Just a quick observation - I believe the spring on the fuse should go on the other side of the soldered connector - between the connector and the case. in that way the fuse is sandwiched between the connectors directly and the spring is pressing on the backside of the connector and case... The way you've assembled it the spring is now also a fuse :)
@@TheDigitalMermaidI was just going to say the same, except the spring is effectively a heating element. If you look at those little yellow silicone boots on the plugs they are crimped with the wire which is why you couldn't remove them. I have to deal with similar plugs and they are always really fiddly to get the terminals out, and you need three hands.
I'm converting my sailboat to be electric powered, and I'm making the helm controls myself from scratch. Mainly so that, if there's a problem when I'm out at sea, I know I'll be able to fix it. All the "turn key" electric conversions are closed so even if you know how to fix it, you can't.
There's some people who feel like they want to be better than others. Instead of taking that as motivation to better themselves, instead they decide it's easier to tear others down. Pretty sad, really, but their problem in the end, not mine.
My scientist self is cheering you on. One must experiment to learn. You're a champ and an example I show to my engineering oriented granddaughter. As they way, "you go girl!'
Qualification: I am an Electrical Engineer. FYI, you could have flipped the field wires going into the motor controller (inverter) to match the reversed hall pinout. Then just simply reverse the motor direction in the controller settings if needed. Another point: The reason to avoid solder in any high-vibration environment is because in the wiring, where the solder wicks into the strands, there is a high mechanical stress concentration right at that point. Even with small long-term vibrations, the copper right past the joint will work harden and fracture and as the individual strands fail, the rest will be under even more stress, hastening complete failure of the joint. If you do solder, always add a couple of layers of marine heat-shrink tubing, with a step down where the conductors exit to gradually reduce the stress concentration. Start with a smaller tube that extends a cm or so on each side of the joint, then add a second larger piece over everything that extends a cm or so on each side of the first.
So that was my initial thought, when I mentioned that the controller had a reverse direction config switch. However, isn't the corresponding hall effect sensor meant to read the associated field? I mean, they're all mathmatically equal angles off, so maybe reading the wrong sensor would still functionally work, but I was assuming the risk came if there was any slight deviation in the true angles of the phases?
As long as you match the halls to phases you are good to go. For instance if halls A and B are swapped, swap phases A and B to match. The worst that can happen is that the motor could run in the wrong direction. If halls don't match phases the drive should detect the mismatch and fault out. A good drive would tell you about the mismatch. A cheap drive is more likely to over current fault.
Hall sensors are used to know which part of the commutation phase you're in, three ~equal overlapping regions for the standard six step trapezoidal. The controller only does one of six things, then waits for the halls to change. The angles aren't precise, calibrated or even optimal, they're "good enough". I built a high power drive system, and it turns out you can squeak performance out of a motor by commutating early "phase advance" at high speed/insufficient controller voltage, we're talking 60% of a hall sensor early for an extra 1000RPM under heavy load. This took weeks to figure out on my own. Super tangent: I only learned it was possible because I found the previous devs used a "wrong" commutation table which compared to the "correct" table works better at high speed, but had weird dead spots when stationary caused by the magnetic field lining up with the rotor exactly, instead of being on either side to produce torque. It was fun playing with many commutation tables and seeing the weird responses the motor had! So I implemented the best of both worlds (out of necessity) to use the correct halls at low speed, then start commutating early the optimal angle past some RPM. My controller needed an encoder, like for sensored FOC, and only crazy people stuck with legacy hardware would do this. FOC is the way to go if you want real control, not at all useful in a sailboat application but its good to know the landscape of what you're working on!) That's not relevant to the Kelly controller other than to say hall sensors are not magic and a proper controller wont break anything even with mismatched halls and phases :) @TheDigitalMermaid
Dipping a crimped connection into a solder pot can can be done to test if the crimp was done correctly. When a proper crimp exists the solder will not wick past the connection and will only bond to the exposed copper and terminal.
You are smart and brave and a true inspiration. I am one of those people who will be heading out on my own electric sailboat adventure soon. You are my trailblazer, and I admire and appreciate you so much!
The little fabric adhesive jewelry price labels and an extra-fine point Sharpie are golden for DIY! Wires, flash drives, ... label at your will. I like your style. Infectious enthusiasm!
