Search found 193 matches

by thorlancaster328
Apr 07 2022 11:55pm
Forum: Motor Technology
Topic: Designing the ultimate (400A+) motor controller - what features should it have?
Replies: 10
Views: 871

Re: Designing the ultimate (400A+) motor controller - what features should it have?

I had rudimentary sensorless from standstill a while back with a Teensy 4. Never got it working really well though. Even if I could get industry-standard FOC working sensorlessly from a standstill, my system has some different components in it compared to standard FOC which enables it to accurately ...
by thorlancaster328
Apr 05 2022 9:49pm
Forum: Motor Technology
Topic: Designing the ultimate (400A+) motor controller - what features should it have?
Replies: 10
Views: 871

Re: Designing the ultimate (400A+) motor controller - what features should it have?

After a bit of testing, everything is looking pretty good, except for the current measurement. Turns out that the "12-bit" ADCs in the MCU I am using (IMXRT1062 / Teensy 4.0) have 3 LSBs of noise... with 8x oversampling :( Looks like the next build will need external ADCs to support the hi...
by thorlancaster328
Apr 01 2022 11:31am
Forum: Forum Rules and Features
Topic: Move to XenForo software
Replies: 221
Views: 21139

Re: Move to XenForo software

If the XenForo software proves too ugly, it shouldn't be too hard to either make a userscript that alters the CSS or alter it at the server level.

It would be nice if there was a test forum for users to give feedback on / play with.
by thorlancaster328
Apr 01 2022 12:01am
Forum: Motor Technology
Topic: New ground-up ESC - MESC_FOC_ESC
Replies: 214
Views: 17737

Re: New ground-up ESC - MESC_FOC_ESC

No so convinced by the thermal design though. The Fet will heat up the entire pcb (plus all components) before reaching the heatsink. Sure, if it works well and the fet stay cool, you can cool the entire pcb that way, but if they run hot, wouldn't it drastically shorten the lifespan of all smaller ...
by thorlancaster328
Mar 31 2022 11:42pm
Forum: Motor Technology
Topic: Designing the ultimate (400A+) motor controller - what features should it have?
Replies: 10
Views: 871

Re: Designing the ultimate motor controller - what features should it have?

The project is coming along so I figured I'd post a few updates. Our original schedule was to receive the boards by early March, and test over spring break, but JLCPCB had to sit on the boards for two weeks before shipping them. :oops: In the meantime, the software/firmware development has been prog...
by thorlancaster328
Feb 27 2022 3:31pm
Forum: Motor Technology
Topic: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource
Replies: 172
Views: 9887

Re: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource

@mxlemming I'm glad to be back on the 'Sphere as well. Had some other projects that I got interested in for a while. D3 is a zener diode. The SMPS IC needs a voltage rail (to switch its internal FET) that must be between 8 and 12 volts. Normally the SMPS IC uses an integrated linear regulator for th...
by thorlancaster328
Feb 26 2022 8:37pm
Forum: Motor Technology
Topic: Designing the ultimate (400A+) motor controller - what features should it have?
Replies: 10
Views: 871

Re: Designing the ultimate motor controller - what features should it have?

Is/can this be adjustable voltage range to customize for a specific hardware throttle already on a system? Is/can this be separate inputs for throttle and braking? (it's much easier/safer for me to ride with separate acceleration and braking controls, so I have a cable operated throttle for braking...
by thorlancaster328
Feb 26 2022 8:21pm
Forum: Motor Technology
Topic: Designing the ultimate (400A+) motor controller - what features should it have?
Replies: 10
Views: 871

Re: Designing the ultimate motor controller - what features should it have?

thor- any estimate on delivering sensorless FOC, and from standstill? Tough ones from my very basic understanding... Sensorless from standstill is somewhat difficult but not that hard. My current implementation (as well as Lebowski's) relies on knowing the inductance of each phase in real-time and ...
by thorlancaster328
Feb 25 2022 5:47pm
Forum: Motor Technology
Topic: Designing the ultimate (400A+) motor controller - what features should it have?
Replies: 10
Views: 871

Re: Designing the ultimate motor controller - what features should it have?

