VESC based INNOTRACE M560/M600 Simple motor controller

[TPEHAK]

I though about the idea of making a simplified version of the INNOTRACE controller just like we did with the INNOTRACE M620 CAN Simple controller and apply similar ideas we realized there and that would fit both M560 and M600 motors.

And it looks like there is a possibility to design such a motor controller that will work with all Bafang M560, M510, M600 and M500 motors that would be possible to easily order from JLCPCB for cheap or solder it home with minimum soldering tools.

Here are the requirements we probably can meet for such controller:

- The controller must fit and work with both motors families at the same time, Bafang M560/510 and Bafang M600/500 (that might require making a separate adapter for the M600/500 motor torque sensor or installing M620 UART torque sensor into M600/500 motor)
- The controller must utilize the stock heat sinks of both M560 and M600 motors
- The controller PCB assembly must be single sided (to reduce the price and simplify the fabrication)
- All the PCB assembly components must be SMD components including connectors, terminals and so on (to make the fabrication one single soldering step with no soldering wires, no soldering through hole components and no post processing and no additional soldering to reduce the price and to ease the fabrication)
- All the components must be pick and place components including the terminals and connectors (to make fabrication through JLCPCB cheaper)
- All the components sizes must be 0604 or bigger (We got read all the 0402 components for easier placement and soldering and no need for a microscope and such)
- All the components must be sourced and available from JLCPCB and be accessible through their PCB assembly service (so you just simply load the BOM and pick and place files on their website and be ready to purchase the controller without extra hassle managing the parts).
- The components must have common packages (so you can find replacements in case of lack of the exact parts)
- Possible to connect a Bluetooth module (a Bluetooth module can be purchased as a separate dongle and connected to the PCB with a connector)
- The controller must be plug and play and be able to come from JLCPCB as a complete unit without a necessity of extra work (so a person who has no idea what soldering iron is does not need to touch it and just need to install the complete controller in the motor maybe just doing minor crimping work)

If we will be able to meet those requirement anyone should be able to purchase a complete controller PCB assembly from JLCPCB without a hassle and spending too much money!

I was not sure it is possible, but after moving the parts around it looks like there is a configuration that allows to replace all the 0402 components by bigger 0602 components and fit all the components on one side of the PCB and even utilize the stock hit sinks of the M560/M600 motors.

 

[TPEHAK]

You can see there is still some place. Unfortunately it is certainly not enough to raise the components size to 0806, but even raising it from 0402 to 0603 should help to someone who wants to solder it home and does not have a microscope.



I was thinking about using that space to implement maybe a couple of MUX switches chips to make it possible to use both M600 and M560 torque sensors without doing anything so you can just plug any torque sensor and it will just work, but that would make that controller really crammed and will require to make a dedicated firmware or complex circuitry or, most likely, both. So I believe it is better to keep it simple and use that space to relax the spacing between the components that will make it easier to solder and be more forgiving. The controller will work as is with M560/510 motor. For M600/500 motor you need either to install an M620 UART torque sensor in M600/500 motor or make a wiring adapter for M600/500 torque sensor and modify the LUNA firmware to make it works on this controller (we do not have such firmware but that should not be difficult to realize).

If you got M600/500 then Installing M620 UART torque sensor to make it works with M600/500 motor is probably the easiest and the best way and you also will have the popular ISIS crank arms interface as a bonus instead of proprietary Bafang crank arms interface

Bafang M500/M600 thread

A clarification, you can change the controller of an M600 with an M500, M510 and M560 have a different torque meter so they should be incompatible with each other. Has anyone checked this? I have not check, but I have an M600 and a spare M510 FC1.0 controller, but I have ask in the forum before...

endless-sphere.com

 

[TPEHAK]

The major idea here is you either obtain a complete controller from JLCPCB you do not need to do anything else with other than install it into the motor or, again, you get a complete controller after applying soldering paste with a stencil, placing the components and baking it on on your kitchen hot top.

The power leads are now separate things you bolt on the SMD terminals on the controller so you do not need to solder those to the controller messing with it and risking damaging it making things worst. You do need to make those leads, but it is way easier and you can practice at much as you want making those things without risk of damaging the expensive controller.

Even better, you do not need to solder those leads, you can purchase them already soldered and you just need to crimp the ring terminals to those.

So you can just purchase some preassembled complete Amass MR60-F with 12 AWG silicone wires longer than 90mm

like this for instance


Some preassembled complete Amass XT60 male with 12 AWG silicone wires longer than 90mm

like this for instance


Purchase some ring tongue 12-10 12AWG terminals like this TE 322447

https://www.mouser.com/en/ProductDetail/571-322447

Purchase some M3x6x6 terminals block screws

like this for instance


Purchase a crimping tool for solar connectors like this for instance

Amazon.com

And you just need to trim the wires to 90mm long



Crimp the ring terminals




Bend the terminals to necessary angle with pliers



Heat shrink the crimped area and you are good to go. No soldering required, no risk of messing the controller PCB up, just attach the leads to the controller with M3X6X6 terminal block screws, simple and easy

 

[TPEHAK]

I already checked the fitment of this controller configuration with M600 motor and it fits great!

You can see you need to bend the negative battery lead terminal slightly before attaching it to the controller terminal for proper cable clearance.



This cables attachment is also more flexible and fits the motor compartment better than sticking out vertically leads soldered directly to the PCB (you also can stiffen if you soak those in solder) because the wires goes along the PCB close to it and then make the turns in more relaxed manner with less interference with the connectors and other internals

 

[competitions]

If you got M600/500 then Installing M620 UART torque sensor to make it works with M600/500 motor is probably the easiest and the best way and you also will have the popular ISIS crank arms interface as a bonus instead of proprietary Bafang crank arms interface.

Isn't buying an M620 UART torque sensor quite expensive? Like your creativity but not sure I would expend so much on an unproven system.