High Tech Fuse Block

Discussion in 'Vendors' started by craftycoder, Sep 19, 2012.

  1. Iball

    Iball Been here awhile

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    I know. It's pure genius. Reminds me of when I building wireless remote temp and weather monitors overseas in the desert using Arduino-based micro-controllers. Each iteration kept getting smaller and smaller as I learned more and more. Even built a couple of mag-mount GPRS/GPS trackers in some Altoids tins so we could track down bedouin who would steal our equipment.
    Can't wait to see the finished product - hopefully it's fairly small.
  2. craftycoder

    craftycoder Motobrain PDU

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    Here are some images for scale. That is a Toyota car key. The box is NOT a playing card box though. It is a slightly taller than normal card box.

    [​IMG]

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  3. Captain Excellent

    Captain Excellent +ll+

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    I quite like this addition. It'll make setup much easier, and perhaps mobility between more than one bike.
    Question though, will you be providing 'in the box' both the male and female connectors so that everything is there for that first installation?
    I have a vision of that fateful Christmas Day when you get the really remote control car from Santa, but he forgot to include the batteries and you have to wait a few days till the shop is open again to buy some.
  4. sierra_victor

    sierra_victor Adventurer

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    I also think is is a good addition, but these connectors are hard to find in Australia & maybe other far flung places on the earth. :thumb

    Salty
  5. lmychajluk

    lmychajluk Long timer

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  6. LoneStrom

    LoneStrom Been here awhile

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    Absolutely. We are going to try out the Anderson powerpole connectors for the main battery connection. It should make it easy to quickly disconnect the whole rig if needed.
  7. craftycoder

    craftycoder Motobrain PDU

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    Ahh yes, I forgot to mention those on the power connector. We are using REALLY heavy duty wire for the 12V input because we plan to allow up to 100A. We realize than most people will never use that much current though, so our plan was to leave a relatively short length of input current wire with the Anderson connector and then allow you to use what wire you deem appropriate to connect to the battery based on your own needs. All the mating connectors for the harnesses WILL be "in the box".

    The question about what you will need that WILL NOT be "in the box" is pretty much a personal choice, but I'll throw some ideas out there.
    • heavy duty battery wire unless you plan to leave the PDU within 16" of the battery
    • posi-taps and/or posi-locks for the signal wire inputs
    • wire to connect your signal inputs to the PDU's signal wire weatherpak harness
    • wire to connector your loads to the PDU weatherpak harnesses
    • zip ties or Dual Lock to fix your PDU to the vehicle
  8. craftycoder

    craftycoder Motobrain PDU

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    I just about finished up the PDU test platform today. The only thing left to do is attach the WeatherPak and Anderson connectors to it so I can connect the PDU and begin testing. The connectors have not yet arrived unfortunately so I am in a holding pattern on that detail.

    <a href="http://www.motobrain.net/wp-content/uploads/2013/07/IMG_20130706_143207_5721.jpg"><img alt="PDU test platform" src="http://www.motobrain.net/wp-content/uploads/2013/07/IMG_20130706_143207_5721-300x168.jpg" width="300" height="168" /></a>

    I will be able to easily pull all the signal inputs high or low with the flick of the switch. I can also short circuit 4 of the outputs to test the circuit breakers (I can test the other 4 rest in software or short circuit them with alligator clips).

    <a href="http://www.motobrain.net/wp-content/uploads/2013/07/IMG_20130706_150232_8071.jpg"><img alt="Test rig switches" src="http://www.motobrain.net/wp-content/uploads/2013/07/IMG_20130706_150232_8071-300x168.jpg" width="300" height="168" /></a>

    I've put two transient generation circuits on board as well. One of them is directly on an output and will be used to test the device for ruggedness to significant transients directly on the output. I can test it with or without the diode I suggest should be installed across all inductive loads. The other is isolated on its own circuit and can be capacitively coupled to anywhere in the circuit to test durability elsewhere.

    <a href="http://www.motobrain.net/wp-content/uploads/2013/07/IMG_20130706_150123_9911.jpg"><img alt="removable diode" src="http://www.motobrain.net/wp-content/uploads/2013/07/IMG_20130706_150123_9911-300x168.jpg" width="300" height="168" /></a>
  9. craftycoder

    craftycoder Motobrain PDU

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    I have begun testing of the latest prototype on the new testing rig. 50A appears to be no problem at all.
    My office is hot as Hades though. :annie
    There is no cool way to burn this kind of power...:bubba

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  10. craftycoder

    craftycoder Motobrain PDU

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    All 8 channels up and running on my new test rig with the new wiring harness.

    <iframe width="853" height="480" src="//www.youtube.com/embed/o3bEP5IVkfU" frameborder="0" allowfullscreen></iframe>

    [​IMG]

    My transient generation circuit is pretty badass. >400V Pk-Pk transients.
    [​IMG]

    The PDU tames them to something like this.
    [​IMG]
  11. craftycoder

    craftycoder Motobrain PDU

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    Light manufacturing begins...

    [​IMG]

    Many thanks to inmate Dirty_Sanchez for his sponsorship of this project with the chemistry we are using.

    [​IMG]
  12. beechum1

    beechum1 Grimace Soup

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    finally!
  13. Riot

    Riot Tiger Rider

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    Hoorah!!
  14. Captain Excellent

    Captain Excellent +ll+

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    This is excellent work! We're excited, I can only imagine how you must feel to be at this stage at last.
    Looking forward to that launch.
  15. craftycoder

    craftycoder Motobrain PDU

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    We built up more PDU brains today and tested the PDU we potted in epoxy last night. The PDU behaved exactly as expected after it was potted. No drama. The radio's range is about 20 meters. I burned 50A, in my garage this time (the house gets too damn hot), for a couple hours (eventually a circuit breaker in the garage popped and it was getting tedious resetting it). The PDU was reading 44C (110F) which is warm but not hot. The potting box does a terrible job are conducting heat away compared to the design I plan to use so I am pleased with the temp thus far. We will have to wait and see if we can actually burn 100A. That is an extremely high amount of current and I don't have any 100A power supplies to test with. Lonestrom is going to take one of these PDUs home and put it in his pickup truck. He will do the 100A testing inside a vehicle.

    We are going to have some sort of product video soon and the Kickstarter should be right behind that. Again, we are not capable to producing these resources ourselves so our reliance on others makes the time frame less concrete.

    PDU (on the left) buring 50A in the garage.
    [​IMG]

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  16. dirty_sanchez

    dirty_sanchez Dirty_Sanchez

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    Hoorah! Hoorah!!

    Watching this whole project unfold and start to bud has been a hoot to watch.

    Dirty
  17. craftycoder

    craftycoder Motobrain PDU

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    I'd like to thank you again Dirty. All the stuff you sent has been very helpful!
  18. beechum1

    beechum1 Grimace Soup

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    Will the pot sticker be heat conductive?
  19. craftycoder

    craftycoder Motobrain PDU

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    :annie damn straight

    [​IMG]
  20. rstott

    rstott n00b

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    Questions for you. If one of the outputs is shorted to ground it should trip the circuit breaker function.

    1. What happens if the unit is powered down and then powered back up? I. E. Does it reset?

    2. Same as question number 1 but the output remains shorted to ground during the power down/up sequence...