Link to Previous Proposed Changes for Pre-Charge:
Link:
New Suggestions
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[Not Choosing This. Prefer Hall Effect Current Sensor]Remove DC-DC
Remove all isolated 12V connection
Replace with VBAT
Replace HV FET with solid-state relays[May not implement. No big advantages for changes]Q1 and Q2 system to be entirely replaced with solid-state relaysEnd changesOne end from HV_INOther end to pre-chargeiso_latch_out might be removed?
Links
Part SearchNeed 150Vhttps://www.digikey.ca/en/products/detail/bright-toward-industrial-co-ltd/AA58F/143025591700V?120mA
https://www.digikey.ca/en/products/detail/panasonic-electric-works/AQY414SX/512420400V100mA
https://www.digikey.ca/en/products/detail/panasonic-electric-works/AQW210EHAX/512337350V120mAPreferring This One
https://www.digikey.ca/en/products/detail/panasonic-electric-works/AQV257AX/646155200V250mA
Add Hall Effect Current Sensor [Need Research]
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
Part search
Check ratings (Current, voltage, sensitivity)
Current
Voltage
120V?
Sensitivity [Check]
https://www.ti.com/lit/an/slia086a/slia086a.pdf?ts=1647014926239
Part list
https://www.digikey.ca/en/products/detail/allegro-microsystems/ACS756SCB-050B-PFF-T/540076050A
No Stock :/
https://www.digikey.ca/en/products/detail/lem-usa-inc/HO-8-NP-0000/4331974
8A
No Sensitivity
https://www.digikey.ca/en/products/detail/tamura/L08P100D15/529421
100A
No Sensitivity
https://www.digikey.ca/en/products/detail/tamura/L01Z200S05/529408
200A
No Sensitivity
https://www.digikey.ca/en/products/detail/texas-instruments/TMCS1101A1BQDRQ1/14634037
45A
50 mV/A
Use this part?
Smaller changes
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