This structure explains how to build your own 100 HP (peak) Motor controller for electric vehicle or motorcycle conversion. It can withstand a voltage of up to 144 v with a peak current of 500 amps. The cost of the component is several hundred dollars, which means you can assemble one yourself and save more than $1000. At 144 v, you can expect a maximum speed of about 75 miles per hour on a car. Look at the whole story you want to read! Welding experience is important. The factory is helpful if you really want to reduce the cost, but the job can be outsourced to the local metal store. You need a control board and etched power board. The power board needs at least 3 ounces of copper. Ebay is a great place to look for cheap copper-clad PCB. For example: you can print the picture from this link and transfer it to a heavy blank PCB in some way, and if you have a stable hand, you can etching it with dremel. The size is 8 \"x 6 \". This link also has G- Code, you can use toetch on the CNC mill, you can also give G- Code for the machine store. Below 2 and 3 are examples of early power boards I made with Dremel. You can get a piece of control board from me, or you can use the schematic below to make the control board in your favorite PCB layout software :~ Tkooistra Here are some pictures of the PCB layer :~ Tkooistra/bottom _ layer_rev2c. Pdf ~ Tkooistra/top_layer_rev2c. Pdf ~ Tkooistra/component _ layer_rev2c. Figure 1 pdfA prefabricated control board. Pictures 7 and 8 are the top and bottom of the Power board, respectively. The 8 solder joints are exactly where vias are added. Once you have these two boards, you can go to the second step. Order these components for the Control Board: order these components for the power section. If you have purchased and drilled these metals on step 2, then do not re-order them. They are also listed here. Everything else is available and you need to program with the motor controller code. You can make your own code, or you can use/modify the following code. You can be a very cheap programmer at atsp168, or you can buy an AVRISP MK2: Download the free AVR Studio development environment: the hex file of the code is here. Use \"coug-unified-16k. Hexadecimal \": Code: Fuse bit expansion level = F8 DC f7. But if you use ponypro, the fuse position is 08 DC f7. If you don\'t want to program yourself then you can buy a pre-programmed one. There are quite a few parts of this process. In short, you need to bolt all the metal parts together and weld 10 mosfet, 10 dry wheel diodes, 16 large electrolytic capacitors and 3 buffer capacitors to the Power board. For more information about all the bloody, see the pictures below and pages 20 to 43 of the compilation help file.
