Search found 113 matches

by owhite
Jan 20 2021 8:33am
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

I see now -- you are referring to these:
http://www.farnell.com/datasheets/1736664.pdf
"Wurth Elektronik 7460408 M5 bushing"

That is an excellent suggestion! I will investigate and see if there's room for them. That part of the board is not too crowded so I think it would work.
by owhite
Jan 19 2021 3:19pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

So I'm happy to help but I'm not sure what changes would be made to the printed circuit board itself. The terminals in that link seem to be things that would be added to the housing around the printed circuit board, but not to the board itself. But maybe I'm still confused.
by owhite
Jan 18 2021 7:11pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

As for PCB feature requests, are screw terminals possible like on the ASI BAC controllers?
i wasnt able to find a pic of an ASI BAC with a screw terminals. Can you post one?
by owhite
Jan 18 2021 6:06pm
Forum: EBike Build Threads
Topic: 5kW ebike motor / controller testing
Replies: 24
Views: 2747

Re: 5kW ebike motor / controller testing

Power distribution system for the bike. These were made with two printed circuit boards with built up bus bars mounted and epoxied into 3D printed boxes. https://i.imgur.com/uJZw1ec.jpg They were constructed from custom circuit boards which solder into XT90 connectors https://i.imgur.com/ZJF79OH.jpg...
by owhite
Jan 16 2021 8:59pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

A CUSTOM SERIAL DISPLAY An update on the display system for the BESC. I got a 3.5inch TFT touchscreen that is 320x480 pixels from adafruit: https://www.adafruit.com/product/2050 They have a lot of documentation, and in combination with a teensy 3.2: https://www.pjrc.com/store/teensy32.html which is...
by owhite
Jan 05 2021 2:26pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

REQUEST FOR PCB CHANGES ?? I am taking suggestions for minor improvements to BESC G2 board. I'm making modifications in kicad and will eventually post the new files if anyone is interested. So far what I have done is: Removed U7. Disconnected lower right mechanical hole from GND - others may not ag...
by owhite
Jan 05 2021 2:24pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

I would not do this again, just not worth the time
I simply could not imagine assembling this board. If youre interested I could help with the files needed to have it assembled for you at PCBway. Let me know. Also, please see my next post, I'd be interested in your opinion.
by owhite
Jan 04 2021 4:03pm
Forum: EBike Build Threads
Topic: 5kW ebike motor / controller testing
Replies: 24
Views: 2747

Re: 5kW ebike motor / controller testing

Thanks John in CR, I appreciate the suggestion about the frame. I will be replacing the wood with laser cut AL, it's just easier to use that because I have a laser that cuts plywood in my shop. Most of all my main goal is to just get on the road to see if the motor, battery and controller combinatio...
by owhite
Jan 04 2021 8:55am
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

Looking good so far! I believe based on the cross section size you should be able to handle the amperage to run at least three houses at the same time. :) So it looks like you have not soldered on some of the SMD parts yet? Will you be adding them by hand? Also, be mindful that there are some throug...
by owhite
Jan 04 2021 8:27am
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

USING THE VESC-TOOL The following is a description of using VESC-tool to get the motor spinning. These steps are probably very close to a step by step set of instructions, but as usual should be treated as a guide because your situation may be different. VESC-tool is great software with lots of gre...
by owhite
Jan 03 2021 11:26am
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

MOTOR TEMPERATURE READING ISSUES Thermistors are based on a voltage divider, and there does not seem to be one in Galp's circuit. It may be that he did this so his board would have the ability to deal with thermistors that have different resistances. Most VESCs assume the motor will be 10k, and in ...
by owhite
Dec 30 2020 6:04pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

well congratulations on getting your board together! I'm not really not sure there is anyway to prevent some kind of warping of the board if you use heat to attach a rod as the bus bar. Here is my thinking. No matter what you cant keep the copper rod from lengthening when you heat it. What then happ...
by owhite
Dec 30 2020 5:49pm
Forum: EBike Build Threads
Topic: 5kW ebike motor / controller testing
Replies: 24
Views: 2747

Re: 5kW ebike motor / controller testing

each batter pack is 2 1/2 inches wide, and in addition to the central frame tube, the whole thing is close to seven inches.

