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From a design standpoint, the important elements in the circuit are The battery voltage Vb The maximum motor current Im to be commutated The turn-off time of SCR1 The voltage rating of SCR1 The values for C1, L1 The value for Lm to minimize the ripple current in the motor armature DIm Motorola still has this product, which is now made by ON Semiconductor (www onsemicom/pub/Collateral/MC33033-FPDF) These are the basics You have a highly modular, very superior solution to the Jones chopper, and you aren t even breathing hard As newer components are introduced, you can take advantage of them just by plugging them into the drive or power stages You can easily change the frequency or even the motor speed control circuitry if it suits your purposes better As for the options, in Figure 7-2 there are two additional circuit boxes: Current limit control RPM feedback control Current limit control monitors motor armature current 1m and feeds a signal back to the shutdown command input on the PWM chip if it goes beyond a preset level The Jones chopper circuit was a popular early electric vehicle controller, even though it was an incomplete circuit Like equivalent circuits of its vintage, it was inexpensive and easy to make (with relatively few components) However, the disadvantages almost outweigh buying off-the-shelf controllers They are relatively unsophisticated Jones Chopper is even potentially dangerous to your series
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The Controller
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DC motor because it has no overcurrent sensing or limiting features; in other words, no recourse or shutdown mechanism if one or both of your SCRs has commutation problems, or other discrete components in the circuit fail outright or drift out of tolerance with temperature and age Now let s move on to more modern solutions, and address the implied question of what can be done to improve the performance of the PWM circuit In other words, can you build your own controller Absolutely But an off-the-shelf controller gets you up and running quickly, and puts your EV conversion on the road with the least fuss That s why you will also find a number of professional conversion shops using them as well
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An Off-the-Shelf Curtis PWM DC Motor Controller
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You can do something today that EV converters of a decade ago could only dream about pick up the telephone and order yourself a brand-new DC motor controller from any one of a number of sources You can have it in your hands a few days later, mount it, hook up your EV s electrical wiring and throttle control to it, and be up and running with virtually a 99 percent chance of everything working the first time Like series DC motors, today s DC controllers are readily available from many sources, they work great, most of them are of the PWM variety, they are easily installed in different vehicles, and the price is right A modern, off-the-shelf PWM DC motor controller is not the ultimate, but it s pretty close to the best current solution More important, it s one that most EV converters will have no trouble in implementing today After you do your first conversion, become the acknowledged genius in your neighborhood; once you know what you really like and don t like, you can get fancy and exotic The DC PWM controller recommended here is from Curtis PMC, a division of Curtis Instruments, Inc of Mt Kisco, New York As with the motors, don t read anything into its appearance here Curtis is only one of a large number of controller manufacturers from the list in 12, and the recommended controller model is only one out of a number they manufacture The Curtis PMC model 1221B-7401 DC motor controller, shown in Figure 7-3, is already very familiar to you Its features include: PWM-type controller MOSFET-based technology Runs at a constant switching frequency of 15 kHz Requires use of an external 5-kilohm throttle potentiometer Automatic motor current limiting Thermal cutback at 75 through 95 degrees C High pedal lockout (prevents accidental startup at full throttle) Intermittent-duty plug braking Overvoltage and undervoltage protection User-accessible adjustments for motor current limit, plug braking current limit, and acceleration Comes in a waterproof heat sink case
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