If you want to see a pic of the controller that is in the Henney Kilowatt
that was ours and is now Mark Farver's here's a link:

http://intrepid-travelers.com/images/henney-controller-1024.jpg

/Aaron Choate


On Tue, Jan 15, 2013 at 9:26 PM, Lee Hart <[email protected]> wrote:

> On 1/15/2013 11:35 AM, Klaus wrote:
>
>> I recall seeing a picture of a mechanical PWM controller comprising of a
>> segmented copper disk being spun by smaller electric motor.  Two brushes
>> that could be moved relative to one another sat side-by-side on the disk
>> making for PWM control.  I can only imagine the shower of sparks it
>> created
>> running an electric motor for the little while it lasted, unless they had
>> some heroic snubber across it.
>>
>
> This idea has surfaced many times. It gets tried, and fails. Arcing is
> *tremendous*, and the contacts soon wear out.
>
> A snubber is vital to get it to work at all (for hours, instead of
> minutes). A freewheel diode helps a lot more (days, instead of hours).
> These weren't available until the last 20-30 years; before that, every
> mechanical chopper was a reliability headache.
>
> There are a lot of very sophisticated design tricks that have to be used
> to make this kind of mechanical switch-based chopper last long enough to be
> at least marginally useful. The usual backyard inventor types usually miss
> this.
>
> One trick is synchronous resonant switching. The circuit is arranged so
> the switch opens and closes at zero current and/or voltage. This was used
> in the 1950's car radio vibrators, to step 6vdc up to 250vdc for the vacuum
> tube radios.
>
> The commutator in a DC motor uses these tricks as well. It's designed so
> the voltage is zero as the brush crosses from one commutator bar to the
> next.
>
> --
> The trouble ain't that there's too many fools, but that lightning ain't
> distributed right. -- Mark Twain
> --
> Lee A. Hart, 
> http://www.sunrise-ev.com/**LeesEVs.htm<http://www.sunrise-ev.com/LeesEVs.htm>
>
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-- 
http://www.aaronchoate.com
@aaronchoate
+Aaron Choate
facebook.com/aaronchoate

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