Motor controller with variable regenerative braking

[Teh Stork]

Hi,

We are going to build 3 test benches for mid drive motors. My question is related to controllers with regen capabillity.

I have used controllers from Sabvoton, Kelly and TIs Instaspin FOC development boards - most have been a simple coasting regen, where the instaspin board did full variable regen.

The testing is automated using a microcontroller controlling everything, 1 battery feeding the test bench and 3 motors with separate motor controllers. 1 motor emulating the human input, 1 motor under test and 1 motor for regeneratively braking the motor under test and motor emulating the human.

Pass/fail testing is based on efficiency measurement, temperature check after extended riding and noise level.

Currently I am researching what motorcontrollers to go for. The motors used are around 1 kW at a bus voltage of 36 V. Originally I was planning external power meters - but researching the problem more maybe this measurement can be internal to the motor controllers.

Where is time researching/programming best spent? Is the VESC project the best bet - or are there simple china controllers of fair quality that will do variable regen like BMSbattery Kunteng controllers?

Appreciate any input,

 

[E-HP]

I believe all of the controllers that Grin sells has variable regen. Is this setup going to be throttle or regen, but no coasting?

 

[Teh Stork]

It is basically going to be throttle or regen, yes - no coasting. Motor 1 will activate torque sensor in Motor under test (motor 2), and Motor 3 will act as a generator. Motor 3 will get the whole brunt of Motor 1 and 2.

Could do a simple 3-ph rectifier on the generator, making sure that the voltage generation would be higher than the battery voltage through gearing - but this would make for a very fixed setup with regards to what loads and rpms can be tested.

Grin products are quite pricy for what they are. I would rather have a go at VESC if allowing that kind of budget for the controllers.

 

[E-HP]

It is basically going to be throttle or regen, yes - no coasting.

The Powervelocity controller I had, had a slide regen setting. I liked it after getting used to it. At first I made a button for coasting, but later just got used to using my throttle to “coast”. Slide regen works as you described.

 

[amberwolf]

VESC and the Phaserunner / Baserunner all do variable regen. AFAIK they can be controlled from the throttle or a separate variable input. Since the *runner are based on ASI, then those do it too, but ASI is much more of a PITA to setup than the Grin stuff, because Grin wrote their own good setup software for it.

 

[stancecoke]

Appreciate any input

Very cheap E-Scooter FOC controller can do variable regen. The command for the motor/regen power is sent by UART, the protocol is well known.
For example the Xiaomi M365 controller:

Amazon.de : m365 controller

Or the Ninebot G30 controller:

Amazon.de : ninebot g30d controller

regards
stancecoke