Blog
I created this page with a dual purpose, one of which was to remind me what my day to day duties consist of as a
hardware manufacturer. The other was to give a glimpse to the viewer what's going on here as well. I hope to update it
at least weekly.
hardware manufacturer. The other was to give a glimpse to the viewer what's going on here as well. I hope to update it
at least weekly.
| Where's the rest of the blog? Right here |
Thoughts? Ideas? email me here
| Click refresh to be sure you're getting the latest scoop |
12/15 The next charger tests didn't fare as well, primarily due to diode recovery noise affecting the PFC max current
level. It seems that the diode parameter variation is wider (probably since there is no max spec, only typical) so the
mfgr has no maximum limit to call parts 'bad'. By not specifying a max spec, most parts can ship, aside from those that
don't meet voltage limits. For boost applications, there are a few parameters that matter most, but max values are
often avoided on the spec, hence the push for new technologies as silicon carbide. But there, the cost goes up 5x for
the benefits. So the designer typically has to add more filtering just to accommodate part variations. Back to work!
level. It seems that the diode parameter variation is wider (probably since there is no max spec, only typical) so the
mfgr has no maximum limit to call parts 'bad'. By not specifying a max spec, most parts can ship, aside from those that
don't meet voltage limits. For boost applications, there are a few parameters that matter most, but max values are
often avoided on the spec, hence the push for new technologies as silicon carbide. But there, the cost goes up 5x for
the benefits. So the designer typically has to add more filtering just to accommodate part variations. Back to work!
12/21 With another 800A system packed up and ready to ship out, the balance of outstanding charger hardware is
nearing completion. Some SiC diodes will be on order to see just how well they will do in the PFC section. Since the
focus will be on getting more 240VAC power out of the charger, the quieter things are to begin with, the better. The
concept is to get 2.4kW/charger section with the dual PFC input configuration. That would equate to 4.8kW on the
240VAC input side! With that much power, internal cooling will have to be upgraded to handle it, so more investigation
will be needed there as well. Opening up the case to be aircooled invites all sorts of stuff coming inside. Back to work!
nearing completion. Some SiC diodes will be on order to see just how well they will do in the PFC section. Since the
focus will be on getting more 240VAC power out of the charger, the quieter things are to begin with, the better. The
concept is to get 2.4kW/charger section with the dual PFC input configuration. That would equate to 4.8kW on the
240VAC input side! With that much power, internal cooling will have to be upgraded to handle it, so more investigation
will be needed there as well. Opening up the case to be aircooled invites all sorts of stuff coming inside. Back to work!
12/29 Testing the PFC section with the new SiC diode looks promising. Much less diode recovery noise and it should
be quieter from the AC line standpoint. Updating some old web pages and the WarP motor pricing page as well. Have
some boards to fab this week with some component changes. I really don't like the TO-220 packages, and switching to
a bridge rectifier in the isolated package will eliminate the case to heatsink isolation barrier. Other than that, hope you
all had a Merry Christmas, hopefully the coming new year will be more rewarding than this one. Back to work!
be quieter from the AC line standpoint. Updating some old web pages and the WarP motor pricing page as well. Have
some boards to fab this week with some component changes. I really don't like the TO-220 packages, and switching to
a bridge rectifier in the isolated package will eliminate the case to heatsink isolation barrier. Other than that, hope you
all had a Merry Christmas, hopefully the coming new year will be more rewarding than this one. Back to work!
1/6/10 Started off the New Year on the slow side of things, getting caught up on internal blogs (keeping a track record
of where things are at with individual PCB designs and system assemblies) along with a few equipment purchases and
a few repairs to do (power supplies occasionally get reversed...) and thinking on the looming new paperless sales tax
forms (online) which is fun having dialup. With 2 PCB revisions to finish up and 3 2.4kW chargers to finish up and a
Flooded PbA system to build, I've got some things to get finished up this month. Hope you all had a safe entry into the
New Year! For me, I've got to get back to work!
of where things are at with individual PCB designs and system assemblies) along with a few equipment purchases and
a few repairs to do (power supplies occasionally get reversed...) and thinking on the looming new paperless sales tax
forms (online) which is fun having dialup. With 2 PCB revisions to finish up and 3 2.4kW chargers to finish up and a
Flooded PbA system to build, I've got some things to get finished up this month. Hope you all had a safe entry into the
New Year! For me, I've got to get back to work!
1/12/10 Modified the output rectifier PCB to accommodate a full wave bridge (built in heatsink) to get rid of TO-220
packages. They're prone to cutting through the heatpad (noted during the assembly process) and with one left to
contend with, it should make things much more reliable isolation wise. Also modified the PFC PCB to eliminate extra
circuitry no longer needed, and created a high power output rectifier stage for an upcoming power increase on the
dual PFC charger hardware. Still pushing the remaining build forward, intend to incorporate some changes into
chargers presently in the queue. Need to locate a better clamping mechanism (aside from the screw / bushing) on the
remaining TO-220 package. Back to work!
packages. They're prone to cutting through the heatpad (noted during the assembly process) and with one left to
contend with, it should make things much more reliable isolation wise. Also modified the PFC PCB to eliminate extra
circuitry no longer needed, and created a high power output rectifier stage for an upcoming power increase on the
dual PFC charger hardware. Still pushing the remaining build forward, intend to incorporate some changes into
chargers presently in the queue. Need to locate a better clamping mechanism (aside from the screw / bushing) on the
remaining TO-220 package. Back to work!
