High-power brushless motor controller compatible with VESC ® 6.0: Ping FOCer (v2.1)

⚠WARNING⚠

• This project has not been extensively tested, and hardware or firmware defects may still exist and affect use. Users are advised to do so at their own risk!
• Improper use of high-voltage and high-power motors may cause personal injury or even death. The author of this project does not bear any responsibility for this!
• This project does not allow commercial use for profit without permission (especially selling information). Please contact the author for any commercial use. There is no restriction on selling small batches at cost price.

Acknowledgments:

• This design software is entirely due to the best open source ESC on the planet: Benjamin  Vedder 's VESC ® Project ( https://github.com/vedderb/bldc ). Please consider donating to him: https://vesc-project.com/donations
• Due to copyright issues, the host computer VESC® Tool is not uploaded here. Please click on the official download https://vesc-project.com/vesc_tool . You need to register an account and click on checkout. All software prices are the same. Different prices just represent different amounts of money donated to the author. If you don't want to donate, just choose the free version.

(PS VESC is a registered trademark of Benjamin  Vedder himself. Only high-quality brands that meet his review can use vesc as a certification. Most of the VESC and keil source codes on xbao are illegal infringements)

• The hardware is modified based on Sharman's Cheap FOCer 2 ( https://github.com/shamansystems/Cheap-FOCer-2 ) schematic. His excellent design made me interested in VESC and finally completed this design. Thanks for his detailed design and instructions.

• Jialichuang has sponsored free prototyping and SMT placement services for this project. Thank you for being with us on the road to open source.

Features:

• Low cost: No need for expensive DRV8301 , (July 2022) JLCSMT mounting is about 350/two pieces (excluding mos), mass mounting is cheaper
• Small size: body size is about 60*40*12mm (excluding wires and electrolytic capacitors)
• Easy to order, install and use: The PCB body can be sampled for free. All SMD components are on the same side of the PCB (except MOS and current-sense resistor). It is possible (and recommended) to use JLCSMT’s economical SMT service to attach only the top layer. All you need to get it is soldering leads, MOS, and current-sense resistors.
• Using USB typeC
• Use domestic components
• I/O with ESD protection
• Open source hardware
• USB does not draw power and needs to be connected to power to operate.

Electrical Specifications

• Phase current: 25A continuously (tested, additional heat sink required)
• Safe working voltage: 50.4V/12S LI-ion (when using switching power supply load, it needs to be derated to 36V, and the Battery Current Max Regren is set to -0.1A, otherwise your power supply and driver will go up together with a brake)

shortcoming

• To use custom firmware that is not currently supported by the VESC project, you need to compile it yourself.
• Not consistent with standard VESC hardware connectors, requires soldering
• No ON/OFF connector

Physical picture

Ordering Guide

It is recommended to use the Gerber file, coordinate file and BOM in the attachment. The board has been assembled and verified to be correct. There may be problems with exporting.

Only the top surface is attached, Fu Ge can directly attach the top and bottom surfaces. If you are from a poor family, it is recommended to stick to the basic library and solder the IC by hand.

SMT notes:

• The three-pin pin header does not need to be soldered, so remember to cancel it.
• The automatic recognition of two SMD LEDs fails and you need to manually select the basic library.
• MOS driver optional EG2134 or FD6288T
• Four operational amplifiers optional TP2274/TP104
• The CAN transceiver does not need to be attached if it is not used.

In addition to SMD components, the following parts are also required:

• 2512 current sensing resistor*3 (10 milliohm maximum current 15A, 5 milliohm maximum current 30A, 4 milliohm maximum current 40A)
• CSD18540*6
  
• M2*7 double-pass copper pillar*4
• M2*4 screws*8 (not black)
• XT30/XT60 female connector*1
• MR30/MR60 male*1
• 10mm diameter lead capacitor*3 (Withstand voltage 63V or higher, low ESR, high ripple current capacitors must be used, solid capacitors are better. Recommended electrolytic capacitors )
• Some heat shrink tubing and silicone wire

Assembly guide

After receiving the goods, separate the three small boards. It is recommended to buy a metal shear to easily cut them in half without damaging the inner layer.

1. First weld the input power cord, just weld a thin one.
2. If there is no patch, solder the power management part, that is, the part below the microcontroller board in the picture above, and solder the patch pin headers on the two boards.
3. Align the two boards with the pin headers and female headers, and screw on at least one corner copper post and screw, as it connects the ground wires of the two boards.
4. Connect an adjustable power supply to the input, just give it 9V0.2A.
5. Test whether 3.3V and 5V are output normally
6. Give 18V and test whether the 12V output is normal.
7. If there is no problem, it is recommended to use low-temperature solder paste to blow up the MOS when soldering CSD18540 and 2512 resistors.
8. Weld the plug and silicone wire. If you use low power (<30W), you don’t need to add an electrolytic capacitor. For high power, you must add an electrolytic capacitor, otherwise it will not work properly. Be careful not to reverse the polarity of the capacitor plate.
9. Download the firmware corresponding to the current sensing resistor. Find three male Dupont wires and insert them into the holes. Press and hold them with your hands to download. No pin header is required.
   
10. Finish! You can connect to the host computer vesc tool for testing.