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by Lebowski
Jan 19, 2018 5:06 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

Some good points there, thanks Marcos. - I'm only putting the component outline in the silkscreen, not their designation (gets real messy real quick) - reduced the copper circle around the 4 corner mounting holes - On request from emmgee I've kept the width below 80 mm (it's at 78 now), so to add em...
by Lebowski
Jan 18, 2018 2:37 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

So this is what I have now, I think I will send it like this to PCBway to get 5 made :

I think I haven't posted the schematic yet:
schematic.pdf
(70.17 KiB) Downloaded 11 times
pic1-1024x1024.jpg
pic1-1024x1024.jpg (131.2 KiB) Viewed 98 times
pic2-1024x1024.jpg
pic2-1024x1024.jpg (119.13 KiB) Viewed 98 times
pic3-1024x1024.jpg
pic3-1024x1024.jpg (174.42 KiB) Viewed 98 times
by Lebowski
Jan 18, 2018 8:01 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

1 question/suggestion : it seems to me that we can pile-up 2 or 3 of this power board to make it a 12/18 FET controller. Apart from shorting the current censors on additional boards and keep them on 1 board only, what other modifications might be needed ? Bit risky but worth a try. I think all it n...
by Lebowski
Jan 18, 2018 5:14 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

I added 2.5 mm holes: pic4-1024x1024.jpg As already mentioned in the 3rd post of this thread, I see the need for mounting holes for a support for the processor board. But to sacrifice electrical performance, however minute, for some mounting holes ... hurts my engineering soul :? Anyway, I had to ro...
by Lebowski
Jan 17, 2018 4:58 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

I come from the world of chip design and making layout for chips.... theres no mounting holes with chips :D neither with the processor board, no holes in the corners...
by Lebowski
Jan 17, 2018 1:42 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

all wired up and DRC clean :D pic1-1024x1024.jpg I added ground planes in the bottom half around the processor board connector, but not around the gate drivers. This to keep the low inductance traces intact, and to keep the star connection I have at the bottom part of the board. I moved the power st...
by Lebowski
Jan 17, 2018 7:24 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

Ok good to know... I was under the impression that noise / interference would be a problem as well. So conceptually, If I keep the gate signal closely coupled with its reference (either GND for low side and phase-out for high side) by having the reference immediately below, and possibly beside as w...
by Lebowski
Jan 17, 2018 5:30 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

But you don't need shielding against interference in the 15V low impedance gate drive. What you need is low jnductance to prevent ringing, and for this twisting the gate drive wires works, But the goal of this PCB is to have everything on the board without needing to handwire the gate drive of 6 fet...
by Lebowski
Jan 15, 2018 2:07 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

front with the busbar and high current wiring exposed for soldering pic1-1024x1024.jpg processor board piggybacking on the main board. Note the exposed battery line to the drain of the high side FETs, this line is exactly on the other side of the PCB as the ground to the low side source, continuing ...
by Lebowski
Jan 14, 2018 2:20 am
Forum: Motor Technology
Topic: build your very own Lebowski controller !
Replies: 293
Views: 35718

Re: build your very own Lebowski controller !

Is there a way to slow down the programming clock, maybe then the code will be correct ?
by Lebowski
Jan 13, 2018 4:10 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

Another thing to keep in mind with PCBs is when fattening up the tracks or adding extra copper wires... they can warp when they get heated up during soldering. I will get the standard 1.6mm for my test pcb...
by Lebowski
Jan 13, 2018 2:48 pm
Forum: Motor Technology
Topic: build your very own Lebowski controller !
Replies: 293
Views: 35718

Re: build your very own Lebowski controller !

