Driving with the new KDH12801E controller lasted only for a couple of weeks resulting in a rotor damage in Corolla's ME1003 motor. I was not able to use low Motor current limits of the KDH12801E controller because it caused very strange behaviour in crawling speeds. Having to use the Motor current limit close to 800A obviously burned the motor. Corolla's former controller PM72401B was a better fit to ME1003 in this application but nothing can change the fact that ME1003 is a too small motor for a car like Corolla.
I decided to upgrade Corolla's drivetrain with higher rated components and double its voltage up to 153,6 Vdc nominal (48 series connected Winston LYP60AHA batteries). The upgrade project started by dropping off the motor and gearbox so that a new motor can be fitted easier into the gearbox.
The above photo shows the burned ME1003. Its brushes had melted badly and the rotor has short circuited. It will be scrap unless a new rotor can be sourced and fitted. The other picture above shows Corolla's gearbox drive shaft where the new motor will be fitted.
Here's Corolla's new motor: Kostov Motors K9HV. This used motor fitted my budget for the Corolla while being a good improvement for the whole car. It's a series motor that can handle voltages up to 220Vdc and it can be rotated up to 7000RPM, which means about 90km/h on Corolla's 2nd gear. I am looking forward to be able to drive my usual trips using only the 2nd gear and not needing to change gears as I had to do with the ME1003 motor:) The down side using a series motor is that I'll be giving up regenerative braking at least for now.
The K9HV Motor will be driven with a custom made motor controller inspired by the awesome Paul & Sabrinas open source DC-motor controller and Evnetics Soliton controller. In the new controller I'll be using Infineon's XMC controller and IGBT Chopper module togheter with a DC-Link with only Film capacitors. I am hoping to also publish this new desing later as open source:)
