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--- astra_conv:conversion:controller_box:controller_box [2013/12/30 19:23]
127.0.0.1 external edit
+++ astra_conv:conversion:controller_box:controller_box [2014/05/11 20:27]
richard
@@ Line 1: / Line 1: @@
 {{indexmenu_n>065}}
-====== motor controller box ======
+====== motor controller ======
-The motor controller box came already pre-wired and tested by Marco Lorey. It is mounted into the [[astra_conv:conversion:auxiliary_frame:auxiliary_frame#controller_frame]], so that the controller's radiator is well ventilated.
+===== motor controller box =====
+The motor controller is built into an aluminimum box that came already pre-wired and tested by Marco Lorey. It is mounted into the [[astra_conv:conversion:auxiliary_frame:auxiliary_frame#controller_frame]], so that the controller's heat sink is well ventilated.
 {{:astra_conv:conversion:controller_box:p1090365.jpg?600|}}
@@ Line 11: / Line 13: @@
 {{ :astra_conv:conversion:distribution_boxes:w_controller_box.jpg?330 |}}
-The large black box is the motor controller itself.
+The box at the bottom is the motor controller itself.
-Supply from the traction battery is switched via a small relais that drives the large contactor.
+Supply from the traction battery is switched via a small relay that drives the large contactor.
-The three orange 50mm² gauge wires connect to the motor.
+The three orange 50mm² gauge wires connect to the motor as shown in the next picture.
 {{:astra_conv:conversion:distribution_boxes:w_motor.jpg?320|}}
-Between contactor and controller, there is an ANL type fuse holder that holds the main fuse (equipped on the second photo).
+Between contactor and controller, there is an ANL type fuse holder that holds the main fuse (equipped only on the second photo).
 {{:astra_conv:conversion:controller_box:p1090920.jpg?600|}}
 {{:astra_conv:conversion:controller_box:p1100046.jpg?600|}}
+The controller connects to the accelerator potentiometer (described in the next section) and to position and temperature sensors in the motor.
+A couple of additional control wires go from the motor controller box to the 12V distribution box. Since some of the contacts are on traction grid potential, exchanging signals to and from the 12V grid requires decoupling by relays. Such relays (both located in the 12V distribution box) are e.g. the immobilizer relay or the solid state relay that conveys the signal from the brake pedal switch.
+\\
+===== motor controller setup =====
+The motor controller can be configured via an external hand-held device. This device allows to modify a set of parameters, that widely determine the controller's characteristics.
+At low RPMs, the secondary current (i.e. the current between controller and motor) gets very high even at low primary (traction battery) current. If the controller settings are not carefully optimized, the controller tends to either temporarily go into "current limiting" mode and reduce the power, or to unexpectedly switch off completely.
+The controller manufacturer finally provided  Marco and me with a configuration "optimized for performance" that makes the motor deliver a lot of torque from 0 rpm on (like the datasheet would suggest anyhow) and avoids shutdowns.
+Besides a lot of parameters that control the motor characteristics itself, there is a couple more settings e.g. for setting the characteristics of regenerative braking.
+Three different kinds of "braking" can be distinguished:
+"directional brake" avoids that the motor starts to spin backwards if stopping on a slope
+"neutral brake" provides braking when the accelerator pedal is released
+"foot brake" provides additional braking when the brake pedal is pressed.
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