Yes, you inspire her. You give her an example to which she totally relates because she's always building some type of robot or programming some game. She can see herself in you. So, thanks for sharing your true self with all of. us. It's a treat to watch and learn.
Lol, cat says "No, human, love me!" 😻💖 Awesome to see that you got this crazy contraption to work and not get any magic smoke, despite the many feline distractions 😊
This reminds me of watching and listening to my father in his shop as a kid. YT just dropped this in my suggestions and I'm so happy to see there are at least 90 more episodes.
Thank you for your videos. You're an inspiration to us people who probably can do that weird project we have in mind, but never start it because of the unfounded fear of failure. So thank you for helping me believe in my abilities again.
I was a an engineer at a wiring harness plant for a few years when I lived in Indiana. I took the prints and setup production. We built harnesses for CAT and EMD. Our policy was that for all hand crimped terminals we had to solder it afterwards. Just where the crimp is. We also had some terminals on specific harnesses that had to be soldered even after they were crimped by a calibrated machine. Most of these that I ran across were for engine harnesses. (if i remember correctly they were glow plug connections) I asked people that were apart of the real engineers that set the practice and they said that perfect crimps are as close to welds as we can get without welding. We don't live in a perfect world so they had us start soldering in order to increase reliability. Soldering didn't make it a brittle/bad crimp since it was done after crimping. All the mechanical strength was in the crimp. The only time I saw this done outside of terminals that went into connectors was with a butt splice crimp that was on a handful of harnesses. It didn't have insulation which made it really easy to solder after crimping. We would place glue lined heat shrink over it that would turn rock hard after it cooled. They also told me that once they started doing this their rejected harness rates dropped quite a bit. I was shown terminals they had cut in half for QC and you could see tiny voids in the crimped terminals and then he showed me what the soldering did. it was pretty neat. None of these joints were outside of strain relieved areas but he also didn't say that it was needed. Also this was neat to watch. I now know what a female version of myself looks like when working while rambling. It's insane how close this is to what I say/do. I wonder if its a trait of ADHD. Side note: check out Jay Bates camera rig for his wood working channel. It's pretty easy and makes it really easy to do camera setup changes. John Heisz has a camera gantry in his shop but its really overkill.
I'm leaning more and more towards using solder _after_ a mechanical crimp for corrosion resistance. I know I'll catch flak for it, but your experience is adding to the "do eeet" column. :) Thanks for the reference, that's a really neat camera mount. I've though about that, and also lighting tracks along the ceiling. I've held off mainly because I struggle to justify the work when I know, long term, I'll be going on the boat. Who knows though, might be a nice small project when I need to just walk away from whatever I'm doing at some point.
I like how you systemically work your way through everything and verbalise as you go. Sometimes, I can easily work and listen and understand most of what you are doing without even watching, just listening via headset.
Awe, thanks for the kind words! There's a lot of other creators that I do the exact same for; Put them on to listen to while doing other things. Especially Big Clive. :)
Exactly! I often say the same thing to my daughter; A mistake is only a mistake if it's repeated. If you take a lesson and are more wise for it, it was a learning experience.
Small stupid idea: if you have a headlamp it lits beautifully what you're looking at! Great to see you succeeding step by step! Good to be along the way to learn from your journey! Love from Italy 🍕
I can see that you do a bunch of introspection. That's respectable. You caught yourself being a bit crude and arrogant in the beginning and then gave a nice lesson on being humble and how to take proper advice without getting a huge head about it. Again, respectable. Keep that up and you will be the change you wish to see. Wonderful video that scratched a bunch of itches I didn't know I had.
I've been extremely fortunate to have had many great teachers, and every one of them had humility. Contrasted with the arrogant people I've crossed paths with who confidently told me things I later realized were wrong...
I was also nervous when I yanked the 70-pound hybrid battery out of my Insight, 144v across the whole pack. I've barely even fiddled with electronic circuits before. But I just watched plenty of videos, took my time, made sure to take all the safety steps (Honda thankfully has very good built-in safety features), and I was able to take out and individually recondition all 20 of the six-cell NiMH battery sticks, reassemble the pack, put it back in the car, and now it works great again. A few hundred dollars for battery chargers/dischargers, instead of paying the dealership $3,000 for a new battery.
Sub. Looks like somebody learned a number of things they didn't expect to learn. I love that. Great documentation of your troubleshooting process, and just generally inspiring.
