go from 144v to 0v, 0v is when motor is fully on. The compartor shut off main power relay. This works very well!

[lazzer408]

I understand what your saying but I think he might need a bit more info then that.

[goku1940]

How far WILL you travel with this car once finished?

[flatpicker1234]

Do you have any place I can go to and get the wiring Doc's or Does that come with the control panel ? Do you have a list of parts used and suppliers ?

[cant7think7clearly]

I took it up the road and back three times (about 3km) with the controller only getting warm. 3km is our average drive distance here too so I'm not too worried in this instance. The next EV I create will probably be a longer distance driver so I'll go the extra mile for that one with heatsinks galore.

[evrimv]

I mean Aluminium plate will not be sufficient for discharge of heat. Sorry about order like writing. Space is very limited so, i cut a lot.

[evrimv]

Very good work. Aluminium plate will be sufficient. I used a 300A unit. Used a 3cm finned open air full heatsink with thermal paste and I can still cook egg on it after half-hour use at 150-200A.

Use a finned heatsink as large as controller and apply thermal paste. Fasten it so face some sweet air flow. Add a thermometer and extra manual fan if it needs. Otherwise If average is over 100A I bet you face an over-heat shut-off during your trip. Feel free to contact me if you like.

Good luck...

[cant7think7clearly]

Thanks guys! I never even thought of using grease. That will save me the embarrassment of buying cheap lipstick again. Good thinking! :)

The High pedal lockout is apparently built into the controller so we were worrying for nothing!

Good for you Gregishere, I hope you get a donor car soon! The price of gas is getting crazy now!

Annnnd the next video is being uploaded as I type this!! :)

[gregishere3]

Great videos mate! Keep them coming! I hope to do a little electric car for the run to the towns and back in a few years time.

[EricsGarage101]

Hi Gav.Just wondering how did you make out with the high pedal lock out problem?? and how is your next video comming alone? cant wait too see it :P

[jmaros15]

Great Stuff, fantastic progress its really come a long way the dream looks to becoming more of a reality for ya each time i tune in. Looking very much forward to seeing the next video.

PS, Lipstick? dude! (shoe polish, cryon, gasket goo, greece, paint) even mud. But purchase lipstick? No way i could do that! LOL :) Good luck and go the Wallabies :)

[cant7think7clearly]

Thanks mate! I hope you get a donor car and have a go with your own EV too! :)

(And hats off to Altavista's "Babelfish" site which allowed me to translate the comment!)

[JanoYago]

Que Bueeno! De verdad que tu proyecto me inspira mucho! Soy de Costa Rica un pequeño país de centroamerica donde la electricidad es muy barata (gracias a las cuencas hidrográficas).

Yo quiero convertir mi auto tambien! Por donde comenzar?

Adelante con el proyecto! Quiero ver tu automobil en movimiento!

[blastergti]

=D Nice work! Keep it up!

I can´t wait for the next vid!

[Berkut13]

Gav, I love what you are doing...BUT...dude, you soooo need to spend a few bucks on a proper wire crimping tool. I've built an airplane and the proper tools can make all the difference! Best of luck and I can't wait ot see this thing drive around!

[cant7think7clearly]

Roger that, I'll try find a proper crimper and re-crimp those mini lugs. As for the huge main cable, I'm having someone do that for me :)

[1foxtrot70]

Gav - I am NOT offended. As I have said in email to you, "Cu-dos and Hats Off To You!"

[DeLorean4]

I'm building an electric bicycle, and although everything is at a much smaller scale than your EV project, the feeling you get when you fire up economical and ecologically friendly transportation for the first time is absolutely amazing. At 3:45, I admire you for your courage, and if there were such a nomination, I'd vote you, YouTube eco-hero of 2007-2008. Keep it up.

[soggynoggin]

aluminium, har hardy har har we say it different in the states, i love the project great work!

[cant7think7clearly]

Sure thing mate! There'll be a huge re-cap at the end of the series going over all the little things like the vacuum pump in action, flashing recharging light, turbo timer etc etc etc.

Still have a bit to do yet, once the batteries are in it'll be time to build my sealed rear battery box. It never ends... :)

[CzechEVclub]

Hi Gav, another great episode! Now, would it be possible in the end of the series to return to some of the earlier briefly mentioned details, like the flashing "low on fuel light" on the dashboard signaling charging mode etc..? I gather this has been already incorporated into the dashboard without camera recording it so at least some comments or diagram would be great..

[willberg1]

Thinking here... Most controllers will hold the voltage back until it gets a Zero or No Signal from the TPS Throttle Position Sensor which in turn is your safety. Look into the manual of the controller for your mains going to motor.

[cant7think7clearly]

Yeah, I checked that out. Rob was wasting his time trying to figure out the high-pedal disable out on paper, it's all built into the controller.

[en3rgy187]

I've seen all your posted video's Gav. Anther nice bit you've got here except I found the soundtrack to slightly detract from the video. The voice(s) singing I believe was the problem. Either way, just an observation. Thank you so much for posting your video's and keep 'em coming!

[cant7think7clearly]

You're right about the music, I've got no more music in my collection without vocals so it's starting to scrape the barrel a bit! I might borrow some other CD's for the next videos. :)

[Ratergray]

Aluminium. Sometimes it's nice listening to fellow kiwis.

[cant7think7clearly]

Hehehe, too true. Youtube's a big scary place for us little Kiwis.

(And I hope I didn't offend all my American viewers by calling them yanks in the video! No offense intended)

[MSIL2]

Nah, your cool. =)

[coreymon77]

sweet!

[waynebw]

Nice stuff... this is getting very exciting Gav, I'm really looking forward to the batteries going in now! :)

[randycarter2001]

I sure hope you didn't bolt that shunt directly to wood. Wood is not a perfect insulator. It absorbs moisture from any source like humidity, rain, car washes, lawn sprinklers and puddles. Wood burns, when it absorbs moisture it conducts more thus creating a current path that will cause heat to be generated, next thing you know fire. All parts of the high voltage system should only be touching plastic even the return path (the negative side of the battery pack).

[cant7think7clearly]

Ah ok. In that case I'll insulate it with some plastic panel I have. Cheers for that!

[RoadRunnerLaser]

Don't forget to ensure that the shunt's bolts are insulated too...

Excellent idea to use lipstick to mark the location to make your holes.

Keep going, Gav... Nearly there.

[IQchallenged]

Great series, its really good of you to take the time to show others the ins and outs of installing an electric conversion. Also loved the use of lipstick to mark the drill locations.

[cant7think7clearly]

Hehehe, thanks mate. Believe me, buying the lipstick was the hardest part.

:)

[brianempson]

Make sure you post lots of videos of you driving it once it's done!

[caa1000]

With oil prices on the rise, we should all give credit to cant7 for this wonderful work! Keep it up cant7!

[cant7think7clearly]

Hey thanks folks! Sorry about the video going all weird at 6:10. On the bright side, I finally got Rob to have a speaking role in the video. Hehehe :)

And he'll read this too. In which case, Rob, clean up your living room, it's a mess. :)

[Rufe0]

The controller will get hot even on short trips

[graphicsguy948]

Nicely done! That control box is really slick! I wish I had the funds for my own project :( ...

[wiccabuddha]

sir, i have discovered your journey through research on alternative energy and i have to say i am very impressed. i wish you and yours the best of luck in your project and i wait anxiously for your dream to become a road worthy reality.

[GharedGhared]

Looks great!

[hobbes32]

The Tredia is looking good! Looking forward to seeing it driving.

[meilzonwheelz]

Great Video, Can't wait to see this thing running!