As my propulsion system evolves from an experimental work in progress, into a permanent dependable installation, certain things that I could tolerate before are now becoming intolerable. One is the occasional necessity to jiggle wires to make things work as they should. I don't want to tinker and fiddle with this stuff forever. Some day I want to be able to just twist the knob and go, and not worry about what is going on with the system.
Many vendors, such as Kelly, sell controller kits with heatsink/mounting plate, contactor, main fuse, contactor coil fuse, plugs and wiring harness. Everything goes together nice and easy with multiconductor connectors. Unfortunately, sometimes the connections are not very good. Sometimes circuits make and break in random fashion due to vibration, etc. I got really tired of once in a while hearing my motor start to stutter as a Hall sensor circuit would malfunction. So I decided I did not need the convenience of the fancy pants gang connector for the hall sensors. Replaced the works with crimped terminals on a nice terminal strip. It isn't as cute as the neat little 6 circuit connector, but it is a lot more robust and the circuits are accessible for testing. Okay, so I don't have an oscilloscope... still, I think it is better. And I know it will never stutter again. Now I have a few more circuits to do the same way.
Shown in the pic is the hall sensor terminal strip, not yet mounted, and the connector shell it replaces. DC + and - to the sensor array, and the three signal lines that give rotor position to the controller's processor. I feel a lot better having that stuff wired more dependably.
Posted by: "Dan Hennis" <dhennis@centurytel.net>
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