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BESC G2 100V 400A

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galp
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BESC G2 100V 400A

Hi!

 

I'm back with second generation of my BESC controller. I took a few different approaches this time.

BESC G2

 

This monstrosity is a 24 FET design. It uses 135V TO-220 mosfets and is designed for input voltages up to 100V. It's primary use case are light electric vehicles and bikes. It features integrated  high efficiency 12V 5A dcdc power supply and custom input connectors to ensure easy throttle connection. Because of high voltage it doesn't use phase shunts but rather three low side 0.2 mOhm shunts. It was designed up to 400A phase current but we'll see about that. PCB is standard thickness 4 layer board. Busbars soldered on bottom and top carry high current. Board is also ready for high voltage modification. With suitable capacitors and mosfets it is possible to turn this board into higher voltage / lower current controller up to 150V input voltage.

To sum it up:

  • 20S LiPo safe
  • 400 A phase current
  • 12V 5A integrated dcdc
  • Easy throttle connection
  • 250€ BOM from Mouser/Farnell

Project is of course open hardware and can be found in my github repository: https://github.com/galpavlin/BESC-G2
You can find pdf of schematic, 3d step files and BOM in documentation folder. Gerbers are also available.

 

I ordered PCBs few days ago. I'l have a few extra. If you'd like to have one write me a PM. I'll be assembling the first unit sometime next week.

pf26
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Very nice !  Please keep posting about your progress on this project. I might be interested in a 150V 100Amp continuous version  (using 200V Mosfet).

Hopefully the current and bemf signal will be clean enough..

nathanielakkermans
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hi, i'm very interested to test this version of you BESC. i'm making an electric bike with 3 25kw motors but I still doubt whether I should build a motor controller myself or buy one. i already started to design my own VESC with your BESC as an reference and inspiration. i want to run the motors on 100 to 130 volt and there are not very much esc's that can do this. so i'm curious if you already tested this version of your design. also i can not open the BOM, is there an excel version available?

zneidi
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I was fascinated by your results and effort in your first version. I wanted to base my own ESC on your files. I found two bugs/issues:

 - both the UVW voltages and the Hall Sensors do not have any input filtering/anti-aliasing filters. is this on purpose?

 - due to some bug in KiCAD the hidden pin on your SN74LVC1G04 is directly connected to GND --> GND and GNDD are connected together. i think this messes up your well thought out ground concept.  

 

Keep up the good work!

galp
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One should be able to open .ods file with excel. If it doesn't work try installing openoffice and open it with that.

I haven't had time to solder it yet. There are quite some bugs as it's expected for first version. I'll get rid of SN74LVC1G04 since it can be easily replaced by inverting signal in software. Current sense is filtered. Components are placed in mcu sheet. I'll move them to powr stage for clarity. If I remember correctly benjamin said voltage sense filtering did not yield good results so it wasn't implemented.