Embarking on the journey of building your own electric vehicle (EV) is an exciting endeavor, and a critical component you’ll need to master is the electric car controller. While the term “programming” might sound purely software-based, in the realm of DIY EV controllers, it often begins with understanding the hardware foundations. To effectively program your electric car controller, you first need to have the right physical components in place: specifically, a control board and a power board.
These two boards are fundamental to the controller’s operation. The power board, ideally constructed with heavy gauge copper (at least 3 ounce copper PCB is recommended for durability and conductivity), handles the high currents required to drive the electric motor. For sourcing materials, platforms like eBay can be valuable for finding copper clad PCB. You can even utilize templates and guides to etch your own power board. Resources like this eBay link for copper clad laminate show the kind of materials needed. For etching patterns, whether you’re using a precise CNC mill or employing a steady hand with a Dremel tool, G-code and templates are available, such as those found at Open ReVolt Fab Files.
The control board, on the other hand, acts as the “brain” of the controller. It processes signals and dictates the power flow managed by the power board. You have options for obtaining a control board: you can purchase a pre-made one, which simplifies the process, or you can choose to create your own. If you decide to build it yourself, PCB layout software and readily available schematics are essential. A schematic like the Cougar Controller Rev2C Schematic provides a blueprint for creating your own control board. For visual aids in the construction, PCB layer images are also available, such as bottom layer, top layer, and component layer layouts.
Once you have successfully sourced or built both the power board and the control board, you are ready to move on to the next crucial phase in bringing your electric car controller to life. With the hardware foundations set, you can then delve deeper into the specific programming and configuration required to operate your EV motor effectively. This involves understanding firmware, software interfaces, and potentially writing code to customize the controller’s behavior to your electric vehicle’s needs.
