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Luna M600 Ludicrous V2 reverse engineering and firmware making
- Thread starter TPEHAK
- Start date
It's awesomeness!
TPEHAK
🚴♂️ Mega poster
3D printed the antenna cup for the VESC M600 controller out of ABS plastic and marked the cover. The parts fit perfect!
Luna M600 Ludicrous V2 controller vs VESC M600 controller
Luna M600 Ludicrous V2 controller vs VESC M600 controller
TPEHAK
🚴♂️ Mega poster
I have only a few parts out of the whole bike at the moment. I need the frame here to take measurements before I can start deciding on other parts and the frame has not arrived yet.
TPEHAK
🚴♂️ Mega poster
The antenna has been installed, the controller has been assembled completely and installed on the motor and tested again. Everything works as on the the original one and Bluetooth works better as expected (when I tested the controller with the original cover it took quite some time before my phone found the Bluetooth, the new cover with the real antenna were found immediately and worked from far distance).
Now it is waiting game before I will have finished the bicycle.
Here is the updated archive with the controller files.
The Gerber files are the same as the previous release, no changes to the PCB (it is still version 0.01) and PCB assembly. The CNC machined cover is the same. I changed only the antenna 3D printed cup CAD model slightly for better fit after 3D printing and updated the KiCAD PCB editor assembly so it has that updated CAD model.
I also included the thermal pad CAD model and PDF file with outline for cutting. The CAD model is also attached to the KiCAD PCB editor assembly so you can see where it is installed exactly
I also included the PCB top face assembly 3D printed jig CAD model to make PCB assembling and soldering process easier
I also included the Bluetooth firmware files
To install the antenna you need to glue the 3D printed antenna cover first with RTV silicone and wait until the silicone is cured
Do not fill the opposite side cavity with silicone yet, apply the silicone only on the mating surfaces, wipe the silicone excess with clean towel and alcohol and let the silicone cure completely
Attach the antenna to the controller
Fill the opposite side of the antenna cavity with silicone and stick the antenna end into the hole in the 3D printed cup
Route the antenna and screw the PCB in the place on the cover and let the silicone cure completely
Cut 0.5mm thick thermal pad. I used ARCTIC TP-3 0.5mm
www.arctic.de
Before peeling the clear tape off the thermal pad I recommend to stick a masking tape rib on the opposite side for handling because of the thermal pad is very soft and delicate
Peel the clear layer off at sharp angle
Attach the thermal pad to the cover
Peel the tapes off
Apply blue Loctite on the fasteners
Install the PCB on the cover and there you have it
Install the controller on the motor following this instruction. Do not forget to install the gasket first before attaching the controller to the motor.
Now it is waiting game before I will have finished the bicycle.
Here is the updated archive with the controller files.
The Gerber files are the same as the previous release, no changes to the PCB (it is still version 0.01) and PCB assembly. The CNC machined cover is the same. I changed only the antenna 3D printed cup CAD model slightly for better fit after 3D printing and updated the KiCAD PCB editor assembly so it has that updated CAD model.
I also included the thermal pad CAD model and PDF file with outline for cutting. The CAD model is also attached to the KiCAD PCB editor assembly so you can see where it is installed exactly
I also included the PCB top face assembly 3D printed jig CAD model to make PCB assembling and soldering process easier
I also included the Bluetooth firmware files
To install the antenna you need to glue the 3D printed antenna cover first with RTV silicone and wait until the silicone is cured
Do not fill the opposite side cavity with silicone yet, apply the silicone only on the mating surfaces, wipe the silicone excess with clean towel and alcohol and let the silicone cure completely
Attach the antenna to the controller
Fill the opposite side of the antenna cavity with silicone and stick the antenna end into the hole in the 3D printed cup
Route the antenna and screw the PCB in the place on the cover and let the silicone cure completely
Cut 0.5mm thick thermal pad. I used ARCTIC TP-3 0.5mm
Thermal Pad - TP-3 | Premium Performance Thermal Pad | ARCTIC
The ARCTIC Thermal Pad ACTPD00055A is a perfect and soft bridger of unevenness for an even cooling surface. Easy to use and safe to handle | Fast processing and delivery | ARCTIC Store
www.arctic.de
Before peeling the clear tape off the thermal pad I recommend to stick a masking tape rib on the opposite side for handling because of the thermal pad is very soft and delicate
Peel the clear layer off at sharp angle
Attach the thermal pad to the cover
Peel the tapes off
Apply blue Loctite on the fasteners
Install the PCB on the cover and there you have it
Install the controller on the motor following this instruction. Do not forget to install the gasket first before attaching the controller to the motor.
