building the BESC - 100V, 400A motor controller [NOT RECOMMENDED]

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Interesting to see that you are making progress :)

I played a little with the vesc tool, but I didnt have a controller to connect to.

I think vesc should have mtpa and field weakening now, but I didnt see anything about it in the vesc tool.
Do you know if they will work on this board?
 
That serial display is well done. I also used adafruit parts to do a display and recently built one using the circuit python language. Adafruit has created a microcontroller board (feather) that uses the SAMD with a CANbus ports and a transceiver. When that gets out of backorder, I'll start developing a CANbus display that communicates with the BMS and controller.

As for PCB feature requests, are screw terminals possible like on the ASI BAC controllers?
 
I misspoke and meant a ring terminal connector. The current ASI BAC 2000, 4000, and 8000 have the connector I meant.

https://www.acceleratedsystems.com/products/electric-motor-controllers/bac2000

I don't know what part ASI uses but the Wurth RedCube Press-fit terminals are usually available from suppliers.
 
The RedCube parts mount directly on the PCB. The diebiems BMS board uses them and you can see them in the photos here:

https://hackaday.io/project/28340-diebiems-a-3-to-12s-battery-management-system

They connectors press fit into a matching footprint on the circuit board.
 
owhite said:
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.
Click to expand...

Hey! I compiled latest vesc code for BESC-G2 and tested it with hall sensors. Download it from the link bellow. You can also find updated HW config files for vesc code in the attachment.

http://pavlin.si/besc/besc-g2/
 

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Hello guys,

I'm building this BESC. I got the board made and mounted all the parts except bus bars and heat sink as I wanted to test before doing these (maybe mistake about the bus bars but we will see later when I will try to put them there). When power is supplied and the run header shorted I get 3V3 LED to light up so my power sources are good. I flashed the binary on galp's website using st link utility and everything went good except the other two LEDs did not light up even after rebooting.

I tried looking for the error but was not successful. I measure about half a volt on the diodes. I can connect to PC and VESC Tool. I can voltage sense according to what is written on the bottom of http://pavlin.si/besc/besc-g2/ but when I try to current sense nothing happens. No fault and no resistance when anchoring, only duty cycle no longer shows up.

Do you have any suggestion what to try to check?
 
Hit the anchor icon in vesc tool and try to spin the motor. If there's consistence resistance then everything should be ok. If it cogs or there's no resistance power stage is not switching properly. Measure gate-source signal on mosfets while anchor icon is activated.. Maybe there's bad soldering.
 
Hey! I compiled latest vesc code for BESC-G2 and tested it with hall sensors. Download it from the link bellow. You can also find updated HW config files for vesc code in the attachment.
Click to expand...

Thanks Galp! I'll try it very soon. The board is working very well so far!

My board is mounted, has been spinning a QS205, and I'm still finishing up the bike for real world testing.

Thanks much for this open source project!!

qcdJwb9.jpg
 
andress.cz wrote:
I flashed the binary on galp's website using st link utility and everything went good except the other two LEDs did not light up even after rebooting.
Click to expand...

andress -- what was the operating system you used to load the firmware? I had a similar problem when I used macOS. See this post:
https://endless-sphere.com/forums/viewtopic.php?f=2&t=109266#p1601595
 
I was using previous FW BLDC_4_ChibiOS.bin and THR LED did light up, after loading lates FW BESC_G2_FW.bin did not, all other functions are ok.Does anybody know how to get Get_VESC_Data over CANBUS?
 
erdogank said:
I was using previous FW BLDC_4_ChibiOS.bin and THR LED did light up, after loading lates FW BESC_G2_FW.bin did not, all other functions are ok.Does anybody know how to get Get_VESC_Data over CANBUS?
Click to expand...

ok I solved it.
 
drdrs said:
did you use COMM_GET_VALUES or COMM_GET_VALUES_SELECTIVE as the command in the CANbus request frame?
Click to expand...

I enabled Can Status Message Mode to CAN_STATUS_1_2_3_4_5 and changed Can Status Rate to 1Hz from Vesc Tool.
 
erdogank said:
drdrs said:
did you use COMM_GET_VALUES or COMM_GET_VALUES_SELECTIVE as the command in the CANbus request frame?
Click to expand...