- precharge - integrated buck converter for peripherals - turn signal control - SOC estimator through coloumb counting Just some ideas :D Having damaged my fair share of connectors from arcing, the precharge is something I will probably add. The only disadvantage is that I will have to run the batt...
by thorlancaster328
Feb 23 2022 5:19pm
Forum: Motor Technology
Topic: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource
Replies: 172
Views: 9887

Re: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource

On one hand I dislike the fact that that resistor will dissipate a fair amount of power (doesn't it overheat?). So lower efficiency for the 12v submodule. On the other hand, that R, together with the C, creates a hefty Low Pass Filter, which probably filters out any voltage spikes -> hence the LM50...
by thorlancaster328
Feb 23 2022 3:07pm
Forum: Motor Technology
Topic: Designing the ultimate (400A+) motor controller - what features should it have?
Replies: 10
Views: 871

Designing the ultimate (400A+) motor controller - what features should it have?

After several iterations of designing various controllers (https://endless-sphere.com/forums/viewtopic.php?f=30&t=109999) I have designed a controller that (should be able to) do 500 peak amps (600A of FETs) in a 100x70x25mm (including heatsink) package. I (and the rest of my startup) are in the...
by thorlancaster328
Feb 23 2022 2:39pm
Forum: Motor Technology
Topic: Another attempt at building a motor controller
Replies: 121
Views: 7739

Re: Another attempt at building a motor controller

Stumbled on this thread looking at different MOSFETs with low RDS values. Seems as if although the IRF100P218XKMA1 is now obsolete, it is being replaced with the IRF100P218AKMA1 from January next year. Not sure what the difference is but it might be of interest to you. Also, have you thought about ...
by thorlancaster328
Feb 23 2022 2:24pm
Forum: Motor Technology
Topic: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource
Replies: 172
Views: 9887

Re: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource

Search LM5017 here before deciding to use it (short version is it doesn't last near 100v.) Seems like you will end up stuck at the same voltage if you try to implement it. From my experience, the LM5017 has had no problems running at up to 20s. It is, however, quite sensitive to voltage spikes and ...
by thorlancaster328
Feb 23 2022 2:09pm
Forum: Motor Technology
Topic: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource
Replies: 172
Views: 9887

Re: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource

Thorlancaster328's quote, not mine.. Some messed up formatting / quoting there. I wish we didn't have to basically edit HTML to produce well-formatted posts, hopefully the new forum software handles this better. :? The Mosfet was not really suited for power, we are going for MDP10N027 which seems t...
by thorlancaster328
Feb 21 2022 5:11pm
Forum: Motor Technology
Topic: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource
Replies: 172
Views: 9887

Re: Motor Controller with Customizable Electronics, easy DIY and repair OpenSource

At this time the Max Volts is 72 (at which the 12V DC-DC module dies) This is the main bottleneck - we could not find a good solution for a small 12V DC module that takes a bigger input. If anybody knows of any small 100 to 12 V DC-DC module, please tell! This is the main barrier i think to making ...
by thorlancaster328
Feb 16 2022 4:48pm
Forum: EBike Technical
Topic: Max safe Flux Weakening
Replies: 30
Views: 3406

Re: Max safe Flux Weakening

Based on my understanding of FOC (I have built a few controllers), Field Weakening (AKA injecting D-axis current to make the effective magnet strength less) is pointless unless you are trying to push more current into the windings than the phase resistance and back-EMF will allow you to. Before the ...
by thorlancaster328
Jul 29 2021 5:43pm
Forum: EBike Technical
Topic: Max safe Flux Weakening
Replies: 30
Views: 3406

