PingFOCerLite_V2.0

High-power brushless motor controller compatible with VESC® 6.0: Ping FOCer Lite V2.0
 
⚠WARNING⚠

This project has not been extensively tested. Hardware or firmware defects may still exist and affect use. Users assume all risks!
Improper use of high-voltage and high-power motors may result in personal injury or even death. The project author assumes no responsibility for this!
This project does not allow unauthorized commercial use for profit (especially selling data). For any commercial use, please contact the author. Small-batch sales at cost price are currently unrestricted.

 
 
Acknowledgements:

This software design is entirely thanks 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 VESC® tool is not uploaded here. Please click the official download link: https://vesc-project.com/vesc_tool. Account registration and payment are required. All software prices are the same; different prices only represent different donations to the author. If you do not wish to donate, choose the free version.

 
(Note: VESC is a registered trademark of Benjamin Vedder. Only high-quality brands that meet his review criteria can use VESC as a certification. Most VESC and Keil source code sold on Taobao are illegal and infringing.)
 
 

The hardware is based on a modified schematic of Sharman's Cheap FOCer 2 (https://github.com/shamansystems/Cheap-FOCer-2). His excellent design sparked my interest in VESC and ultimately led to this design. Thanks to him for the detailed design and explanation.

 

JLCPCB sponsored free prototyping and SMT placement services for this project. Thank you for your support on this open-source journey.

 
Features:

High power: Output power exceeds 1.5KW (actually measured)
Small size: Dimensions are 50*70*8mm (excluding wires and electrolytic capacitors)
Easy to order and install Use: PCB body can be sampled for free (6 layers), all SMD components are on the same side of the PCB, JLCSMT's economical surface mount service can be used (and is recommended)
Uses USB Type-C
three-phase current sampling, can use silent HFI function
I/O with ESD protection
USB does not draw power, requires connection to power to operate

 
Electrical specifications

Phase current: Continuous 60A (tested, requires external heatsink and forced cooling), instantaneous current >75A, sampling current range: ±82.5A
Maximum input voltage: 80V (absolute value, should not be exceeded at any time)
Recommended input voltage:

 
Disadvantages

Uses custom firmware that is not currently supported by the VESC project, requires self-compilation.
The hardware connector is inconsistent with the standard VESC, requiring soldering.
It lacks CAN functionality (too much space).

 
[Image of the actual product ]
 
Other considerations:

The current amplifier is compatible with INA240 and AD8418. Note the package and amplification factor.
The MOS used is the IST019N08NM5AUMA1 (80V 1.9mR) available from LCSC. Alternatively, salvaged parts such as IAUA250N08 (80V 1.8mR) can be selected; this package should not currently have counterfeit products.
The BOM does not include a large bus filter capacitor (10mm diameter), requiring the use of high-frequency, low-resistance electrolytic capacitors; solid-state capacitors are recommended.
The verification board uses 6-layer 2OZ thick copper, which is relatively expensive. Free samples of 1OZ/0.5OZ have slightly lower thermal performance but are cheaper; the choice is yours. (Group buying could be considered to lower the price.)