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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]Simplify Charge Pump and Depletion Mode FET (U4)

  • Original parts

    • Charge pump switch regulator

      • https://www.

    powerelectronicsnews.com/power-supply-design-tutorial-part-1-2-topologies-and-fundamentals-continued/

    • • digikey.ca/en/products/detail/microchip-technology/tc7662beoa713/418710

    • Depletion mode FET

      • https://www.

    maximintegrated

    • • digikey.

    com

    • • ca/en/

    design

    • • products/

    technical-documents

    • • detail/

    tutorials

    • • ixys/

    2

    • • ixth6n50d2/

    2031.html

• 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?

    • Links

      • https://electronics.stackexchange.com/questions/261711/how-can-i-replace-a-relay-with-a-mosfet-transistor

        • Reverse it?

  • Part Search

    • Need 150V

    • https://www.digikey.ca/en/products/detail/bright-toward-industrial-co-ltd/AA58F/14302559

      • 1700V?

      • 120mA

    • • 2183273

  • New Change

    • Find closed switch to replace the two components

    • Part requirement

      • Normally closed relay

        • Form B (Form C can work)

        • https://forum.digikey.com/t/understanding-form-a-form-b-form-c-contact-configuration/811

      • 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

  • 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

  • Links

    • 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

      • http://www.electricalterminology.com/types-of-relays/

      • https://www.electronicshub.org/classification-of-relays/

    • Solid-state relay

      • https://www.digikey.ca/en/products/detail/panasonic-electric-works/

      AQY414SX

      • AQZ404/

      512420

      • 400V

      • 100mA646386

        • AQZ404

        • 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)

      • https://www.digikey.ca/en/products/detail/panasonic-electric-works/

      AQW210EHAX/512337

      • 350V

      • 120mAAQZ104/646370

        • 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/

      AQV257AX

      • AQZ206G2/

      646155

      • 200V

      • 250mA

  Add Hall Effect Current Sensor [Need Research]

  • • • 9597209

        • 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)

  • 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

        • https://www.

      bristolwatch

      • • mouser.

      com/hall_effect/ac_hall_effect.htm

      • • ca/ProductDetail/Panasonic-Industrial-Devices/AQZ104?qs=wKtUvITRiakdB78b%2F5Uijg%3D%3D

          • Cheaper ($12-16)

          • In stock

          • Current rating may not be enough at 60C

        • https://

      electronics

      • • www.

      stackexchange

      • • mouser.

      com

      • • ca/

      questions

      • • ProductDetail/

      338601/hall

      • • Panasonic-

      effect-sensor-for-current-sensing-in-high-dc-voltage

    Part search

    • Check ratings (Current and voltage)

      • • Industrial-Devices/AQZ206G2?qs=w%2Fv1CP2dgqpfmR1EUJ61AQ%3D%3D

          • More Expensive ($30)

          • Have to wait

          • Enough current rating

        • Note: May not implement if not enough space

      • Q3, use relay (AQZ404) with series resistor

        • https://www.mouser.ca/ProductDetail/Panasonic-Industrial-Devices/AQZ404?qs=Wn4D5qJAqBJmKpb9gy8Awg%3D%3D

        • 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

      • NCP45521IMNTWG-H

        • https://www.digikey.ca/en/products/detail/onsemi/NCP45521IMNTWG-H/5257785?s=N4IgTCBcDaIHIGEAKAWArGsBGAkgWTgBUB1AcQFoAJEAXQF8g

        • https://www.mouser.ca/ProductDetail/onsemi/NCP45521IMNTWG-H?qs=72ObqG5T4UZ6w73ghQANGg%3D%3D

    • Alternative

      • NCP45770IMN24TWG

        • https://www.digikey.ca/en/products/detail/onsemi/

      allegro-microsystems/ACS756SCB-050B-PFF-T/5400760

      • 50A

      • • ncp45770imn24twg/12180092

  • CAN Controller

    • OOS

      • MCP2515T-I/ST

        • https://www.digikey.ca/en/products/detail

      /lem-usa-inc/HO-8-NP-0000/4331974
      • 8A

        • /microchip-technology/MCP2515T-I-ST/593682?s=N4IgTCBcDaILIGEAKYCsBGVAVAtASQHoBlLEAXQF8g

        • https://www.mouser.ca/ProductDetail/Microchip-Technology/MCP2515T-I-ST?qs=uMUszenkLLIwkGYxhCCgRQ%3D%3D

    • Alternative

      • MCP2515-E/P

        • https://www.mouser.ca/ProductDetail/Microchip-Technology/MCP2515-I-P?qs=hklUZQQMghMXVOd4j8inGA%3D%3D

        • Note: Through-hole

  • CAN Reciever

    • OOS

      • TCAN332DR

        • https://www.digikey.ca/en/products/detail

      /tamura/L08P100D15/529421
      • 100A

        • /texas-instruments/TCAN332DR/5823563?s=N4IgTCBcDa4JwDYC0AWAzAdgIxabgcgCIgC6AvkA

        • https://www.mouser.ca/ProductDetail/Texas-Instruments/TCAN332DR?qs=n%252BTO0c4TDSYIUeM9WmVMtA%3D%3D

    • Alternative

      • MCP2551T-I/SN

        • https://www.digikey.ca/en/products/detail

      /tamura/L01Z200S05/529408

      • 200A

  Smaller changes

  • • • • /microchip-technology/MCP2551T-I-SN/509535

  • Optoisolator

    • OOS

      • HCPL-0211-000E

        • https://www.mouser.ca/ProductDetail/Broadcom-Avago/HCPL-0211-000E?qs=xnajaXqBF9%252BJAicV1wntGA%3D%3D

    • Alternative

      • HCPL-0211-500E

        • https://www.mouser.ca/ProductDetail/Broadcom-Avago/HCPL-0211-500E?qs=xnajaXqBF9%2FtZ67k7S1qGw%3D%3D

• 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

Part List

• AQZ404 (Solid State Relay)

  • Replaces Q3

    • Needs to be with series resistor

  • https://www.mouser.ca/ProductDetail/Panasonic-Industrial-Devices/AQZ404?qs=Wn4D5qJAqBJmKpb9gy8Awg%3D%3D

• IC Load Switch

  • NCP45770IMN24TWG

    • https://www.digikey.ca/en/products/detail/onsemi/ncp45770imn24twg/12180092

    • https://www.mouser.ca/ProductDetail/onsemi/NCP45770IMN24TWG?qs=7MVldsJ5UayF2EDms7TgPA%3D%3D

• CAN Controller

  • MCP2515T-I/SO

    • https://www.mouser.ca/ProductDetail/Microchip-Technology-Atmel/MCP2515-I-SO?qs=KwArPi4cUogGDbGnphOvtQ%3D%3D

      • Present in the bay but OOS

• CAN Reciever

  • MCP2551T-I/SN

    • https://www.digikey.ca/en/products/detail/microchip-technology/MCP2551T-I-SN/509535

• Optoisolator

  • HCPL-0211-500E

    • https://www.mouser.ca/ProductDetail/Broadcom-Avago/HCPL-0211-500E?qs=xnajaXqBF9%2FtZ67k7S1qGw%3D%3D

    • Same as HCPL-0211-000E