I enabled Can Status Message Mode to CAN_STATUS_1_2_3_4_5 and changed Can Status Rate to 1Hz from Vesc Tool.
Click to expand...

and receiving canbus messages from chinese BMS and BESC
ESC 51.40V -2.10A 0rpm 138 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
BMS 51.47V 0.00A 9.55Ah 20Ah 0 48% 14 2 0C 0C 3.702V 3.668V 3.669V 3.671V 3.670V 3.674V 3.674V 3.620V 3.672V 3.672V 3.673V 3.655V 3.665V 3.789V
ESC 51.40V -2.30A 0rpm 134 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.40V 2.70A 0rpm 129 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.40V 2.40A 0rpm 123 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.40V 2.50A 0rpm 118 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.40V 2.30A 0rpm 112 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.40V 2.40A 0rpm 106 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
BMS 51.47V 0.00A 9.55Ah 20Ah 0 48% 14 2 0C 0C 3.702V 3.668V 3.669V 3.671V 3.671V 3.674V 3.674V 3.620V 3.673V 3.672V 3.673V 3.655V 3.665V 3.789V
ESC 51.40V 2.30A 0rpm 101 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.50V 2.30A 0rpm 95 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.40V -2.70A 0rpm 90 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.40V -2.30A 0rpm 86 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0Wh
ESC 51.40V 2.20A 0rpm 81 0 0C 0C 0.04A 0Ah 27Ah -12Wh 0W
 
drdrs said:
beautiful. is vesc tool reading the bms values and creating those text outputs?
Click to expand...

I have extra partially soldered BESC boards with CPU and canbus chip, have connected canbus,serial,speed hall sensor and wrote small stm32 program that outputs all this data to an OpenWrt router with webserver and I'm using Kindle as a dashboard.

ESC 051.30V -002.70A 00000rpm 62738 000 00027C -0001C 000.00A 000.008Ah 000.001Ah 0000.433Wh 0000.049Wh
SPD 00000rpm 000kmh
ESC 051.30V -002.20A 00115rpm 62835 019 00027C -0001C -00.10A 000.009Ah 000.001Ah 0000.455Wh 0000.049Wh
SPD 00000rpm 000kmh
ESC 051.20V -001.80A 00187rpm 63383 028 00027C -0001C -00.20A 000.009Ah 000.001Ah 0000.458Wh 0000.049Wh
SPD 00113rpm 010kmh
ESC 051.30V 0002.80A 00188rpm 63985 028 00027C -0001C 000.70A 000.009Ah 000.001Ah 0000.460Wh 0000.049Wh
SPD 00120rpm 011kmh
BMS 051.28V 0000.00A 0009.51Ah 0020.00Ah 0000 00048% 14 02 024C 000C 3.693V 3.660V 3.662V 3.663V 3.663V 3.666V 3.666V 3.611V 3.665V 3.664V 3.666V 3.648V 3.656V 3.694V
SPD 00122rpm 011kmh
ESC 051.30V 0004.00A 00208rpm 65805 032 00027C -0001C -00.20A 000.009Ah 000.001Ah 0000.467Wh 0000.049Wh
 
owhite said:
would you have any interest in posting an overall diagram and your stm32 code?
Click to expand...

source code is attached written in STM32CubeIDE 1.4.2, OpenWrt is not finished yet, show only battery pack and part of motor data, when finished I can share them too.Kindle is only using Experimental Browser to display html pages from the router website.
 

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I'm almost too embarrassed to write what was the problem with my BESC :D
After some more measurements around the mosfets and drivers I found out that the driver always receives signal on the disable pin. After looking in the schematic where is it coming from I saw U7 and got a bad feeling that I have read something about U7 before. Sure enough my whole problem was that I forgot that in current firmware U7 has to be bridged. So my drivers were always disabled and that was the cause of it not working.
I removed U7 and now it works like a charm including FOC and everything (but no LEDs apart from 3V). So far I did just a freewheeling bench test but once I install the bus bars and heatsinks I wanna build electric unicycle. If it works it's gonna be sweet.
 
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