12V Controller selection help

[HoverBoarder]

Is there anyone who can suggest a 12v controller that I could use to power four 12V 18A fans?

Ideally I would like to have a remote motor controller, but anyone that can suggest one that actually works would be very much appreciated. If it does not have a remote control, than reversable would also be nice, but even if it is just a straight motor controller that actually works than I would be very happy.

I have bought almost all of the high power 12v remote power controllers on Ebay when I was working with just two fans, but either I could not hook up two 12v motors in -(edited to be parallel insted of series)- with them, or they were not meant for continuous use as they only worked for a short period of time...

I also have been having battery problems. I tried to use a 13.3V LiFePO4 40AH battery with them, but it never worked (my friend who has an electric pedicab business said that it should work, but...). I ended up having to use three 12V 10AH NIMH batteries instead, but I would really like to switch to lithium.

Clearly I have a lot to learn, and any help any of you could provide would be very much appreciated.

Thank you!

 

[amberwolf]

4QD makes good brushed controllers:
http://4qd.co.uk
I used the 2QD
http://www.4qd.co.uk/prod/2qd.html
on my CrazyBike2 with a brushed powerchair motor; it's discontinued but they still have some. By itself it doesn't do reverse, but you can use two back to back as an H bridge and get reverse, too.

The 1QD is also still available:
http://www.4qd.co.uk/prod/1qd.html
but I haven't used that one.

This is their product chart:
http://www.4qd.co.uk/prod/index.html
The 4QD is the next one up, but it only goes down to 18V. But they have several others that will do 12V:

http://www.4qd.co.uk/prod/proMk2.html
http://www.4qd.co.uk/prod/vtxbx.html
http://www.4qd.co.uk/prod/uni.html
http://www.4qd.co.uk/prod/Walker.html
http://www.4qd.co.uk/prod/ptr.html

I have bought almost all of the high power 12v remote power controllers on Ebay when I was working with just two fans, but either I could not hook up two 12v motors in series with them, or they were not meant for continuous use as they only worked for a short period of time...

Keep in mind that if you are going to hook up more than one 12V motor in series, you need at least a 24V conroller, not 12V. (would go up 12V for every motor added in series).

If you mean in parallel, then you just need to ensure the controller is rated for continuous duty at the max continuous draw the fans will have in total (number of fans times amp draw of each)

I tried to use a 13.3V LiFePO4 40AH battery with them, but it never worked (my friend who has an electric pedicab business said that it should work, but...). I ended up having to use three 12V 10AH NIMH batteries instead, but I would really like to switch to lithium.

If the Li battery would not work, I would suspect that it's BMS is set to limit current at some point below what the startup current of the motor draws, so it never spins up the motor as it cuts out before it can.

Or, it's cells can't handle the current draw and drop below the BMS's LVC, so it shuts off.

Either that, or it's simply defective.

 

[HoverBoarder]

4QD makes good brushed controllers:
http://4qd.co.uk
I used the 2QD
http://www.4qd.co.uk/prod/2qd.html
on my CrazyBike2 with a brushed powerchair motor; it's discontinued but they still have some. By itself it doesn't do reverse, but you can use two back to back as an H bridge and get reverse, too.

The 1QD is also still available:
http://www.4qd.co.uk/prod/1qd.html
but I haven't used that one.

This is their product chart:
http://www.4qd.co.uk/prod/index.html
The 4QD is the next one up, but it only goes down to 18V. But they have several others that will do 12V:

http://www.4qd.co.uk/prod/proMk2.html
http://www.4qd.co.uk/prod/vtxbx.html
http://www.4qd.co.uk/prod/uni.html
http://www.4qd.co.uk/prod/Walker.html
http://www.4qd.co.uk/prod/ptr.html

Thanks for the suggestions Amberwolf!

I have bought almost all of the high power 12v remote power controllers on Ebay when I was working with just two fans, but either I could not hook up two 12v motors in series with them, or they were not meant for continuous use as they only worked for a short period of time...

Keep in mind that if you are going to hook up more than one 12V motor in series, you need at least a 24V conroller, not 12V. (would go up 12V for every motor added in series).

If you mean in parallel, then you just need to ensure the controller is rated for continuous duty at the max continuous draw the fans will have in total (number of fans times amp draw of each)

I can't believe that I said series, I definitely meant parallel.

You were correct that the problem with *most* of the controllers was that they were not continuous, and the other ones just didn't work.

I found a remote controller awhile back that was continuous and reversible, but I didn't save the link and have been looking for it ever since.

I tried to use a 13.3V LiFePO4 40AH battery with them, but it never worked (my friend who has an electric pedicab business said that it should work, but...). I ended up having to use three 12V 10AH NIMH batteries instead, but I would really like to switch to lithium.

If the Li battery would not work, I would suspect that it's BMS is set to limit current at some point below what the startup current of the motor draws, so it never spins up the motor as it cuts out before it can.

Or, it's cells can't handle the current draw and drop below the BMS's LVC, so it shuts off.

Either that, or it's simply defective.

A low level limit on the BMS definitely sounds like the reason why the 13.3V LiFePO4 40AH battery that I got from BatterySpace did not work. Could I replace the BMS on the battery to work on lower voltages? Or is there another lithium battery that you could suggest that I could use with this 12V application?

I am eventually going to use this on my hoverboard project, so low weight is key.

Thanks again for your responses and advice.

It is very much appreciated!

 

[amberwolf]

BMS vs battery pack issue: If the BMS is causing the problem, bypass it and see if it works that way (but use a multimeter to measure the balance wires under load, to see what the cells measure). If a cell is causing the problem, you'll see it in a low voltage on that cell vs the others.

Regarding making it as light as possible, if you went brushless you'd be able to make it lighter because it would need less battery for the same runtime, assuming the brushless motors weigh the same (or less) than the brushed ones. The extra controller complexity would probably not add much if any weight, possibly it would weigh less, as you could probably use RC controllers (whcih are very very small and light) and sensorless brushless motors. Plus, if a brushed controller fails, it usually fails full-on.

Something you might also think about is using separate controllers for each motor. Using the same controller for all means all will get *nearly* identical power, but you dont' have an easy way to tune them for identical performance. It might be close enough, even just all in parallel, but if it isn't you may have to play around with various solutions to fix that, to keep the board in balance.

Additionally, separate controllers allows you to use a MCU to do auto-correction functions, if desired, such as auto-levelling if it tips too far over (obviously once it goes beyond a certain point, only the rider might be able to save it, and probably not even then, unless they are quite skilled).

Of course, with separate brushed controllers you run the risk of any controller failure causing one corner to go full throttle when the others might be nowhere near, and tipping the rider right off. With a single brushed controller, failure would turn all the fans up to full (or off), so at least it would be level when going at the wrong height. :lol:

BTW, if you used brushless, and RC controllers, you most definitely can have a remote control for it.

 

[HoverBoarder]

Thanks a lot AmberWolf!