I just stumbled across this video and i don't have the slightest clue what's going on. But you seem to have succeeded and are happy, so i'm happy for you too. Greetings from the DEEP south of Germany.
haha, thanks for the watch! Slowly building a long-distance, all electric sail boat. I've taken the hard road as I want to make sure I understand and can fix as much of the boat's systems as I can, so I'm avoiding closed systems.
Success!!! Congrats! This was big achievement - as I've seen you splicing the cables, I was like "this is going to be interesting...", but you nailed it! Wow!
That makes me happy to hear. I worry sometimes I'm getting too into the weeds, but the process of problem solving is, I think, just as important as any other skill when DIY'ing big things.
honestly i like long form vids it lets me learn quite a bit more then just short and sweet ones. it also shows how your mind works that too i quite enjoy seeing . @@TheDigitalMermaid
Another milestone in the build! Funny when is hear you talk about everything you're thinking. When I do my projects it's so quiet it's all in the mind haha.
I used to have a set of repinning tools for various Molex type connectors. I’m sure there’s a set for that connector but in a pinch, you do what you must.
I think it was Adam Savage that said "Failure is always an option". We learn just as much from failure if not more, its the fun part of experimenting and i love it. I'm new here, no idea what your bigger project is, but its an interesting video to have on in the background.
Absolutely! Savage is like a real-life MacGyver, amazing world view and talented as could be. The project is that I am converting my sailboat to electric. The plan is to do long distance, high-latitude sailing. Part of why I'm doing this, beyond it being fun, is to be sure I can fix anything anywhere, if whatever broke is fixable at all.
@@luther99flame Cody has been one of the youtuber's I've watched the longest. Absolutely love his approach to projects and the style of his videos. ^_^
watching this bring me back 6 years ago when im still undergraduate student using simillar kelly controller and that big golden motor applied to small gokart and my friend crash it few days later to one of my lecturer car😂
28:22 Actually those connectors are called Dupont, in the old times Berg connectors. JST have compatible connectors, but generally I wouldn't call these JST to avoid confusion.
Love the pin swap. I salvage everything. They can be easy or difficult. Just when you push in something the right size it pulls right out like butter. I make everything. Secret tip: They hide stuff in electronics to disable secret functions.
One of the folks who taught me a LOT when I was younger was like that. He saved everything he could, and it was amazing seeing how often things he'd saved came in handy. It's a careful line between saving what could be use and hoarding though, so gotta be mindful. :)
@@TheDigitalMermaid i think it is ancient hunter gather DNA memory 😉 Pack Rat vs Hording Pack Rat is all useful Hording is seven cases of broken 1920s light bulbs 😁
this segment 39:08-43:10 "On Constructive Criticism and Naysayers" is one of if not *the* most important things I've ever heard someone say in my entire life
I'm learning about servos/motors for RC cars (for now) and go through something similar, so my searches lead to your adventures too. I have 1000 pages to check out and my place is full of micro controllers, modules, extra motors and whatnot.
Madi, bms/battery assembly 101 is to never have the balance leads plugged into the bms when you are connecting the leads to the cells. All it takes is for a balance lead to momentarily touch the wrong terminal and the bms will never be right, even if the bms is off.
Yup, you're absolutely right. It's why I was so nervous. In hind-sight, I should have wired all in first, then one by one plug them in, but by the time I realized that, I was half done. It is, though, why I put the big "this is a bad idea" disclaimer out there. :)
As allways, interresting too follow your work/journey. I can see that cats like dogs have the ability too be jerks and so irresistible and cute at the same time. But apart from interuptions from cats it look like you are having a good time finding out how to get things running, and you are not the only one whit a big smile when the motor moved. You talked about using some standoffs behind the controler i the final build, and you probably have thougt about it, but just in case, maybe use the type whit at bolt mouled in rubber, to protect the electrical components from shaking apart.The price of the controler and lack of backup part would make that a good investment i would think. There is always something to spend more money on a boat as you surly knowh. good luck moving farward.
Hrm, integrating an anti-viration thingy into the controller mounts... I think the controller is fine without it, but keeping a bit of movement away from the terminal bolts might make it worth it. Thanks!
no damages to these expensive beauties .. personaly i can entertain myself burning my converters every single day learning more about em.. you stick to progress and success!!
