Hi everyone,
I have a project I've been working on in regards to a high-speed belt system for laser measurements. My system consists of a Flipsky FSESC6.6 with Bluetooth module, paired to a Flipsky 63100 190Kv motor, and powered by a Meanwell 48V 2000W DC PSU. The motor is direct-drive connected to a pair of 8" OD x 6" wide pulleys, which drive a 50" OD x 3.75" wide belt (in other words, think of it like a giant belt sander, but at insane speed!). The goal is to reach 100 meters per second (223mph) on the surface of the belt. There is no load on the system, other than the belt tensioner to keep it tracking correctly, and whatever friction that is experienced by the belt as it contacts the drums.
So far, I have tried current, no reverse, and duty cycle, no reverse, with somewhat mixed results. I also attempted PID speed control, no reverse, but it was only 1/4 speed
Current, no reverse will get up to about 198mph. However, it just kind of speeds up and slows down at will. Regardless of the PWM input, I can't keep the speed steady enough for the desired outcome. My current draws are well within the limits of the ESC, so I'm guessing it's just a control problem
Duty Cycle control can very precisely control the speed and it pulls a little harder on the amps, but it seems to work very well up to a certain speed, then it just goes haywire. There is always some kind of surging going on in the current, but it doesn't seem to affect the speed until it gets around 133mph. I can get it to go faster, but then it really starts surging in bigger steps (+/- 2.5mph). If I get above 150mph it either surges +/-5mph or will go into OVP and it stops the motor (safe start enabled, so it doesn't restart until RPM goes to 0).
PID speed control seems to get to 48mph and stays there (full 2200usec PWM control input applied). I'm assuming I can adjust these settings, but I'm not exactly sure how to get started. I understand PID control fairly well, but the Ki Kp thing is a bit weird to wrap my head around.
Any advice or pointers would be greatly appreciated! Even if it's a link to other topics or articles, that would be fine. Many thanks in advance!