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When 100250 is not enough

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eptv
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When 100250 is not enough

Hello Makers,

 

I found original 100250 could handle only 180A in a hot day. I have ventilated cooling with big radiator..

 

To improve performance, I milled copper block...

 

 

Please any one can tell the truth about 100500 controller? Any news?  ETA?

kubark42
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That looks really nice! How'd it work out?

If you're interested in what we hope will be a next-gen thermal issue management, over on the discord server we've been playing around with heat pipes simulations: https://discord.com/channels/904830990319485030/910536475488190464/91855...

One thing we lack right now is validation data. Would you be willing to run a few heat tests so we can see how well our models work? I have a normal VESC 100/250 and could use that as the benchmark to your upgraded heatsink.

 

eptv
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Hello Kubark42,

I can't access Discord chat. It says you have no permissions. You can contact me with Telegram, username 'chatbro'.

Your thermal design seems not finished, because thermal tubes should pass via radiator edges like this: https://store.supermicro.com/2u-passive-cpu-cooler-snk-p0048p.html

Only 15mm circle around thermal tube on the edge actually works.

 

I will share my results when tested. Could you please share any information about 100500 board?

kubark42
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> I can't access Discord chat. It says you have no permissions. 

Try via the link at https://vesc-project.com/node/3284

> Your thermal design seems not finished

I agree. The simulation was to give an idea of how a heat pipe might work to equalize the temperature across the FETs. Any final designs will likely look very different.

> Could you please share any information about 100500 board?

I only have a 100/250, I don't have any specific knowledge of the 100/500. 

Markula
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Hi 

How you tried change to better thermal pads between mosfet and heatsink ? 

https://www.aliexpress.com/item/1005003141008265.html?spm=a2g0o.productl...

What gain did the cobber heatsink do ? Is 180A with alu or cobber. 

Regards

Markus

eptv
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Thanks for the tip about thermal pads!

 

Ordered some to try.

Also I'm going to try 0.05mm tape as isolator with good thermal paste.

Markula
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Hi 

I have th 75300 and get about 220A with better thermal pads. The 100250 will generate some more heat( mosfet with lover voltage have less internal resistance). How mutch better cooling did you get when chaning to copper ? 

eptv
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Still in progress, do not know results yet.

 

 

Markula
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ok i see. I removed the alu casing and milled directly into a large heat sink. Locking forward for your results!  

 

frank
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It would be best to hard anodize the aluminum, so that it becomes non conductive. Then use a 17W/mk heat pad. 0.5mm thick.

You can also but a 8mm thick aluminum plate over the cover PCB to create even pressure over the entire surface.

eptv
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Results of copper block test: 

It can handle 100A without fans. After 5 minutes of foc_openloop FETS 62C, radiator edges 52C, 27C ambient. Only 10 degree delta is good for me.

 

I assembled it with thermal paste and tape on the FETS:

tape_2400x.jpg