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Motor controller capacitors are currently charged with a constant voltage source and series resistor. This is always 50% efficient. For a challenger vehicle, it might be better to have a switching circuit (buck topology) to charge with constant current (which would also be faster).
Keep to 12V by removing DC DC inversion
Add hall effect sensor
Make simpler by removing irrelevant portions (e.g. fan control and thermistor may have been exclusive to MOV since shorts less of an issue?)
Research Summary
Switching Circuit [Need Research]
Remove DC-DC
Remove all isolated 12V connection
Replace with VBAT
Replace HV FET with solid-state relays [Need Research]
Q1 and Q2 system to be entirely replaced with solid-state relays
End changes
One end from HV_IN
Other end to pre-charge
iso_latch_out might be removed?
LinksOriginal parts
New Change
Find closed switch to replace the two components
Part requirement
Part Search
Check ratings
- [Need to find parts that can handle 150V]
Support
151.5V + safety factor (x1.5) [227.27V]
0.5A
Ratings at 60C
Controllable
Can close on-demand or
Closes when car close
Part Search
Implementation routes
For lower current parts
Add a series resistor to discharge path for lower current
Drawback
Slower to discharge (0.25s)
For lower voltage parts
Use relay in parallel
Less preferrable
Drawback
Expensive
May not share load equally (reduce one relay lifespan quicker)
Types of relay
Solid-state relay
AQY221R2MY/1964538AQZ404
400V and 0.5A (0.3A at 60C)
Datasheet below
https://www.mouser.ca/ProductDetail/Panasonic-Industrial-Devices/AQZ404?qs=Wn4D5qJAqBJmKpb9gy8Awg%3D%3D (mouser link)
Need lower current part implementation
Form B (Normally closed)
AQZ104
400V and 0.6A (~0.4A at 60C)
https://www.mouser.ca/ProductDetail/Panasonic-Industrial-Devices/AQZ104?qs=wKtUvITRiakdB78b%2F5Uijg%3D%3D (Need to wait till August for parts to ship)
Form A (Normally opened)
https://www.digikey.ca/en/products/detail/panasonic-electric-works/
?
Remove entire middle section with Hall Effect Current Sensor
Must connect to IN+ and IN-
Unsure if AND gate and MOSFETs need to be changed
Part search
- Check ratings (Current and voltage)
AQZ206G2
600V and 1A (~0.6A at 60C)
Datasheet below
https://www.mouser.ca/ProductDetail/Panasonic-Industrial-Devices/AQZ206G2?qs=w%2Fv1CP2dgqpfmR1EUJ61AQ%3D%3D (Need to wait till September for parts to ship)
Form A (Normally opened)
- Check ratings (Current and voltage)
Implementation plans
Existing parts
Remove
Charge pump and corresponding capacitors (C11, C12, C13, U4)
Series Resistor (R19)
Depends on parts
Pull-down resistor (R21)
Zener diode (D8)
Keep
LED and resistor (LED5 + R43)
Schematic
Q1 and Q2, replace with single relay
Cheaper ($12-16)
In stock
Current rating may not be enough at 60C
More Expensive ($30)
Have to wait
Enough current rating
Note: May not implement if not enough space
Q3, use relay (AQZ404) with series resistor
Needs to be done
If approved, should buy early
Pre-charge timing
Using 270 uF Cap MC
300 ohm
500 ohm
Out of stock IC
IC Load Switch
OOS
Alternative
CAN Controller
OOS
MCP2515T-I/ST
Alternative
MCP2515-E/P
CAN Reciever
Removing:
Fan control
Thermistor
- Can we revert back to 1.1 and use that for 2.0?
OOS
/lem-usa-inc/HO-8-NP-0000/4331974?
Revision 1.2 revert?
Optoisolator
Smaller changes (Check with)
Removing:
Fan control
Remove fan connector
Remove entire fan control sheet
Thermistor
Remove thermistor connector
Remove entire thermistor sheet
Add jumpers near AND gate to skip it
Simplify Charge Pump and Depletion Mode FET (U4)
Add Hall Effect Current Sensor [Need Research]
Part List
AQZ404 (Solid State Relay)
Replaces Q3
Needs to be with series resistor
IC Load Switch
CAN Controller
MCP2515T-I/SO
Present in the bay but OOS
CAN Reciever
Optoisolator
HCPL-0211-500E
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