According to the datasheet the 617 has double the rom and ram of the 615, but i think otherwise they are the same (so same signal sequence from the programmer). Maybe your universal programmer comes with a human readable settings file for each chip ? Maybe you can edit the file for the 615 and just ...
by Lebowski
Jan 13, 2018 10:18 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

Think I've got it now: pic1-modified.jpg pic2.png pic3.png The 'clou' it that the gate drive lines are no longer 2mm track spaced 2.54mm (with a 16nH/cm inductance) but now are 3mm wide track opposite each other on both layers of the PCB (giving a 6.7nH/cm inductance). This reduced inductance can be...
by Lebowski
Jan 13, 2018 2:48 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

I dont think thats possible as the caps are on the bus bars.. so both pcb layers are in use at the caps location and i cannot route across...
by Lebowski
Jan 12, 2018 12:26 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

minimum wrote:
Jan 12, 2018 11:37 am
Gate drivers on separate PCB, on top (or underneath, depending on the POV) of FET PCB?
Gate drivers in SMD underneath the current sensors... but it should be an easy to solder board for everyone
by Lebowski
Jan 12, 2018 10:41 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

I hear your comments... Swapping the place of the gate drivers and current sensors: pic1.png pic3.png pic2-800x800.png I like the straight shot of the output to the current sensors. If I only use the top layer for the high current path, then I can route the gate signals underneath the current sensor...
by Lebowski
Jan 11, 2018 1:53 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

pic1-800x800.jpg note the little to92 transistor like component at the left side of the power stage. This is a temperature sensor, it is placed here so it can easily be clipped or glued to the same (~1/4" or 6 mm) aluminium cooling strip as the FETs... pic2-800x800.jpg What do you guys think would ...
by Lebowski
Jan 10, 2018 1:01 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

some more squeezing...
pic1.png
pic2.png
pic2.png (164.93 KiB) Viewed 256 times
note how each of the gate drivers has its own vss line to the main bus bar. This to keep the low inductance. The vss lines at the gate drivers are also connected together, it is this line that will be extended and used as the vss for the processor board.
by Lebowski
Jan 10, 2018 9:54 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

Very interesting to see how this evolves including the comments on your decisions. Are all the components identical to your original design, except that there are 6 FETs now (2 caps per FET-pair (TO247)) instead of 2 caps for the full bridge (4110, 4115)? It would be very helpful to stay below 80mm...
by Lebowski
Jan 10, 2018 4:38 am
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

busy with the gate driver layout... I've decided on a 2.54mm grid and a 2mm track width, giving 0.54 mm spacing. This small spacing should limit the parasitic inductance, as twisted wiring to the gate is not possible on a PCB... The 0.54 mm spacing in the gate lines limits the by the gate wiring enc...
by Lebowski
Jan 09, 2018 2:40 am
Forum: E-Scooter and Motorcycle Photos & Videos
Topic: Andre´s GSXR 1000 K2 with QS Motor 273 80H, 34kW
Replies: 128
Views: 11291

Re: Andre´s GSXR 1000 K2 with QS Motor 273 80H, 34kW

Arlo1 is running not a hubmotor but a car, i would guess at least 1000kg...
by Lebowski
Jan 08, 2018 4:03 pm
Forum: E-Scooter and Motorcycle Photos & Videos
Topic: Andre´s GSXR 1000 K2 with QS Motor 273 80H, 34kW
Replies: 128
Views: 11291

Re: Andre´s GSXR 1000 K2 with QS Motor 273 80H, 34kW

Strange, your 1/4 mile time is slower than Arlo1's (12.8 sec) but your power to weight is roughly the same I guess (he has 300kW)... any idea what the reason for this is ?
by Lebowski
Jan 06, 2018 12:43 pm
Forum: Motor Technology
Topic: Power PCB for Lebowski Controller to be combined with Bobc's processor board
Replies: 67
Views: 1316

Re: Power PCB for Lebowski Controller to be combined with Bobc's processor board

Pats are in :D so I've started the PCB design. This is how I image the PCB busbar and the FETs (still thinking about where to place the caps, each FET pair will have 2 caps as shown). Notice how the source of the low side FET has its leg clipped off and is soldered to the top of the PCB. This allows...
by Lebowski
Jan 01, 2018 3:50 pm
Forum: Motor Technology
Topic: Mid drive vs Hub Motor for 10000 watt project
Replies: 61
Views: 1218

Re: Mid drive vs Hub Motor for 10000 watt project

I would swap the controller for one with fieldweakening. How much field weakening current you need to set for a certain speed increase depends on the motor, so if you dont know the motor parameters its hard to predict. Extra losses from field weakening are I^2 R... with I the field weakening current...