[Prototyping] High power VESC 6.4 variant

Pimousse · June 15, 2020, 8:08pm

What an amazing project !
What do you plan for source files ? Open or closed source ?

Also, do you consider adding some protections here and there (such as Zener/TVS diodes, etc.) ?
Could be awesome to create a bulletproof VESC where user won’t kill idue to common fails/mistakes (3.3V, CANbus on unpowered VESC, motor phase short…)

It’s defo a really interesting project ! Keep up the good work !

linsus · June 15, 2020, 10:28pm

Nice job! Powerstage looks abit long. Could just be the FETs not being mounted that makes it look weird. Looking forward to your results testing it

How much cap is that on the DC inlet? I might be blind but you skipped lytes entirly? alot of bang for the buck with lytes 🤷

JantySVK · June 15, 2020, 10:39pm

@linsus Preview

Esk84life · June 15, 2020, 11:21pm

Need some tester your project is awesome ! good work

skate420 · June 16, 2020, 12:28am

Wicked!

hardunclejohn · June 19, 2020, 10:31am

so what’s your electric spec exactly?

Vanarian · June 19, 2020, 11:18am

Looks great!! and kudos for the half-bridge driver topology instead of DRV

The IPT007N06N have very low RdsOn but switching gate and rise /fall times are kinda slow, it can be a source of issues for FOC commutation. A200s faced issues in FOC, I believe it might be related. You want faster switching MOSFETs IMHO.

Note that your limiting factor here will be your MOSFETs since it’s 60v max rated, so good for 12S max?

See above, I think that’s why however for bldc I see no issues!

Looking forward to tests, do you do assembly by yourself?

district9prawn · June 25, 2020, 4:02pm

Nice work fitting the gate drivers and buck converter on to the board!

JantySVK · August 5, 2020, 9:05pm

First successful tests with assembled board.

Tested:
CPU section, correct voltage and current detection
Mosfet + drivers
12V main regulator (does not drop voltage under load)
5V and 3.3V post regulators

Not tested:
CAN-bus
NRF section

Known issues:
Does not have NRF51822 IC and needs external dongle for Bluetooth communication
Not DIY friendly (needs expert assembly)

JantySVK · August 5, 2020, 9:10pm

foc_detection

Bavioze · August 5, 2020, 10:27pm

How didnt i see this project before, looks awesome! Im very curious to how this wil unfold!

ShutterShock · August 5, 2020, 10:45pm

Quite the tidy circuit board if I do say so myself, and excellent reflow job

Interesting decision for the cap / power lead placement.

Creavenger · August 6, 2020, 8:55am

Looks very neat, topology looks great. Looking forward to see more

Vanarian · August 6, 2020, 9:31am

Nice, clean and compact, no DRV, this thing has potential to be a killer!

linsus · August 6, 2020, 9:41am

Real tidy soldering if thats done by hand.
Black PCBs really does make the difference

now snap on a heatsink and put it to the test!

DavidF · August 6, 2020, 11:39am

Isn’t it beautifull?

PixelatedPolyeurthan · September 11, 2020, 10:41am

@JantySVK update?

joshoujoe · October 17, 2020, 5:31am

man this is some engineer typa porn lmao

JantySVK · November 29, 2020, 9:05pm

Hi guys, I created updated version based on your suggestions

Mosfet area is basically the same, temperature sensor was moved closer to mosfets
NRF24L01 replaced by NRF51 module, that can communicate with phone via Bluetooth. No external dongle is needed
Low efficiency LDOs replaced with high efficiency DC-DC converters

TO DO:

Measured V_IN is incorrect, about 70% of real value, regardless of connected battery. Maybe it has some problems due to DC-DC converters ripple. I measured voltages with multimeter and they were ok, but I will have to do elaborate tests with oscilloscope and differend loads on DC-DC converters

FOC and control via VESC phone app both work

Schematic
1_low_ripple_2.pdf (106.6 KB)

BOM

Minimadness · November 29, 2020, 9:34pm

Nice, love those matte black PCB’s. Any plans for IMU support?