Project-X: Electric go-kart with MOSFET-power unit (approx. 50V, 12.5kW) - Page 1
Forum section: electronics / projects

author: MiHu_CH
author_rank: Newbie
timestamp: April 29, 2014, 06:15:28 pm
content: Hi allAbout 15 years ago, I have finished my EE-studies at ETH (http://www.ee.ethz.ch/en/home.html).I am currently working as a consultant/software-developer for my own small company in Zürich (Switzerland/Europe).EEVblog has inspired me to start "tinkering" with electronics again... at least as a hobbyistRecently I have developed the electronics and control-software for an electric go kart (see picture).Most of the mechanical stuff and soldering has been done by a team of 4 teenagers. At least two of them will (should) become engineers in the futureIf you are interested, I may publish some more info about this hobby project.Regards,Michael

author: SeanB
author_rank: Super Contributor
timestamp: April 29, 2014, 06:35:30 pm
content: Definitely more info. I think that the power board you have developed might find use elsewhere.At the very least Dave could make a high power C5 when he eventually gets around to it.

author: MiHu_CH
author_rank: Newbie
timestamp: April 29, 2014, 06:47:41 pm
content: -Perm-magnet DC-Motor "Mars-ME1004" (approx. 6.4kW nominal, 16kW-peak power)-Batteries: 4x AGM "Long WP-50" in series, total: 50V (AGM-batteries are heavy, but "cheap")-Electronics:--Power-Unit:---8x PSMN3R3-80PS MOSFET---8x STTH6002CW diodes--Control Board:---CPU: atmega328---Numeric PID-controller (500x/sec)---Digital filtering of ADC-values---PWM-frequency: 16kHz---No OS (CPU-interrupt programming)---SW for comm. with PC ("Telemetry") and display-module---SW for data-logging on SDHC-memory card--Display unit (software not finished yet):---CPU: atXmega128a3u---Bluetooth-module---Color display (300x160 px)--Tools:---PCB-design: Eagle PCB V5---Analog-sim: LTSpice IV---SW-dev (Controller/ Display-Board): Atmel Studio V6.1---SW-dev (PC): MS Visual Studio 2010

author: MiHu_CH
author_rank: Newbie
timestamp: April 29, 2014, 07:13:34 pm
content: I have designed a simple PCB (approx. 100x100mm) that can be usedto construct reliable halfbridge-circuitswith-MOSFET/diodeor-MOSFET/MOSFET...configs.The PCB has (non-standard) 4oz-copper layers for high current capabilty, which is more expensive to produce that the regular 1oz types.If somebody needs such PCBs for his/her project:I may sell some of these boards for 15 USD/piece (+shipping).

author: calexanian
author_rank: Super Contributor
timestamp: April 29, 2014, 07:54:42 pm
content: That looks fun!!!

author: MiHu_CH
author_rank: Newbie
timestamp: April 29, 2014, 07:55:43 pm
content: LoRes-video of the first successful test-drive... with (software-)limited output-power of approx. 8kW.During the summer holidays (july/aug. 2014) we will do some additional measurements and test-runswith 12.5 to 16kW.---P.S.:The AGM-batteries are are very heavy... (approx. 50kg in total), which is not optimal for acceleation.... But the drive-performance is still better and more "fun" than with a standard go-kart.But sure: This is not a race-kart

author: MiHu_CH
author_rank: Newbie
timestamp: April 29, 2014, 08:24:16 pm
content: This is a picture of an early version (2013) of the PWM/control-board, which has been used to write the firmware (atmega328).The current PCB is very similar (but just a little smaller to fit into an aluminum case).PCB-design software: "Eagle V5"PCB-production:www.seeedstudio.com(for all standard PCB with 1oz copper layers)