Alan B wrote:I thought you wanted to build a motor controller. Apparently not.
Alan B wrote:The controller I bought most recently is rated for 100V 100A, and the hubmotor for 4KW. I don't have much use for 250W controllers.
casainho wrote:I started by removing the controller IC from the KU63 controller:
because always the current is over 10Amps and the power supply try to cut/maintain the current.
amberwolf wrote:casainho wrote:I started by removing the controller IC from the KU63 controller:
I think you are also going to want to change out that swollen cap:
There could be other caps that are bad, too, but I can clearly see that one.
amberwolf wrote:because always the current is over 10Amps and the power supply try to cut/maintain the current.
If it is always over 10A even at no load, I'd say there is something a bit wrong somewhere. It shouldn't take more than a tenth of that current to spin the motor even at full throttle. My guess is timing of the phase outputs vs where the motor coils/magnets are actually at. but it could also be bad caps not able to smooth the current flow sufficiently.
amberwolf wrote:Regarding not having any position feedback, that would certainly cause very high currents, and noise, vibration, etc. I don't doubt that if you ran that on a power supply capable of much higher currents that you would have blown up the FETs already.
amberwolf wrote:It's pretty important that the controller know where the magnets are in relation to the stator poles, so that it can output the correct sequence and timing of currents to cause the right magnetic fields at the right times. Without that, it is basically just outputting currents in a fixed sequence, and the magnets on the rotor will try to follow that--if anything (like a load) interferes with that, it falls out of sync, and BEMF is now induced in conflicting patterns to the controller-induced currents, resulting in nearly random fluctuations in current thru the FETs, and voltage spikes as the currents coincide or conflict.
This is one of the things that blows up controllers when they lose sync, in applications like using sensorless RC motors and controllers on ebikes.
Lebowski wrote:I went for a totally different approach.
Lebowski wrote:Don't investigate commercial controllers. Understand how a motor works. Get some ideas
from literature. With these basics covered, ask yourself the question 'how would I do it'
and start designing from scratch !
casainho wrote:is there any chance of motor blocking due to failure of the controller??
casainho wrote:That problem of loosing sync/high currents, seems that this controller have 3 feed-backs:
1 - current measure on the shunt resistor
2 - BEMF
3 - temperature measure of the controller
Maybe 1 is enough to avoid high currents? and as a security 3, since high current will make temperature go higher??
ram0nb wrote:I have some ideas of creating a sensored bldc controller based on an Arduino myself for a while now. Never came any further then a diagram and the beginning of a pcb design.
ram0nb wrote:My final goal is to develop a 80V 50A BLDC controller with wifi ap and webserver (or bt) for communications with smartphone to control and monitor my ebike.
Will have a look for the my controller design files in Eagle. Can post those if any interest.
ram0nb wrote:Allthough I've no so much time to spend, I'dd like to join the project.
I'm not stuck to Arduino platform. Just started with a Netduino, a Wifi module and .net micro framework to play arround.
ram0nb wrote:Also got a controller over here with the same X8M06-C processor. Any luck with uploading / changing the parameters like on Infineon based controllers? Anyway, I like the idea of swapping the cpu with your own.
carfreemaine wrote:Just when I think I'm starting to become the local "E-Bike Expert" I find a thread like this and I realize how much of a beginner I really am! Let me just say that while I know almost zero about electrical engineering this is almost EXACTLY what I've been looking for! Ever since I first learned to blink an LED with an Arduino suddenly I'll find myself "mentally reverse engineering" anything with a circuit. But this is one I've been looking for months! I doubt I can add very much to the conversation as it stands other than to say "keep doing what your doing"! but I urge you to consider that there might be a broader demand for such a product if presented right.
I stumbled upon the E-Bike community via a broader search for rural transportation innovations which otherwise involves real-time vehicle location data feeds and other software oriented stuff and I keep asking myself why it should be necessary to have a microprocessor run the motor, another to log data and another on the smart phone. Please let me know if you need a beta tester. Info on my own project can be found here-http://humblehackers.wikispaces.com/The+Flying+Yankee-+A+DIY%2C+Foldable+E-Bike%21
int main (void)
/* Initialize the system */
update_duty_cycle (250); // 25% duty-cycle
// Testing the start-up motor
delay_us (5000); // 5ms commutations of each step --> ~30ms period, measured on Cute85 slow/start velocity.
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