BBS-FW: Open Source Firmware for BBSHD/BBS02 Controller

[26aintdead]

It seems everything is working properly, but the motor stutters and doesn't want to give me full power.
Seems like it does spin the motor properly until full power kicks in, and then limits itself to about 100W.

I will play around with settings and hopefully find a way to omit this issue, otherwise I might have to give in and buy a new controller sadly enough.

 

[26aintdead]

I suspect it has something to do with with the current ramp setting - does anyone have any information as to what they configured this setting to succesfully with a BBS02B?
Changing current ramp from 10 to 15 makes the behaviour worse, from what I could find 15 is supposed to be the default setting.

Both PAS and throttle give little jitters. Occassionally the throttle does go up to 600 something what, the expected power the motor is supposed to put out.

 

[geofft]

I suspect it has something to do with with the current ramp setting - does anyone have any information as to what they configured this setting to succesfully with a BBS02B?
Changing current ramp from 10 to 15 makes the behaviour worse, from what I could find 15 is supposed to be the default setting.

Both PAS and throttle give little jitters. Occassionally the throttle does go up to 600 something what, the expected power the motor is supposed to put out.

I run a BBS02B (12s, 44v) with this fw and don't have any of the issues you mention. Current ramp set to 10, max current 25A. Your issues are not any way 'known' which makes me suspect your problem probably lays somewhere other than the fw. Maybe battery sagging badly (under min voltage..) or a bms or controller glitch - or maybe just a connection issue somewhere. Just guessing really so probably not much help, but good luck with it...

 

[26aintdead]

I run a BBS02B (12s, 44v) with this fw and don't have any of the issues you mention. Current ramp set to 10, max current 25A. Your issues are not any way 'known' which makes me suspect your problem probably lays somewhere other than the fw. Maybe battery sagging badly (under min voltage..) or a bms or controller glitch - or maybe just a connection issue somewhere. Just guessing really so probably not much help, but good luck with it...

I have two 24AH 48V packs that are still good on my 1000W hub motor pulling 2.5KW peaks so it for sure isn't the battery, I can confirm its not the current ramp setting, I tried disabling the thermal sensor but it didn't change anything meaningfull.
Note that on my original firmware my controller was limiting to about 350 watt due to the thermal sensor being faulty, but other than that, the controller had no problem albeit power limited.


I was a fool not to back up my original firmware sadly enough.

 

[26aintdead]

Sorry for the updates in rapid fashion but I thought I would share my process.

I ended up re-flashing the custom firmware a few times after I have tried to restore a firmware supposedly for the BBS02B I found on this very same forum.
That firmware gave me error 30 and did not work.

Upon returning to the custom config tool I noticed that the tool said;
"Failed to read status from motor controller"

I spammed restore a few times and kept having it write to the controller until I did not see this error.
I then disabled the speed sensor, shift sensor and the temp sensors after which to my pleasant surprise - the motor now seems to deliver full power again. With the wheel against the wall it did not stutter and I've seen an output of around 900W on throttle before obviously stopping.

Tomorrow I'll once again come back to update and troubleshoot a bit further to see if I can narrow down what my problem was after testing if it actually does ride at full power again now in real world riding conditions.

 

[26aintdead]

Sorry for the updates in rapid fashion but I thought I would share my process.

I ended up re-flashing the custom firmware a few times after I have tried to restore a firmware supposedly for the BBS02B I found on this very same forum.
That firmware gave me error 30 and did not work.

Upon returning to the custom config tool I noticed that the tool said;
"Failed to read status from motor controller"

I spammed restore a few times and kept having it write to the controller until I did not see this error.
I then disabled the speed sensor, shift sensor and the temp sensors after which to my pleasant surprise - the motor now seems to deliver full power again. With the wheel against the wall it did not stutter and I've seen an output of around 900W on throttle before obviously stopping.

Tomorrow I'll once again come back to update and troubleshoot a bit further to see if I can narrow down what my problem was after testing if it actually does ride at full power again now in real world riding conditions.

Everything seems to be working flawlessly again.
I've turned the speed sensor option back on without any error to the functionality of the motor.
My conclusion is that the shift sensor option ticked on caused the stuttering / janky throttle & PAS.
Turning the shift sensor option back on reintroduces the problem.
It almost feels and sounds like when the phase wires on a hub motor are shorted out and you put throttle on.

I've solved the issue of the disabled shift sensor by putting it on a brake switch connector.

A bit of troubleshooting and Nils's firmware is working a treat.
I have two profiles set up for both road and offroad profiles, switching is easy via the light button.

Only time will tell how long my controller will last, but atleast its back from the dead and fully functional again, plus extra's to play around with.

Some info about my motor and controller:

BBS02B bought 2023 via AliExpress.
750W controller 48V, MCU; STC15F2K60S2

TLDR: Users flashing this firmware and experiencing throttle / pas problems should try disabling the shift sensor option, in my case, it solved my issue.