Given I am still holding on insurance, so work on the boat is on hold, I think this is the best / most productive thing I can be doing while I wait. :)
Experimenting is fun. The results may not be what was intended. Other times, they are perfect. If you do something that fails, I can avoid that. If it is successful in away I would not have approached it, I get to learn something new. You channel format is like being in a lab or on an R&D project. Keep up the good work.
There is little to be learned from success. Failure on the other hand has many opportunities to learn just use the opportunities. Learning is success in itself.
5:13 If it's not OK that it's backwards, you could create a short section of wires with connectors on both ends to insert in between those connectors, and it would route the wires the correct way. So it would "convert" from backward to forward.
@@TheDigitalMermaid Ha! Well if it helps, I'm giving you advice as I watch. I'm yelling at the screen, "Don't try to pull the pins out!" Oh, she pulled the pins out... I've messed up connectors trying to do that. I usually get impatient and just pull at some point. Seems like it went better for you.
Nice to look it up! I just came across it looking for something else and see you have answered it! Since i have only limited acces to ABYC standards, could not find a answer to this Question: What is the maximum DC voltage ABYC recommends to be used on a boat? And do the make a difference in used for propulsion or not? Question entered my thought because when putting 2 large solar panels in series it might exceed the what is to be the safe limit of 60 Volts. So if you have an extra minute, i thank you if you know or find an answer.
@@LucScheffers I'm not aware of a max voltage rec from ABYC, although I'm sure they have many recs for specific scenarios. I didn't find anything in a quick google. Generally, for solar, you'd want to avoid exceeding 48V jsince industry standard hardware doesn't really go above that today. RE: propulsion, there are boats out there pushing multi-kilovolt motors. The Washington State Ferries are going electric, for example. The first few have 7000HP motors. That's around 5 million watts. Dunno how thick their wiring is, but it must be thicker than EV high-voltage wires bc EV wires would have to push 10 kilovolts to hit that power level. If you have solar AND a giant motor, you probably need a house bank, a separate high-voltage propulsion bank, and a converter to charge the former w/ the latter. In cars, they call it the traction pack or high-voltage pack. The Cybertruck has a small 48V pack for everything other than the driveshaft, for instance.
@@LucScheffers Also, as a little side note, your solar panels can be higher voltage than the rest of your system, as long as your solar charge controller can handle the higher voltage at its input. The SCC converts whatever voltage from the panels at its input to whatever voltage your system needs (12v, 24v, or 48v) at the output. So I believe you could install several hundred volts of solar in theory. According to ChatGPT, neither ABYC nor OSHA currently recommend a voltage limit on solar panels. I've heard of panel arrays above 500V, but never above 1000V.
@@eagleray1 Thanks for your fast reply! And search, Nice! I was asking myself this because there is a tendency to leave 12 volts batteries and go for 48V systems. That would require panels with higher output voltages. No problem but that is above the as regarded, as stil safe below 60 Volts DC. Above that would at least in my thoughts an above 60 VDC is likely to require much more extra safety precautions, which i don't see used. So i was curious what the "officials" had to say, But they don't apparently.
Impressive! Don't worry about the motor case spinning, it can't spin but just move a smidge when accelerate decelerate stop ( think mm's). The magnetic flux is equal and opposite and the centrifugal effect is at a right angle like holding it with a hand. Me thinx.
A girl and her cat, I am sorry, your motor is an impressive project but… that cat purr ❤ Of course I wish you that that motor be purring just as nicely soon, but I am getting all gooey over the wonderfully recorded purrs from him!
girl just sitting on her floor and fucking around with power electronics, this could be me. your bouncy presentation style makes me get out of bed and work on my projects.
Just for future reference, the spring in the fuse holder is intended to be placed on the *wire* behind the contact to make the *contact* spring loaded. If you put the spring between the fuse and contact not only is it not captive (which means it is virtually lost already) but now you rely on the spring for an electrical connection which is… not optimal.
I can very much relate to this hyper-tired-excited-scared-confused-determined state of the late night in front of almost close to completion mess of a project (never in public though). Btw, was almost upset you did not drop anything and shorted those open battery terminals that where in the open all through the video... and tell "I told you soo!" 👍
Just watched it, and it is nice. But, in my humble opinion, from experience, shorting LI batteries with a ratchet wrench, like the one you had in the video, and no fuse would make it much more entertaining... again, a little disappointed. Still subscribed though, will be waiting for the next opportunity, which judging by the amount and scale of projects is sure to come :)
To each their own, of course, but what part of the video led you to that decision?
