larsb wrote:I guess you probably have the halls combinations correct from what you describe.
Hi larsb thanks a lot for the super-fast reply!
unlike your case, I have been able to auto-configure the Kelly controller (lucky me!)
Alexey still suggest me to try other hall/phase combinations, I doubt that will be the solution!
Here are the tests that I made (I have checked all the possibile six phase combinations, assuming that the auto-configure on controller is able to identify the related and correct hall sequence/angle):http://www.cerberotech.com/etrial/test_plan.PNG
here the results:http://www.cerberotech.com/etrial/t1.mp4http://www.cerberotech.com/etrial/t2.mp4http://www.cerberotech.com/etrial/t3.mp4http://www.cerberotech.com/etrial/t4_1.mp4http://www.cerberotech.com/etrial/t4_2.mp4http://www.cerberotech.com/etrial/t5.mp4
All the tests produced the exactly same results in term of engine speed and sound (obviously in some cases the rotation direction changed).
The vibration that you hear in the video came from the frame not from the motor.
All the tests had the same result because every time I set up the controller for auto-configure, otherwise the result are in the following video:http://www.cerberotech.com/etrial/Wrong_phase.mp4
larsb wrote:Here's what i did to get my Revolt to work (i guess you know it all but here it comes):
I tried auto-identify first, that did not work on my motor so i had to switch the hall wires manually until i found the good hall wires combination.
Google a commutation table so you can see what the correct hall sequence should be. From the diagnostic screen on the Kelly program you can see the status for each hall sensor.
If you turn the motor slowly by hand in the correct direction you will see the halls status change - if it follows the table then you can move on to the phase wire combinations.
If it's not according to the table then you can use the table to see which hall wires should be switched to get the correct sequence.
As you suggested I have compared a commutation table found at the following link to the controller phase value in the Controller under "Monitor" section.https://e2e.ti.com/blogs_/b/motordrivecontrol/archive/2013/11/08/generate-your-own-commutation-table-trapezoidal-control-3-phase-bldc-motors-using-hall-sensors
The results, as reported in the following video are right, the controller follow the correct sequence on the table slowly by turning the engine in the correct direction.
I have no Idea how to check the correspondence between the Hall Sensor position (the first column in the table) with the motor phase (the second column in the table), but I think that it doesn't matter, the engine will manage the current on phase according to the Hall position (yes if the angle is wrong it is a problem, with kelly no way to manage that).http://www.cerberotech.com/etrial/phase_check.mp4
Do you think that is enough to consider the correct phase/halls settings?
larsb wrote:According to Fany at Kelly there is no manual tuning of the phase angle in the Kelly program. If your hall placements are as bad as mine then you need to replace the hall sensors to ever get any good performance - good luck!
Thanks for this precious info, I am struggling to find the correct entry in the controller settings to change the phase angle, it isn't !
larsb wrote:The phase current that was recommended to lower heating from Revolt in my case was max 200A so phase current percent would be lowered to 66
Gearing recommended from Revolt in my case was minimum ratio of 9front/45rear in 26" wheel
Yes, I have reduced the Current Percent
to 50% (150A), I feel a considerable performance decrease, unfortunately engine still getting hot (it requires quite more time).
Said that, I see the following opinions:
- Get refund because the engine do not respect the paper performance (but nobody redound you for taxes and shipping costs)
- Disassemble/verify the phases with an oscilloscope and eventually replace the hall sensors (void the warranty)
- Provide an active cooling system to keep temperature low to the maximum accepting the energy waste
I will update soon...