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TPEHAK
🚴♂️ Mega poster
I just realized the controller cover might interfere with the Kunlun frame. The ribs pattern is different and it looks like the frame line follows the original Bafang ribs pattern. It might fit if the motor is narrower than the frame in that area but I can not tell for sure looking on the Markhor Kunlun pictures I found. We might need to redesign the controller cover ribs pattern to fit that frame. It looks like Luna designed that cover to fit specifically to Dengfu E10 frame.
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TPEHAK
🚴♂️ Mega poster
Today I built a canable cable for the VESC Express dongle to see if it is possible to setup that controller without the Bluetooth module and unfortunately the VESC Express did not work with this controller (it does not see the controller). Maybe they locked it like Innotrace did?
forums.electricbikereview.com
Archon X1 Programming Thread (questions and experiences)
The motor with controller CAD model can be downloaded or checked on the GrabCAD https://grabcad.com/library/vesc-for-bafang-m620-uart-1 You can use it for reference to see the cables connections and proper cables routing. The motor controller area is precisely reverse engineered and can...
forums.electricbikereview.com
TPEHAK
🚴♂️ Mega poster
Obtained a 3x3 nine high torque high power gear hub to handle the 4000 W power of the VESC for Bafang m600 controller. That monster is bigger and heavier than the motor!
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TPEHAK
🚴♂️ Mega poster
It is time to get excided guys! The frame is here and looks strong enough to handle the VESC power!
TPEHAK
🚴♂️ Mega poster
That's something new, Markhor M560 RS motor, never heard about such thing
But I think VESC M600 is more powerful anyway
But I think VESC M600 is more powerful anyway
TPEHAK
🚴♂️ Mega poster
Welp, we need to shave the controller cover rib down a bit, there is a little interference
TPEHAK
🚴♂️ Mega poster
3D Printed modified controller cover to check fitment before doing the adjustments on the actual cover
Now it fits
Now it fits
TPEHAK
🚴♂️ Mega poster
3D printed a jig for milling the controller cover
Shaved off the interference with milling machine
A little touch up with black sharpie
And now it fits the frame like a glove
Shaved off the interference with milling machine
A little touch up with black sharpie
And now it fits the frame like a glove
TPEHAK
🚴♂️ Mega poster
The Kunlun V2 frame needs some work to fit the 3x3 nine gear hub and other stuff. It looks like they designed this frame strictly for one only setup (limited amount of cables channels, limited amount of cables openings, openings are small etc).
Milled the interference off from the post mount to fit the 3x3 nine torque arm
The motor front mount brace had issues too (from the factory it does not fit the motor properly causing mount holes misalignment and an issue with attaching the motor mounting fastener). Milled the interference off.
Milled the interference off from the post mount to fit the 3x3 nine torque arm
The motor front mount brace had issues too (from the factory it does not fit the motor properly causing mount holes misalignment and an issue with attaching the motor mounting fastener). Milled the interference off.
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TPEHAK
🚴♂️ Mega poster
I am wondering what is inside this motor too. I am waiting for the chaining locknut tool to open it up.
As far as I know the M600 has different torque sensor than M560, and M560RS has different torque sensor than M560. I do not know if the new torque sensors have different pinout, power supply and output signals though. If it is then it might not work with the controller.
Meanwhile the VESC M600 works with the Kunlun electronics just like with other Bafang CANbus electronics. The dealer said there is special firmware for KunLun electronics only, but it looks like it should work with any Bafang CANbus motor.
My display shows Bafang logo though while I saw in the Internet videos with Kunlun logo on the display
The VESC M600 spins with Kunlun electronics
The speed sensor is new and it uses metal plate mounted on the rear brake. The metal plate has openings. The new speed sensor works with VESC M600 controller just like the old one with magnet (each opening in the metal plate is like one turn of the wheel though so the LUNA firmware needs to be adjusted for correct speed or maybe there is a setting in the VESC Tool to change it). This new sensor works with magnet too so you can use in the old way with one magnet on the wheel and there is no need to change the firmware in this case.
