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  1. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    A bit of progress, i had some time to machine the bus-bars and the case, the pcb bus bars ware a bit of headache to make since they are so small and thin, the copper is so soft i had to add some aluminum plates to support the copper in order to be able to machine it (see photo). Now i have all...
  2. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    A bit of progress here, i have made a fuse box to encase the fuse witch will be bolted to the battery + cable, now i know that fuse is rated at 32V and i'm pushing 92V thru it, it might arc a bit when it blows, but still better then nothing and blowing up my power board, i'm aiming for a bit...
  3. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    Yeah... i feel you, that is that way that i felt when i saw 4 layer pcb-s around here, then i tried JCL-PCB, i was reluctant to try it, i taught is is expensive and complicated, but now i can have 4 layer pcb-s too. You can try to give your parts to a machine shop they might charge about 50 to...
  4. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    A bit of progress, i drilled the heat sink (200x100x25mm) and machined the slots to give clearance to the boltheads of the cable lugs, it came out nice. The sink is extruded Al, and on 200mm length was out of plane about 1mm in the center, so i had to do some fine pressing to bend it back in to...
  5. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    Yes is continous under and connected only to B- Edit: and the inner lower (purple) the unused part in the middle is also grounded (B-)
  6. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    I have made a die (jaws) for crimping cable lugs, for 35 and 25 sqmm cables, i followed the specifications for hex size for correct crimping. I came out nice, a big vice (100mm at least) is needed to make a good crimp. Here a few photos of the die and a crimped cable and lug.
  7. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    Kv is 36, delta terminated. 10x for appreciation.
  8. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    There are 3 physical separate boards, so yes the blue gnd plane is split
  9. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    hey guys,the power boards are on they'r way to europe (jlcpcb), in the meantime i'v been redesigning all the power distribution section and the casing, most of the work and taught was for the laminated busbars, i have found this https://www.youtube.com/watch?v=zGsHuoK9Egs they give some good...
  10. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    I have changed the layout a bit in order to better acomodate the battery feed to the boards, i added snubbers they are over the fets close to the legs to keep inductance small, added foot prints for external Cgs, gate pull down resistor and TVS (or zenner), the gate traces are routed outwards...
  11. Mihai_F

    Building a motor

    My motor was run in both ways wye and delta, in delta 36kv 7A no load at 37v, in wye 21kv 4.1A no load at 37v. Care must be taken when making the delta connection, so that all coils pull/push in the same direction. Now about drive pattern, delta motors can be driven in push or pull mode (pull...
  12. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    are you refetring to V+ to Gnd snubbers or D-S fet snubbers? V+ to Gnd snubber (decoupling) caps are there 9 ceramic pieces between the V+ and Gnd plains, per board, they will be 6x1uF and 3x10uF ceramics, i made foot print larger for 10uF it is 2220smd . the D-S fet snubbers might place them...
  13. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    yep i'l will put the snubbers i'l have to find a good place for them I tried a version with 9 fets in a raw on a single board, and was about 166mm, but there was not much space for gate routing without crossing under the high current planes, and i will try to avoid that as much as possible...
  14. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    I have been working on the new power board design V1.4 , 4 layer, it is work in progress, not finished yet, and if you can give some opinions on layout of the gates and switching loop. I got inspired from mxlemming (most of it), zombies (on board per phase) and a bit of peters(fet-s staggered)...
  15. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    Thank you everyone for you appreciation! I had a look at power board v1.2 and compared it to v1.3, and made a list with differences and similarities, then i remembered (a year ago i woked on it) what made v1.2 functional, and v1.3 does not have, and these are: 6 x 0.1uF ceramics and 15 x 1uF...
  16. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    I took a look at you design, i got inspired and learned from it, and started designing a new powerboard (v1.4 :D ). On the v1.3 power board i went with 22r on gates and 20n+1.8r snubbers, that cleaned the ringing and weird pulses on t-on/t-off at no load, but sadly with increasing load the "bad...
  17. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    The toolchain is atmelstudio. The software that i use for pcb is Copperconnection from Robotroom, 6 years ago was free, but then was bought by a big company and now it does not exist anymore (officially) .... :shock: I will give a try to kicad, i heard of it but never used it. As for a 4 layer...
  18. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    Thank you guys for your appreciation ! Well the build quality it is mostly because of the CNC machining, my job is CNC mill machinist, so this just standard practice to me, even if the parts were not made at the shop where i work (various reasons), i knew exactly how to draw it, what to put...
  19. Mihai_F

    20Kw motor and 300A ESC (ultralight aircraft propulsion system)

    Hy guys, i will move here the discussion about my 20Kw motor and 300A esc. This is been a project for my past 6 years, it's been a huge learning curve. Before i started this project my experience with electronics was with power audio circuits, analog stuff, and nothing digital. I will start...
  20. Mihai_F

    Building a motor

    Thanks guys for appreciation of my motor, i will make a separate topic to show you a bit of the past 6 years of me learning how to make an BLDC ESC and the motor, so i don't hijack mxlemming topic 😬, and hopefully it won't take me that much time to get the ESC back working. Nice rotor by the...
  21. Mihai_F

    Building a motor

    yep, it centers on the shaft, and the magnets are inserted in the slots and then outward to the ring the plastic one is the same magnets were glued with 2 part epoxy for metal, it bonds well, they held in place while testing at vibrations at a thigh torque and high speeds
  22. Mihai_F

    300A bldc esc, mosfets ringing, help

    Well in that trace, the motor was running WOT at 3000rpm, at that speed commutation time is 166us, pwm is not present since duty cycle is 100%, hence wot, my scope was set for 64 captures and every now and then, completely random about 10 to 14 shots out of 64 but not in a order, they are...
  23. Mihai_F

    Building a motor

    Nice job, looking good for testing. About magnets precise placement, (within +/- 0.05mm) the larger the diameter of the rotor, the greater the electrical degres error you will have if magnets have different distaces between them. On my rotor i made a wooden slotted tool for precise magnets...
  24. Mihai_F

    300A bldc esc, mosfets ringing, help

    I did not fully understand that “is this the on in 4... “ And can you elaborate a bit on the first part the one with changin hall states, pwm, and clamping
  25. Mihai_F

    300A bldc esc, mosfets ringing, help

    No gate traces, i have to wait for some parts. Is dead time necesarly if there is NO complementary switching, i had 700ns at some point, but also none, and it worked both ways...., my switching scheme is bloc commutation with pwm on low side, with NO complementary switching.
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