water cooling - cpu components

this place is good to start with - has power dissapated info

http://www.koolance.com/water-cooling/default.php?cPath=54_90

subaru r160 rear differential

I had originally thought that the subaru differential, although being readily available and about the right power would be too long.  However, it may be possible to mount the stator back towards the driveshafts which would allow it to fit into the space available.  However there may be an issue with the mounting holes for the diff fitting in the middle of the stator.

here is a good article with an image of the differential with dimensions and some info on sourcing these diffs including lsd ones

http://pages.prodigy.net/mikeross/00019.htm

santa fe or ford escape diff?

an impreza diff would be ideal but probably too long.

a rav4 and a crv both have a clutch arrangement bolted onto the front of the rear diff.


http://www.awd.ee/article.html?inc=hyu

looks like it will just be a diff not also a viscous coupling

or maybe a ford escape one
http://www.autopartslib.com/2010/06/18/car/2008-ford-escape-axle-and-differential-components-parts-diagram

not as nice a flange for the rotor but nicer for the stator

Mazda Mx5 Diff option

This would require two custom driveshafts and could have packaging issues.

It is helped however by allowing a higher ratio if a toothed belt drive is used as well.

this link shows a good image of the diff
http://www.google.com.au/imgres?imgurl=http://www.mx5parts.co.uk/images/si2999.jpg&imgrefurl=http://www.mx5parts.co.uk/product_info.php/products_id/1654&usg=__61qnrl4MxN6DlBN6Y_J26K6dBy4=&h=413&w=550&sz=41&hl=en&start=4&zoom=1&um=1&itbs=1&tbnid=QLdHnhjs-bnnfM:&tbnh=100&tbnw=133&prev=/images%3Fq%3Dmazda%2Bmx5%2Bdifferential%26um%3D1%26hl%3Den%26sa%3DN%26tbs%3Disch:1

http://www.miata.net/garage/diffguide/11.jpg

the link above shows that it may not work as there is no inner cv joint

you can get a torsen diff for a miata

http://www.google.com.au/imgres?imgurl=http://memimage.cardomain.com/ride_images/1/557/3141/1391570086_large.jpg&imgrefurl=http://www.cardomain.com/ride/139157/2&usg=__m1sDf7M1VRikNw49Zzm8UNuJvGw=&h=383&w=575&sz=40&hl=en&start=36&zoom=1&um=1&itbs=1&tbnid=FiVfw8FWIhOroM:&tbnh=89&tbnw=134&prev=/images%3Fq%3Dmazda%2Bmiata%2Bdifferential%26start%3D20%26um%3D1%26hl%3Den%26sa%3DN%26ndsp%3D20%26tbs%3Disch:1 



this must be some of the best ratio data available.

http://www.miata.net/garage/KnowYourCar/S8_Gears.html

two motor option

It is nice as it is something really different, needs smaller controllers and potentially a lower voltage, however it has a few hassles.

The main hassle I see is sorting out the variable gap controller with two motors. Wouldn't it be better to get this control sorted out with one first?

There is also an issue with the maximum reduction possible with a single stage toothed belt - for the power required, it seems to be about 4:1

Thinking about the next step....

With the mazda almost registered, it is time to think about the next step.

I think that I am pretty sure that the next step will not be another car, rather an upgrade of this one.

That means sticking with the front wheel drive platform.

three current options,

Keep the mazda transmission with gearbox and diff.
Use a mx5 differential to allow direct drive.
Use two motors and some toothed belts to get the gear ratios correct.

IGBT module plan

I want to keep it simple

this module looks pretty good for a gate driver (with DC DC converter inside)

http://www.rell.com/resources/RellDocuments/SYS_21/vla500_01.pdf

not too expensive - $38USD each

http://www.rell.com/Pages/Product-Details.aspx?productId=603937

how about two of these for the h-bridge

http://cgi.ebay.com.au/IGBT-Module-600V-75A-310W-Fast-29ns-Trise-Half-Bridge-/180509113865?cmd=ViewItem&pt=LH_DefaultDomain_0&hash=item2a072e7e09

here is the datasheet

http://www.fairchildsemi.com/ds/FP/FP7G75US60.pdf

maybe they are too slow.

if 30A is enough, then maybe an IRAM is the neatest option:

http://www.irf.com/product-info/datasheets/data/iram136-3063b.pdf