Image
by owhite
Dec 28 2020 9:15am
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

That's curious, because the files I found at the github site had fixed R66 and C66. Did you have old copies of the files or something?

Also, have you started to solder on the bus bars? Be careful, I've had a lot of problems with warping the board when I put on larger wires.
by owhite
Dec 26 2020 8:23pm
Forum: EBike Build Threads
Topic: 5kW ebike motor / controller testing
Replies: 24
Views: 2747

Re: 5kW ebike motor / controller testing

Next installment of going from here to here: https://i.imgur.com/WpgjdF2.png Larger pic of design: https://i.imgur.com/phPwDpM.png Larger pic of progress: https://i.imgur.com/ZWRHSph.jpg This process took a lot of work to figure out the lines of the frame and then get them into CAD. Lesson learned. ...
by owhite
Dec 05 2020 8:48pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

There are a couple issues. I can imagine the firmware will work pretty well as it is now. But I'd feel better about you trying it if there were other people using this thing that could help you if you need it - the forum over on VESC-projects is active for the VESCs, but I was not able to get much h...
by owhite
Dec 02 2020 6:03pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

CREATE A CUSTOM SERIAL DISPLAY So hey - ever wanted to get serial data out of your motor controller and display it using an arduino? Since the BESC G2 is based on the VESC family, it's really simple. VESCs are very well supported, and among the things they can do is stream data in a couple formats,...
by owhite
Nov 30 2020 12:27pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

sounds great. be sure to read galp's blog entry:
http://pavlin.si/besc/besc-g2/
which notes you should remove U7 and instead put a wire across some of the pins.
by owhite
Nov 30 2020 9:49am
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

FLASHING FIRMWARE The following is a short write up for flashing firmware to the BESC G2 from scratch. Things like firmware change all the time but this is a quick write up for flashing the firmware on the BESC circa December 2020. Basically, go to https://github.com/vedderb/bldc and read the instr...
by owhite
Nov 28 2020 3:17pm
Forum: EBike Build Threads
Topic: 5kW ebike motor / controller testing
Replies: 24
Views: 2747

Re: 5kW ebike motor / controller testing

Swing arm build. https://i.imgur.com/BqUoNXp.jpg I am starting with this frame and need to replace the back swingarm to fit my QS205 motor: https://i.imgur.com/yyEgZCn.jpg I did a bunch of CAD work for 3/8ths thick aluminum, set up with slots and tabs to help the whole thing fit together: https://i...
by owhite
Nov 27 2020 11:55am
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

Hey some additional good news. Detection of the hall sensors was solved when I stopped using the binary for the board's firmware. This originally not possible because the gcc-arm tool chain on my macOS did not make a correct firmware file. But compiling it on linux ubuntu does work. This is an impor...
by owhite
Nov 26 2020 8:52pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

Re: building the BESC - 100V, 400A motor controller

I still cant recommend building this board -- yet. The firmware needs to make analog to digital calls to the thermistor, and read the halls, and so far it doesnt look like it's working. Bear with me, I'm working on it.
by owhite
Nov 23 2020 6:38pm
Forum: Motor Technology
Topic: BESC - beefed up VESC motor controller for high power ebikes
Replies: 173
Views: 39348

Re: BESC - beefed up VESC motor controller for high power ebikes

Yes. As a matter of fact I just wrote up my experiences with building one here:

viewtopic.php?f=2&t=109266
by owhite
Nov 23 2020 6:37pm
Forum: EBike Technical
Topic: building the BESC - 100V, 400A motor controller
Replies: 97
Views: 6462

building the BESC - 100V, 400A motor controller

Ever want to build your own controller? https://i.imgur.com/x0HzrMm.jpg INTRODUCTION This write up is an overview of building an open source electronic speed controller (ESC) that was originally posted here: https://endless-sphere.com/forums/viewtopic.php?f=30&t=97765 The designer of big(?) ESC ...
by owhite
Nov 05 2020 11:06am
Forum: EBike Build Threads
Topic: 5kW ebike motor / controller testing
Replies: 24
Views: 2747

Re: 5kW ebike motor / controller testing

A post about upgrading a sabvoton motor controller to a 100v rating. Tools. Before starting let me recommend some incredibly helpful tools that I dont think would have made this possible. Item 1 can be found by searching on "claw pen" and helps with grabbing small parts. Item 2 is a desold...