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The Controller
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If automobiles had improved as much as electronics in the past few decades, they would go a million miles per hour, cost only pennies, and last for decades he controller is another pillar of every electric vehicle If one area could take credit for renewed interest in EVs, the controller would be it You can buy a controller, plug it in, and be up and running in no time something earlier EV enthusiasts could only dream about In the future, there will be only be further reductions in size and improvements in efficiency of the motor control electronics While the motor may only benefit from small improvements due to technology changes, future motors may become distributed and located in the wheels themselves Your controller decision follows logically from your initial EV conversion choice: tire-smoker, high-range flyer, or around-town commuter But, unlike the plethora of choices with electric motors, your controller choices are rather simple, and are dictated by the electric motor you use, your desire to make or buy, and the size of your wallet or purse In this chapter you ll learn what the different types of controllers are, how they work, and their advantages and disadvantages Then you ll encounter the best type of controller to choose for your EV conversion today (the type used in 10 s conversion), and the electric motor controller you re likely to be seeing a lot more of in the future
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You can relax now The useful but largely theoretical equations of 6 are behind you Controllers can generate even more equations, but we ll save those for the engineers who are building them The objective here is to give you a brief controller background and introduce you to a working controller for your EV with minimum fuss A controller basically is the brain or computer of an electric car This computer controls or governs the performance of the electric motor The controller integrates the motor speeds and expected battery range/speed through its energy density Coordinating between the controller and the motor can help a car accelerate from 0 to 60 in 6 to 7 seconds (or less), which can determine the range of the car and the top speed The controller controls both manual or automatic drive systems for starting and stopping, going forward or backward, governing the speed, regulating or limiting the torque, and protecting against overloads and faults
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Off-the-shelf sources mentioned in 12 are really the only way to include a controller into your electric vehicle While a switch-based handmade controller is OK, safety is the key Whereas, there are no interlocks or revlimiting features on a switch-based handmade controller For those who do not know, revlimiting a technology inside the controller that regulates the highest speed the vehicle will be allowed to go This basically acts as a rev limiter Also, resistors waste energy A controller from a reputable company that can provide safety and reliability is the number one priority The controller correctly matched to the motor will give it the right voltage The weight of the motor magnets and size of its brushes determine the power and torque You can buy a reliable controller from a number of sources today at a good price
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Controller Overview
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A motor speed controller uses a microprocessor to drive a preamplifier and then power stage amplifier which controls the flow of power from the battery to the motor, with various feedback sensors to monitor the system s operation Red arrows indicate pulse width modulated outputs, green indicates feedback sensors
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Switch Controller
Switch controllers are the oldest type They have been used in EVs for over 100 years, and there are still lots of them in use today Basically, they are a set of big switches that connect the batteries and motor(s) in various series/parallel combinations to get discrete speeds For example, four 12 volt batteries could be connected for 12v, 24v, or 48v to provide slow, medium, and fast motor speeds Switch controllers are cheap, simple, and efficient Their main drawbacks are the stepwise speed control, and minimal feature set You don t generally buy such a controller; instead, you buy standard parts and wire it yourself according to a basic wiring diagram (like an electrician wires a new room in a house)
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