Help with rebuilding electric golf trolley.

Hi guys, recently my electronics packed up in my electric golf trolley.
The company no longer has parts, and my local electronics company couldn't fix the problem.

Unwilling to chuck the trolley, as it is in perfect condition, i decided i will embark into the arduino world.

This world is fascinating and a little daunting, i have only managed to program a thermistor in which outputs temperature into IDE on my screen.

Ok so the basic functions of the trolley are as follows:

12v Motor to spin one way (forward :slight_smile: )
Potentiometer to control speed
LED bar to show the charge left in the battery.

Unfortunately the motor has no markings on it, but looking at similar trolleys on the market, i would say its between 160-180watts.

Rather than just state what i need and let everyone else sort it out for me. I have tried to do as much research as possible and come up with a drawing.

If anyone could let me know of any mistakes/improvements/advice, it would be much appreciated.

Furthermore the code supplied, is taken from sources on the web. Once i get the code corrected by someone and i know its correct, it will make it easier for me to study it, and apply it to my real life situation. Unfortunately i find it easier learning like this, rather than reading books and stuff.

EDIT: I forgot to mention that there is a simple switch that needs to be incorporated, im guessing this just goes inline with the 12v supplying the arduino.

int pot = 0;
int relay = 3;
int motorPin = 11;  
int val = 0;

void setup()                    // run once, when the sketch starts
{
  //Serial.begin(9600);           // set up Serial library at 9600 bps
//  pinMode(pot, INPUT); //don't need this
  pinMode(relay, OUTPUT);
  pinMode(motorPin, OUTPUT);
}

void getPot() 
{

  val = analogRead(pot);
  val = constrain(val,90,255); //this restricts the analog value to between 90 and 255;
  if(val=<90){
    val = 0;
  }


}

void run() 
{

  analogWrite(motorPin, val); //this will run the motor at the speed set by the pot value

}


void loop()                     // run over and over again
{
  getpot(); //THIS CALLS THE FUNCTION NAMED getpot ABOVE WHICH SETS val BASED ON THE ANALOG INPUT
  run(); //THIS CALLS THE FUNCTION NAMED run ABOVE

}

I just checked the spec for the transistor you specified, I.e TIP120 and it seems to be rated at 5 amps, but you have said that the motor is rated at 180W, which at 12v requires at least 15 amps and I suspect the starting current may be higher.

You are probably going to need one or more high power FETs for this.

Also, I suspect its cheaper just to buy a motor speed control module from eBay etc, from what I recall the are around $20 and are custom made to do this sort of thing.

Or course if you want an arduino controlled project that's great, you could do some funky stuff, but the I suspect the power control of the motor is going to be the toughest part of the project

Thanks for your reply.

Are you reffering to something like this:

http://www.ebay.co.uk/itm/12V-15A-180W-DC-Motor-Speed-Control-PWM-HHO-RC-Controller-/200771251390?pt=UK_BOI_Industrial_Automation_Control_ET&hash=item2ebee62cbe

If not could you provide a link to a suitable control module as im not sure what im looking at with these. Will it still work with potentiometer to control the speed?

Furthermore if i chose to go down the arduino root, would my schematic still work, but with a transistor that can take 15 amps?

Hi, if you have the old controller, you should be able to identify the output transistor, and if lucky read its part number.
This will give you a idea as to the spec needed on the replacement device.

Tom...... :slight_smile:

Tom,

Thanks for the reply, and great suggestion. I will have a look later to see what part number it is.

Furthermore, is anyone able to make on the feasibility of the code?

Would this be suitable?

You must have a different golf cart than the ones around here. Most work on much higher voltages than 12 volts. Normally 6 to 8 6 volt batteries in series.

Are you thinking of an actual golf cart that you can drive.
This is like a push along trolley with a motor attached, and 12v bike battery.

Is the "electric golf trolley" the same as an electric golf caddie? You probably could use a logic level MOSFET with a heat sink like below.

i think so, exactly like the pull along ones, but with a motor lol

decided to take some pictures of how the motor is connected.

BTW the red yellow and green wires are to the motor.

I personally would use a solid state relay as they have come down in price and controlling that much power is a trivial thing for an SSR as long as you use the spec'ed heat sink. I may be a little biased but spending a little extra money and getting one a little oversized is a good thing. It is hard for manufa, ctures to over spec things because they are making 100's, 1000's whatever and want to make as much profit as possible and compete, you are only doing one so you can overbuild it in places.

wade

this is the relay in which is used in the original electronics:

http://www.hebertech.com/datasheet/songle/slb-12vdc.html

Hi, just a quick check, i think DC switching SSRs are still relatively expensive.
What are the numbers on the four to-220 case semiconductors?

Tom.... :slight_smile:

two out of the top 3 have this information:

stbs20s1000
7sabz vw
phl 029

The third being this information:

80nf 70
g4debx

The one in the middle i have no information for. but will get some later

STP80NF70 N-channel 68 V, 0.0082 ?, 98 A, TO-220 STripFET™ II Power MOSFET

STPS20S100C POWER SCHOTTKY RECTIFIER 10A 100V (two diodes, common cathode)

Tom...... :slight_smile:

WOW i didnt think i had enough information to make anything out. very impressed.

Any one able to give me a quick mock up of how components would be laid to help me understand what i gotta do here to build a replacement using arduino.

BTW the red yellow and green wires are to the motor.

Hello jamiew123, did you finally make the circuit with Arduino?
I´m in the exactly same situation with my golf trolley rigth now
I will try Arduino + Mosfet IRFB3207, I think to build a simple on/off circuit with a potenciometer trougth PWM.
Thank you.
Pablo