6 месяцев назад
@@TheDigitalMermaid when you said Victron stuff won't run on anything but bare iron windows. I struggle enough with the chinese software ran in wine... :))
@ Aaaah, yes. Let me elaborate on that some more; That was one of their old tools I was trying to use to setup time-shifting (charge off the grid when power was cheap, run off the batteries when power is expensive). They've been actively moving all of those functions into their phone app, and in the year or so since then, I've not run into a case where I needed that legacy software. The OTP cable plugged into my (android) phone does any direct configuration of VE.Bus devices (like the Quattro and Multiplus). I say this, not so much to forgive that legacy app, that still annoys me, but to reward their commitment to open source. They provide their Venus OS raspberry pi OS, and have been quite good at exposing much of their devices and protocols for those who want to tinker. So on the whole, I quite appreciate Victron's willingness to work with DIY'ers / tinkerers.
6 месяцев назад
@@TheDigitalMermaid Oh... I just took a peek at their site on the matter but damn, that's a shy attempt at opening up... "There is and will be no official support on the functionalities of(...)" I admit, an attempt is more than nothing and their hardware is sure shiny and appealing... It remains to be seen what will become of it but yes, many thanks, interesting stuff I didn't even suspect it could be.
I can totally understand their unwillingness to officially support any DIY/hacking use of their kit, it would be a support nightmare. I'm a software dev / sysadmin by day, and so I'm sympathetic to how a minority of users can make unreasonable demands of a company. Overall, I've been very happy with Victron, and wouldn't hesitate to recommend them, even with the "blue tax" you pay. Their reputation is well earned.
There isn't such thing as fail. It's just a different result from what was expected. The same applies to mistake - it is not bad, it is just "oh look, so the result is different and that's interesting. Let's figure out why is it this way" and that's it :)
Not too many woman are interested in electronics so its somewhat enjoyable to see women get into it. When women try to learn something they really go in head first. Ive been lucky to know a couple women like this so Im hear to find out what your going to do with that massive electric motor. Are ya gonna power a locomotive with it? That thing is Giant. I might `be a lil scared powering that thing on
Part of the reason I started the channel was to help encourage more women to get into tinkering, sailing and electrics. If kids don't see adults they can relate to doing something, they grow up thinking it's not for them. I'll be adding a second 5kw motor also, and the two will be used for long distance sailing in my '81 C&C Landfall 38. The one I have now will be for high power, and the 5kw will be for low-speed efficiency (I go into details on this in the "Decisions Made" episode).
Hi, just started watching this video and I have subscribed and I did slam the like button. I am going to go back and watch these videos from the beginning. But until then I did want to reach out and tell you that you are doing a great job!! I am learning! Thank you. I also want to say that you are definitely my type. If I was to guess you are a winter born baby.. Scorpio right? There's a little tip on that BMS, before you start wiring the string of red wires, unplug the wires from the BMS until you get all the wires connected to the batteries, that way if you make a mistake wiring the red wires to the batteries it will not harm the BMS. One way to make a “standoff” for your controller. ( To elevate it) is to take some half inch or 3/4-in pipe and just cut it to the length that you need and then use it as a thick washer 👍. Please continue to teach me. 😁
Haha, can't say I buy much into astrology, but yes, I was born in late December. I wonder though if being the eldest child and fairly strong ADHD had more to do with my personality though. :)
I hydraulically crimp AND solder in that order BUT, messing around be carefull cause with enough watts of heat the solder will wick down the leng of the wire. you only want to solder the lug not the cable strands inside the cable.
I've not yet cut a crimp I made, but from what I've see from others, if it's done right it's the closest you can get to a welded connection and there should be no open space for solder to wick into. My thinking is to add just enough to resist future corrosion.
@@TheDigitalMermaid when i was... 10 years old i blew up my bedroom.. door open window in the driveway.. my mom said are you ok? i stood there yeah im ok.. with blood dripping off my chin.. this was a worse event then when i was 3 & shorted out the power in the whole NYC apartment building.. lol
What a nightmare to get one of these running. So many things can go wrong in the chain. Anyway, it´s a lovely motor and I hope it runs well in the end.
To be fair, that's true for diesel as well. The difference mainly is trading off mechanical complexity for software complexity. For me, I find software and electronics more enjoyable, so for me, it's not a nightmare, it's a fun challenge.