 

[geofft]

Everything seems to be working flawlessly again.
I've turned the speed sensor option back on without any error to the functionality of the motor.
My conclusion is that the shift sensor option ticked on caused the stuttering / janky throttle & PAS.
Turning the shift sensor option back on reintroduces the problem.
It almost feels and sounds like when the phase wires on a hub motor are shorted out and you put throttle on.

I've solved the issue of the disabled shift sensor by putting it on a brake switch connector.

A bit of troubleshooting and Nils's firmware is working a treat.
I have two profiles set up for both road and offroad profiles, switching is easy via the light button.

Only time will tell how long my controller will last, but atleast its back from the dead and fully functional again, plus extra's to play around with.

Some info about my motor and controller:

BBS02B bought 2023 via AliExpress.
750W controller 48V, MCU; STC15F2K60S2

TLDR: Users flashing this firmware and experiencing throttle / pas problems should try disabling the shift sensor option, in my case, it solved my issue.

Well done, thanks for posting a conclusion to your issue, that way we all learn something..
Just wondering if a triggering shift sensor shows up in the Event Log, if so maybe there was an early clue there....

 

[GoopGoop]

Is it possible to use bbs-fw on a CANbus version of the BBS02?

 

[26aintdead]

Well done, thanks for posting a conclusion to your issue, that way we all learn something..
Just wondering if a triggering shift sensor shows up in the Event Log, if so maybe there was an early clue there....

I did not see anything in the log concerning a shift sensor, or a shift sensor error.
I'm also not sure why the motor behaved the way it did with the shift sensor on, but it would not power up the motor under load, and not properly under freespin no load either; it felt like the motor was "knocking"

All I can say is I have been following this project for a very long time, from the first versions until now, very happy to have my motor back up and running.
I'll eventually order a new controller just to have one as a back up but very sweet to be able to switch profiles etc.

 

[26aintdead]

Is it possible to use bbs-fw on a CANbus version of the BBS02?

As far as I know this is for UART based controllers only, the firmware and protocol for CANbus controllers, displays and such are alot different from UART.
Correct me if I'm wrong though, anyone.

I have seen someone buy a UART controller and swap his CANbus based BBS02 out to UART with only a little bit of modification of the connectors on the motor side of the controller housing.

 

[Vicv]

Is there a way to add a base current injection into the motor that's always on? 5-10w to keep driveline slack tight so no freewheel clunk when using throttle. Kind of like grin phaserunner simulated freewheel setting

 

[aae34]

Is there a way to add a base current injection into the motor that's always on? 5-10w to keep driveline slack tight so no freewheel clunk when using throttle. Kind of like grin phaserunner simulated freewheel setting

I think something like that was already introduced here:

Feature/apply pretension by EigenMania · Pull Request #255 · danielnilsson9/bbs-fw

Pretension feature, since many users keep asking for it. When enabled, a constant current of 1% is applied when above a configured road-speed. Speed sensor necessary to use the feature. Can be enab...

github.com

And, if you look at the screenshot at the base of that repo, you'll see there's option for pretension*.

*) as is atm., might require building from source - idk., as i don't use that config tool, nor released
binarys from there anyway.

 

[Vicv]

I think something like that was already introduced here:

Feature/apply pretension by EigenMania · Pull Request #255 · danielnilsson9/bbs-fw

Pretension feature, since many users keep asking for it. When enabled, a constant current of 1% is applied when above a configured road-speed. Speed sensor necessary to use the feature. Can be enab...

github.com

And, if you look at the screenshot at the base of that repo, you'll see there's option for pretension*.

*) as is atm., might require building from source - idk., as i don't use that config tool, nor released
binarys from there anyway.

Nice. But ya I'm not sure how all this stuff works. But is it implemented in the newest release? I know it wasn't added to the notes that I saw at least

 

[aae34]

But is it implemented in the newest release? I know it wasn't added to the notes that I saw at least

Nope. Will be in the next release, but i have no idea when that will be.

 

[Vicv]

Nope. Will be in the next release, but i have no idea when that will be.

That's great thanks

 

[sysrq]

Can throttle start current be set to 0.5%? The throttle wasn't jerky at 1% when using battery with 73 mili ohm internal resistance but it started to get jerky again after upgrading the battery to 34 mili ohm internal resistance.

 

[sysrq]

With this firmware my throttle is super easy to modulate. Like I can even walk next to the bike and do a little throttle to function as a "walking mode". Or I can cruise anywhere from almost standstill (0 - 5kmph) to max speed and anything inbetween with just throttle.


Check the settings, I think it might be:

Start Current
Minimum power to apply for lowest throttle input. Setting this to 10% will map throttle range to 10-100% power output.

Default: 1

Can throttle start current be set to 0.5%? The throttle wasn't jerky at 1% when using battery with 73 mili ohm internal resistance but it started to get jerky again after upgrading the battery to 34 mili ohm internal resistance.
Or should I change the throttle mapping by tweaking the voltage to get smoother response?