1/21/10 Just realized my last web update crash resulted in my blog entry being lost. Now trying to remember what I
wrote about...Well the last few days were a battle to stay energized. We lost power for a few hours, then yesterday and
part of today for 26 hours. Fortunately I had 144V at 155Ah on reserve for the dyno, used around 100Ah for the
furnace, fridge, some lighting and TV/internet use. Now that the power pole down the street was replaced, its nice to
be 'online' power-wise. I have yet to build a well pump power supply, which is now added to the list. Tried to run it at
30Hz and 120VAC, but it didn't do much. It wants MORE POWER! I also have an upcoming opportunity to use some
lab space here for work coming in from my former employer, so it will be nice to refill the bank tank. Sure would like to
get a set of LiFePO4's for the Scirocco someday and dump the lead-sled approach and see how it runs on less
weight. Projects are moving along, I'm noticing minimum qty's for things like wire are 2x higher this year. I hate when
that happens, what I could have ordered last year is now 2x more this year (don't need 2x qty) so it makes things a
little tighter than I would like. Factory stock seem to be on the decline, likely due to stagnant inventory. I sure hope
things get moving industry-wise, or its going to end up like the banking industry. Had an interesting issue with the
DC-DC that was due to a large amp controller with a small bus capacitance. It was blowing a power trace on the PCB
just before the bulk cap, likely due to the DC-DC cap being 50X larger than the controller's bulk cap! A series inductor
fixed it, and its noted on the web for the DC-DC converter. The changes made to the charger have been operational
for 2 units, so its looking good thus far. Its getting time for - more power. I've had 1 complaint due to the website, text
and pics are overlapping. If there are others having this issue, let me know. I need more ammo for Sitebuilder
feedback. Back to work!
wrote about...Well the last few days were a battle to stay energized. We lost power for a few hours, then yesterday and
part of today for 26 hours. Fortunately I had 144V at 155Ah on reserve for the dyno, used around 100Ah for the
furnace, fridge, some lighting and TV/internet use. Now that the power pole down the street was replaced, its nice to
be 'online' power-wise. I have yet to build a well pump power supply, which is now added to the list. Tried to run it at
30Hz and 120VAC, but it didn't do much. It wants MORE POWER! I also have an upcoming opportunity to use some
lab space here for work coming in from my former employer, so it will be nice to refill the bank tank. Sure would like to
get a set of LiFePO4's for the Scirocco someday and dump the lead-sled approach and see how it runs on less
weight. Projects are moving along, I'm noticing minimum qty's for things like wire are 2x higher this year. I hate when
that happens, what I could have ordered last year is now 2x more this year (don't need 2x qty) so it makes things a
little tighter than I would like. Factory stock seem to be on the decline, likely due to stagnant inventory. I sure hope
things get moving industry-wise, or its going to end up like the banking industry. Had an interesting issue with the
DC-DC that was due to a large amp controller with a small bus capacitance. It was blowing a power trace on the PCB
just before the bulk cap, likely due to the DC-DC cap being 50X larger than the controller's bulk cap! A series inductor
fixed it, and its noted on the web for the DC-DC converter. The changes made to the charger have been operational
for 2 units, so its looking good thus far. Its getting time for - more power. I've had 1 complaint due to the website, text
and pics are overlapping. If there are others having this issue, let me know. I need more ammo for Sitebuilder
feedback. Back to work!
1/28/10 With power restored and stable, the sun finally breaking through the clouds to help dry out, things have been
getting back to normal. Builds are progressing along, with PFC boards made to use the smaller SiC diode package. A
few charger G2 upgrades have been performed, slowing progress a bit. Not too much to report since some of the time
slot for build labor was consumed due to weather related issues, and finalizing sales tax spreadsheets. Getting part
quotes for new builds is getting crazy. One vendor quoted 1k piece quantity pricing, which costs far too much to
accommodate financially. There is a slow pinching effect between high cost-low volume, or higher volume and the
accompanying higher cost for that quantity. It would be a different story if the economy was blazing along and sales on
the rise. I don't think its going to be small businesses speeding the economic recovery as some would hope. Yahoo
Sitebuilder has been made aware for issues related to their tool and overlapping text boxes. Time to get back to work!
getting back to normal. Builds are progressing along, with PFC boards made to use the smaller SiC diode package. A
few charger G2 upgrades have been performed, slowing progress a bit. Not too much to report since some of the time
slot for build labor was consumed due to weather related issues, and finalizing sales tax spreadsheets. Getting part
quotes for new builds is getting crazy. One vendor quoted 1k piece quantity pricing, which costs far too much to
accommodate financially. There is a slow pinching effect between high cost-low volume, or higher volume and the
accompanying higher cost for that quantity. It would be a different story if the economy was blazing along and sales on
the rise. I don't think its going to be small businesses speeding the economic recovery as some would hope. Yahoo
Sitebuilder has been made aware for issues related to their tool and overlapping text boxes. Time to get back to work!
