We had the same problem - for about two days - and then here is what we found -
The CIM is designed to run at higher RPM - to stay below a 40 amp continous draw you must keep the motor at 3500 RPM or higher - under that (3500 RPM), and/or under high stress conditions (where the motor is slowed down due to the either weight of the bot or pushing against something), you will be running the risk of blowing the fuses. You can go from a standing start to running because of the time delay that the fuses have built into them - and depending on the "low gear" RPM - will not blow once you are up to speed (has to be above 3500 RPM to not be drawing over 40amps).
The comments made about torgue are right - and in discussion with the folks that make the CIM's - you have to be geared upwards of 25-35 to 1 at a minimum to keep the CIM at a speed that will not blow fuses and keep the speed under 10fps - we started with a 16:1 and will move tomorrow to a 32:1 to stop any problem we have with the popping at lower bot speeds (<10 fps at max speed).
Hope this helped
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