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I need help designing 200v 80a vesc

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qwerasdf
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I need help designing 200v 80a vesc

I'm trying to make brushless motor controller for my ebike.

I need it to have (forward reverse) (potentiometer input) (maybe brake) (hall inputs)

it's going to be mostly running hall less 

Im trying to make it as cheap and simple as possible.

list of components that I have on hand:

smd ceramic capacitors: 50v 1nf 10nf 100nf 1uf 10uf 100uf  100v 48uf

disc ceramic capacitors 50v 106 104

smd resistors: 10 100 1k 10k 100k (2512 shunts) 0.004 0.001

tht resistor kit with values :

1 000 000
680 000
470 000
300 000
220 000
200 000
100 000
68 000
51 000
47 000
20 000
15 000

10 000
6 800
5 100
4 700
3 300
2 200
2 000
1 000
680
510
470
330
270
220
150
100
47
22
10

and a lot of 120

diodes: in5819 uf4007

zener diode kit

current sense amplifier:INA180A3IDBVR

stm32:SMT32G431KBT6

mosfet drivers: irs2186 ucc27211

 

This is phase voltage sense part, what value should I use for these components and do I even need a capacitor there?

phase voltage sense dividing resistors and capacitor (C6, R10, R9)

This is input voltage divider

voltage divider for input voltage sense (R5 R8 C5(1uf))

can I connect my hall sensors directly to stm pins? I've seen some schematics with filters and voltage dividers.

5 pin connector ((gnd)(stm_pin)(stm_pin)(stm_pin)(3.3v))

 

Can I use internal pull up resistors?

2 pin thermocouple connector ((gnd)(stm_pin))

 

is using capacitor C4 good idea and what values of components should I use in this scheamtic

irs2186 driver with dual 2 pairs of mosfets

 

 

I would prefer to use only one shunt amplifier but if measuring current on each phase individually has some important advantages I can do it.

Again does that schematic look good? Should I use some filters? Different shunt values?

ina180a with 2 0.001 shunt resistors

 

 

Lastly what stm32 can I use, vesc hardware schematics use STM32F40X_LQFP64 does that mean that I can use any flash size?

Do I need to use 64 pin package?

Is there a list of stm controllers that I could use Or any starting with f40 that has 64 pins will work?

stm32 Software:

Are there vesc software branches?

How do I set up pins, do I need to change some kind of .h configuration file?

Do I need to tell it that it has different than normal resistor values on its phase voltage sense pins?

Is there some kind of pin out diagram?

Are there pin out diagrams for every (supported boards) type that you choose inside conf_general.h?

Should I stick to any of the default board types and base my schematic on that?

Can I simply download zip file from github (without any of this git command line stuff) then somehow compile it and upload it using st-link v2 by using some kind of tool inside cube ide?

Is there some kind of wiki page for vesc with answers for all of these questions? There shoul be since vesc is such a big project right?

 

TheFallen
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Joined: 2017-09-11 11:46
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To design a VESC for you my hourly rate starts at £1000. However all the information you require is on these forums somewhere.

antonchromjak
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Posts: 57

You can use stm32f407 or stm32f405 without firmware changes. With stm32f446 you need to remap uart in firmware.

Firmware is above 200KB so STM32G431 with 128KB is not enough.

 

You can use 2 or 3 phase shunts without large firmware changes. I am not aware of implementation with 1 in vesc project.

 

C4 is for limiting voltage spikes with long battery cables and to stress less battery at low duty cycles which can lead to improved efficiency.

qwerasdf
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Last seen: 1 day 11 hours ago
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Thanks for replying.
Sorry for not making it clear but I met to ask if I can use one current shunt that would measure power form all phases at once like it is done in cheap brushless motor controllers.
I forgot to ask if I could use internal oscillator? I haven't seen any schematics without external ones.

There is a lot of open source hardware could you recommend one for me to follow with similar characteristics to what im trying to make (200v/100v 80a constant current)?

antonchromjak
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 I met to ask if I can use one current shunt that would measure power form all phases at once like it is done in cheap brushless motor controllers

I know.

I forgot to ask if I could use internal oscillator? I haven't seen any schematics without external ones.

There is no guarantee that USB will work with internal oscillator. With 10% variance you could get bad reading of motor parameters.

In my opinion you are searching for cost reduction in wrong places. When I design my priority it's to make it work. Which is hard anyway. And than you can try to improve cost if it's even possible.

There is a lot of open source hardware could you recommend one for me to follow with similar characteristics to what im trying to make (200v/100v 80a constant current)?

look at this forum,there are some with IGBTs

vadicus
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Cheap and high voltage should not be used in the same sentence. At  the very least, protect yourself and property by getting a good extinguisher rated for electric fires.