2/6/10 Revised a relay board for the stand alone DC-DC to tighten up the autostart thresholds for use with LifePO4's
while lowering standby power to 1/4W @ 150Vin. Now 3 modes of operation can be done with this revision, full
autostart from powerup, remote enable with soft-start, and remote enable (currently used in charging systems). The
build is moving along, and its time to divert some effort in finishing the dyno setup with the new pack installed. The
current hardware build is moving forward only to compete in time for these other things on the get done list. No
response from Yahoo sitebuilder, I think its pretty much a moot point with them. Seems their web customer service is
no longer existent. Might be time to find another web host with better service. Also need to update the website with the
800A system info and pricing! Time to get back to work!
while lowering standby power to 1/4W @ 150Vin. Now 3 modes of operation can be done with this revision, full
autostart from powerup, remote enable with soft-start, and remote enable (currently used in charging systems). The
build is moving along, and its time to divert some effort in finishing the dyno setup with the new pack installed. The
current hardware build is moving forward only to compete in time for these other things on the get done list. No
response from Yahoo sitebuilder, I think its pretty much a moot point with them. Seems their web customer service is
no longer existent. Might be time to find another web host with better service. Also need to update the website with the
800A system info and pricing! Time to get back to work!
2/18/10 With board mods behind and build progressing, Belktronix will be embarking on utilizing some lab space for
component testing. Part of this week's activity is to move things around to make room to use an existing workbench for
my former employer. This in turn drives the need for another usable workbench, forcing the creation of a foyer
equipment storage area. A silicon manufacturer I used to work for came up with a win-win scenario, I do some test
work in exchange for a bank-tank refill. Since the market is typically slower in the winter time, I figured it would be a
good time to go ahead with it. With all their equipment installed and near ready for making amps (up to 200A for a high
performance microprocessor) things will likely get warmer in the lab. The build will still progress as before, since I'm
lacking a work commute and mandatory breaks leaves ample time to get things done. Time to get back to work!
component testing. Part of this week's activity is to move things around to make room to use an existing workbench for
my former employer. This in turn drives the need for another usable workbench, forcing the creation of a foyer
equipment storage area. A silicon manufacturer I used to work for came up with a win-win scenario, I do some test
work in exchange for a bank-tank refill. Since the market is typically slower in the winter time, I figured it would be a
good time to go ahead with it. With all their equipment installed and near ready for making amps (up to 200A for a high
performance microprocessor) things will likely get warmer in the lab. The build will still progress as before, since I'm
lacking a work commute and mandatory breaks leaves ample time to get things done. Time to get back to work!
2/25/10 Its been a busy week, and its not over yet. The dyno is setup once again with the new pack and a place for all
the resident hardware to sit, waiting for a controller to test out (soon). Had to divert a day for the long awaited wireless
broadband to be installed. Now surfing the web is a joy to do in far less time than before. Try surfing at dialup speeds
now a days with web page content much larger than 5 years ago. It will make revising the website easier as well. With
1 charger done and 2 to go, along with a controller and system build to do, there's still much going on. Getting a
insurance policy is as tough as getting a loan, it all ties back into risk. Seems to be a common thread these days.
Hopefully I can squeeze in some pack recharge time with a new charger design. Time to get back to work!
the resident hardware to sit, waiting for a controller to test out (soon). Had to divert a day for the long awaited wireless
broadband to be installed. Now surfing the web is a joy to do in far less time than before. Try surfing at dialup speeds
now a days with web page content much larger than 5 years ago. It will make revising the website easier as well. With
1 charger done and 2 to go, along with a controller and system build to do, there's still much going on. Getting a
insurance policy is as tough as getting a loan, it all ties back into risk. Seems to be a common thread these days.
Hopefully I can squeeze in some pack recharge time with a new charger design. Time to get back to work!
3/8/10 Been busy with time sharing on board fabs, board builds, testing, finishing up the dyno configuration, and
getting ready to dyno a controller, and doing some side work to keep the bills paid. Looking at ways to speed LionMon
calibration times as well to increase throughput in the lab, as well as general cleanup and resetting the shop to flow
better when build orders arrive. Usually this time of year is when R&D is going on since new orders are historically slow
in the winter months, usually 'till until it warms up outside and tax refund checks have arrived in the mail. Time to get
back to work and finish up the to-do list for the day!
getting ready to dyno a controller, and doing some side work to keep the bills paid. Looking at ways to speed LionMon
calibration times as well to increase throughput in the lab, as well as general cleanup and resetting the shop to flow
better when build orders arrive. Usually this time of year is when R&D is going on since new orders are historically slow
in the winter months, usually 'till until it warms up outside and tax refund checks have arrived in the mail. Time to get
back to work and finish up the to-do list for the day!