As far as I know the M600 has different torque sensor than M560, and M560RS has different torque sensor than M560. I do not know if the new torque sensors have different pinout, power supply and output signals though. If it is then it might not work with the controller.
Meanwhile the VESC M600 works with the Kunlun electronics just like with other Bafang CANbus electronics. The dealer said there is special firmware for KunLun electronics only, but it looks like it should work with any Bafang CANbus motor.
My display shows Bafang logo though while I saw in the Internet videos with Kunlun logo on the display
The VESC M600 spins with Kunlun electronics
The speed sensor is new and it uses metal plate mounted on the rear brake. The metal plate has openings. The new speed sensor works with VESC M600 controller just like the old one with magnet (each opening in the metal plate is like one turn of the wheel though so the LUNA firmware needs to be adjusted for correct speed or maybe there is a setting in the VESC Tool to change it). This new sensor works with magnet too so you can use in the old way with one magnet on the wheel and there is no need to change the firmware in this case.
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TPEHAK
🚴♂️ Mega poster
The gear hub has been laced
TPEHAK
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The Kunlun battery is here! 48V 30A so we can squeeze around 1500W out of it. I think it is enough for the initial test of the controller. Later we can build maybe something like 72V 60A and go crazy with 4000W of powah!
If someone recognizes this battery case can be purchased on Aliexpress please let me know.
If someone recognizes this battery case can be purchased on Aliexpress please let me know.
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TPEHAK
🚴♂️ Mega poster
Designed and 3D printed the magnet holder for the speed sensor out of carbon fiber filled PETG for mounting it on the 3x3 nine rear brake rotor
The magnet is glued into the holder with superglue and the holder is fixed on the brake rotor with a rubber O-ring. Will see if it is going to work with the new speed sensor. The new Bafang speed sensor has magnet inside and it might react on the steel rotor and give false speed reading, but I hope it is far enough from the brake rotor to read only the magnet.
The magnet is glued into the holder with superglue and the holder is fixed on the brake rotor with a rubber O-ring. Will see if it is going to work with the new speed sensor. The new Bafang speed sensor has magnet inside and it might react on the steel rotor and give false speed reading, but I hope it is far enough from the brake rotor to read only the magnet.
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TPEHAK
🚴♂️ Mega poster
Disassembled the Markhor M560RS motor
The power wires diameter is smaller than Luna controller wires diameter
The torque sensor cable is now separate part
Took some measurements and tried to fit the Luna PCB mock-up
It certainly will not fit. Maybe only 1 hole is in correct place, other holes do not match. The MOSFETs will interfere with the heat sink bumps and those heat sink surfaces cover the MOSFETs only partially and not all of them. The phase wires soldering spots interfere with the heat sink surface. The big inductor from the 12V circuit is probably too tall and will interfere with the bottom of the motor housing. The PCB needs to be redesigned for M560 motor
The power wires diameter is smaller than Luna controller wires diameter
The torque sensor cable is now separate part
Took some measurements and tried to fit the Luna PCB mock-up
It certainly will not fit. Maybe only 1 hole is in correct place, other holes do not match. The MOSFETs will interfere with the heat sink bumps and those heat sink surfaces cover the MOSFETs only partially and not all of them. The phase wires soldering spots interfere with the heat sink surface. The big inductor from the 12V circuit is probably too tall and will interfere with the bottom of the motor housing. The PCB needs to be redesigned for M560 motor
Wow, hats off for all this work!
That's unfortunate. I was looking forward to an open-source controller for the M560, mainly in the hope that it would reduce the noise.
That's unfortunate. I was looking forward to an open-source controller for the M560, mainly in the hope that it would reduce the noise.
TPEHAK
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Wrapping the frame
rezystor1990
🔌 New-ish
- Joined
- Nov 18, 2022
- Messages
- 16
Did you disassemble the engine beyond what's shown in the photos (M560RS)? Does it have a plastic gear?
TPEHAK
🚴♂️ Mega poster
I did not check the gears so I do not know.
TPEHAK
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Great news! I opened up the gears compartment of the Kunlun M560RS motor and all the gears are steel so no need to upgrade the gear for high power. The stator windings are potted so we should expect better cooling. Just need to design the new VESC Labs for M560RS controller.
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