Re: Max safe Flux Weakening

Although you've probably found out already, I'm just going to put this for posterity: BLDC / FOC controllers with field weakening only start to apply field weakening once the back-EMF from the motor reaches the battery voltage. This only occurs when you are going fast enough to generate enough BEMF ...
by thorlancaster328
May 23 2021 12:24am
Forum: Motor Technology
Topic: Another attempt at building a motor controller
Replies: 121
Views: 7739

Re: Another attempt at building a motor controller

And again similar to advanced race/OEM active suspension, the real way to do this is by capturing suspension data, even if just by dumb binary switch on the front fork . Since an ebrake switch only allows throttle cut (this is a baseline feature for me), a separate controller input (even just open/...
by thorlancaster328
May 23 2021 12:17am
Forum: Motor Technology
Topic: Another attempt at building a motor controller
Replies: 121
Views: 7739

Re: Another attempt at building a motor controller

Since it has both an accelerometer and a gyro, I should be able to do traction control and stable wheelies. Being a vehicle dynamics guy, I believe this is the killer app that will separate current- from next-generation controllers (or, as you may prefer, technically next-generation from functional...
by thorlancaster328
May 23 2021 12:03am
Forum: Motor Technology
Topic: Another attempt at building a motor controller
Replies: 121
Views: 7739

Re: Another attempt at building a motor controller

How big is this? Looking like quite a pile of stuff. The board is 160x86mm. I designed it to fit onto this heatsink - https://www.heatsinkusa.com/3-500-wide-extruded-aluminum-heatsink/ . With 3 layers of pin headers, the finished controller should be 3.5" wide, 7" long, and a little less ...
by thorlancaster328
May 20 2021 10:34pm
Forum: Motor Technology
Topic: Another attempt at building a motor controller
Replies: 121
Views: 7739

Re: Another attempt at building a motor controller

Although this version works well (aside from the Captastrophe), it was a total PITA to assemble and debug. Since I plan on commercializing this, I have made some big changes to the next version. * More ceramic capacitors, placed properly. No more thermal shock when soldering and if 1 blows, it's not...
by thorlancaster328
May 20 2021 9:29pm
Forum: Motor Technology
Topic: Another attempt at building a motor controller
Replies: 121
Views: 7739

Re: Another attempt at building a motor controller

A while back, Could you not have just made your PCB 5mm bigger and put the caps on properly? I really should have. A few days ago, I was cruising along at ~25 MPH, not accelerating much, and then a long, soft popping sound and the controller lost all power. Having a solid strip of caps epoxied to th...
by thorlancaster328
May 05 2021 3:55pm
Forum: Motor Technology
Topic: 10kW BLDC motor controller up to 90V and 200A with sensorless FOC - build thread
Replies: 63
Views: 4682

Re: 10kW BLDC motor controller up to 90V and 200A with sensorless FOC - build thread

Another option is a neural network-based observer. I've covered a bit of neural networks in my CS classes and I think it's worth giving it a shot. The hardest part would be getting the motor to initially spin, as untrained NNs are useless for everything. Perhaps you could guesstimate the parameters...
by thorlancaster328
May 05 2021 3:45pm
Forum: Motor Technology
Topic: 10kW BLDC motor controller up to 90V and 200A with sensorless FOC - build thread
Replies: 63
Views: 4682

Re: 10kW BLDC motor controller up to 90V and 200A with sensorless FOC - build thread

If another FETs on the same board wouldn't oscillate, that would be because of different reverse recovery transients, I think, but I haven't tried these new IRF100Pxx and IRF150Pxx series yet. Older TO-247 and TO-220 FETs I tried all oscillated. Next time you replace your FETs you should maybe give...
by thorlancaster328
May 05 2021 3:23pm
Forum: Motor Technology
Topic: Another attempt at building a motor controller
Replies: 121
Views: 7739

Re: Another attempt at building a motor controller

So... I won't be continuing with the 36-FET board. There are still some small issues with even heating and I don't want to have to solder 36 FETs for a production controller. I decided to put this controller to the side and add snubbers to my 12-FET IRF100P218 controller... Before snubbers @ 20v 20a...