Sevcon-Puma settings

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Johnny J
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Sevcon-Puma settings

Having som issues trying to "fine tune" the Sevcon settings together with my "Puma" 8kW hub motor.

Does anyone know what "Current Control Proportional Gain (Kp)" and "Current Control Integral Gain" really means and how they affect the performance of the motor?

So far the performance is worse than the original motor, top speed 87km/h compared to 97, acceleration about the same, top A around 168 on the CA.

Another question that I am a little bit embarrased not to know: Since the Puma (QuanShun) motor is rated for 100V, and I am running it on 72V, will the RPM be lower, or are the max RPM controlled by the controller (PWM)?

Johnny

MEroller
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Re: Sevcon-Puma settings

Proportional and integral gain are related to position control or in this case probably vector control. The higher the proportional gain, the quicker the controller will try to match the actual to the intended value, but the higher the likelyhood of overshoot, thus causing oscillation if you overdo the proportional gain.
Using just proportional gain is however not enough to ensure that actual equals intended value quickly enough. Integral gain adds up the difference of intended minus actual value over time and increases or decreases the gain accordingly. If that integral gain value is too small it will take too long for actual to reach intended position, if it is too big there will be slow oscillation of actual around intended position.

So much to the controller theory. What EXACTLY those values do in a PMSM vector controller I cannot tell you, but maybe it helps a little... Normally it should be ralated to controlling the phase current in relation to rotor position, power requested by the rider and rotor rpm, but that is only according my logic, not knowledge.

As for motor RPM vs. voltage, it all depends on the motor rating. The normal 5/8kW motor should be around 14.9rpm/V, for your "Puma" Quanshun that value could be smaller due to different winding and/or permanent magnets. You would need massive field weakening to be applied by the Sevcon to counter that at least a little. But I have no clue as to what part of the Gen4 programming would need adjusting to get field weakening... Alternatively an additional pack of 4 cells could be stacked into the under seat compartment and connected in series to the other 24 cells, and all would be happy ;-)

My rides:
2017 Zero S ZF6.5 11kW, erider Thunder 5kW

Johnny J
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Re: Sevcon-Puma settings

Thanks Mathias!

I think I will change back to the old motor and use the QuanShun for some other project which involves more cells :-)
I have a couple of really nice 3-wheel motorcycles with 250cc engines coming here in a few weeks that I'm thinking about converting.

KXA-R22-04liten.jpg

MEroller
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Re: Sevcon-Puma settings

That thing sure looks sharp! Is it street legal in Sweden?

My rides:
2017 Zero S ZF6.5 11kW, erider Thunder 5kW

Johnny J
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Re: Sevcon-Puma settings

Yep EEC-approved.

tef
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Re: Sevcon-Puma settings

Hello everybody,

I want to replace the existing controller of my scooter with a sevcon gen4 size 4 controller.
The motor is a 6kw from kelly and very similar to the Puma ( Quanshun ).

Could you please help me with a confg file for the controller, so that I have a base configuration to start with?

M.Chen
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Re: Sevcon-Puma settings

We have Sevcon 80180 in stock which can sell you at Usd300/pc FOB China.

M.Chen
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Re: Sevcon-Puma settings

We have Sevcon 80180 in stock which can sell you at Usd300/pc FOB China.it can bear max 120V voltage.

mountain.chen [at] gmail.com

IMAG1143_0.jpg

pcarlson1979
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Re: Sevcon-Puma settings

We have Sevcon 80180 in stock which can sell you at Usd300/pc FOB China.it can bear max 120V voltage.

mountain.chen [at] gmail.com

IMAG1143_0.jpg

This is the same controller that's in my 2 year old scooter. It's never faulted or anything. VERY good controller but you can't program yourself and the programmer is very expensive but once it's set, you just leave it.

------------------------------
eRider 8000w Scooter - PDT Version
72v 50AH CHL battery
350A Sevcon controller

24km: Delivered - 24 September 2011
2490km: Installed dual 35w HID lights Bi-Xenon Projectors - 27 November 2011
8313km: Installed BMS -

MEroller
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Re: Sevcon-Puma settings

This is the same controller that's in my 2 year old scooter. It's never faulted or anything.

You mean to say that your Sevcon does not conk out on you at times when you want get going quickly after a stop, like at a junction/crossing or a traffic light? I seem to faintly remember a report of yours along those lines, and it is currently happening to the first Puma riders which still have the Sevcon controller on board, not the FOC that is now installed...

My rides:
2017 Zero S ZF6.5 11kW, erider Thunder 5kW

Johnny J
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Re: Sevcon-Puma settings

It has only happened like 3-4 times totally on mine. Not really worth mentioning, takes a couple of seconds to turn the key off and back on again and your off.

pcarlson1979
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Re: Sevcon-Puma settings
This is the same controller that's in my 2 year old scooter. It's never faulted or anything.

You mean to say that your Sevcon does not conk out on you at times when you want get going quickly after a stop, like at a junction/crossing or a traffic light? I seem to faintly remember a report of yours along those lines, and it is currently happening to the first Puma riders which still have the Sevcon controller on board, not the FOC that is now installed...

Ah!! I stand corrected, I slightly remember that when the bikes were new. But either I have got used to it or it doesn't do it anymore? When taking off from a set of lights on a steep hill if I went full throttle the bike would start to go, but then "jerk", it was actually keeping the current down to 115A as programmed. I am used to it now though. But yes on I think 1 occassion I took off from the lights and the hall sensors didn't line up and there was a big clunk and the controller shut down, turn off then on, fine again.

But with over 2 years of great performance, it's hard to remember the 2-3 times where it wasn't perfect. I rode full speed (95km/h) yesterday in 48°c heat and needless to say the controller hit high temperature and had to lower it's speed after 28km on the expressway. It was during my lunch break. I got back to work and parked it again in the blazing sun and after work I rode home like nothing happened.

------------------------------
eRider 8000w Scooter - PDT Version
72v 50AH CHL battery
350A Sevcon controller

24km: Delivered - 24 September 2011
2490km: Installed dual 35w HID lights Bi-Xenon Projectors - 27 November 2011
8313km: Installed BMS -

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