Hi
VESC 100/250 MKIII
After 7 to 10 test of 2 to 10 minutes of varying power settings I had a failure on FETs on 1 phase.
After setup that took long time to optimize and get stable I ran many tests to be sure it was working reliably.
The esc was always climbing in temperature and I was in the process of removing heat from it with heat sink.
I always stopped tests at around 70 to 75C and it was taking 5 to 10 minutes to get there at cruise setting and 45 seconds at max power.
iI was testing the new heat sink and after 4 minutes of steady state, 1 Phase blew. T fet reported at this time was 67C
There were one instance of jamming the motor with plastic film that was sucked by the propeller. Protection kicked in, and everything seemed fine.
My motor is a Neu 8057-100KV
I need 220A / phase peak needed for 120 seconds
110 A continuous for 45 minutes
ESC was close to battery, I have around 50cm of 4AWG cable
Motor is 100 cm from ESC with 3 x 6AWG cables. Cables are bundled together.
20S25P Samsung battery AC Ir is 14 milliohm
Any hints ?
I need a reliable setup and will use heat sink to keep things at recommended temperature.
I was well within specs, was the motor phases wire too long and I got spikes that were not detectable by the hardware ?
<?xml version="1.0" encoding="UTF-8"?>
<MCConfiguration>
<pwm_mode>1</pwm_mode>
<comm_mode>0</comm_mode>
<motor_type>2</motor_type>
<sensor_mode>0</sensor_mode>
<l_current_max>230</l_current_max>
<l_current_min>-210</l_current_min>
<l_in_current_max>160</l_in_current_max>
<l_in_current_min>-30</l_in_current_min>
<l_abs_current_max>380</l_abs_current_max>
<l_min_erpm>-100000</l_min_erpm>
<l_max_erpm>100000</l_max_erpm>
<l_erpm_start>0.8</l_erpm_start>
<l_max_erpm_fbrake>300</l_max_erpm_fbrake>
<l_max_erpm_fbrake_cc>1500</l_max_erpm_fbrake_cc>
<l_min_vin>12</l_min_vin>
<l_max_vin>90</l_max_vin>
<l_battery_cut_start>68</l_battery_cut_start>
<l_battery_cut_end>60</l_battery_cut_end>
<l_slow_abs_current>0</l_slow_abs_current>
<l_temp_fet_start>85</l_temp_fet_start>
<l_temp_fet_end>100</l_temp_fet_end>
<l_temp_motor_start>85</l_temp_motor_start>
<l_temp_motor_end>100</l_temp_motor_end>
<l_temp_accel_dec>0.15</l_temp_accel_dec>
<l_min_duty>0.005</l_min_duty>
<l_max_duty>0.95</l_max_duty>
<l_watt_max>1.5e+06</l_watt_max>
<l_watt_min>-1.5e+06</l_watt_min>
<l_current_max_scale>1</l_current_max_scale>
<l_current_min_scale>1</l_current_min_scale>
<l_duty_start>1</l_duty_start>
<sl_min_erpm>150</sl_min_erpm>
<sl_min_erpm_cycle_int_limit>1100</sl_min_erpm_cycle_int_limit>
<sl_max_fullbreak_current_dir_change>10</sl_max_fullbreak_current_dir_change>
<sl_cycle_int_limit>177</sl_cycle_int_limit>
<sl_phase_advance_at_br>0.7</sl_phase_advance_at_br>
<sl_cycle_int_rpm_br>36000</sl_cycle_int_rpm_br>
<sl_bemf_coupling_k>1682</sl_bemf_coupling_k>
<hall_table__0>-1</hall_table__0>
<hall_table__1>1</hall_table__1>
<hall_table__2>3</hall_table__2>
<hall_table__3>2</hall_table__3>
<hall_table__4>5</hall_table__4>
<hall_table__5>6</hall_table__5>
<hall_table__6>4</hall_table__6>
<hall_table__7>-1</hall_table__7>
<hall_sl_erpm>2000</hall_sl_erpm>
<foc_current_kp>0.0902</foc_current_kp>
<foc_current_ki>41.76</foc_current_ki>
<foc_f_zv>20000</foc_f_zv>
<foc_dt_us>0.12</foc_dt_us>
<foc_encoder_inverted>0</foc_encoder_inverted>
<foc_encoder_offset>180</foc_encoder_offset>
<foc_encoder_ratio>7</foc_encoder_ratio>
<foc_sensor_mode>0</foc_sensor_mode>
<foc_pll_kp>2000</foc_pll_kp>
<foc_pll_ki>30000</foc_pll_ki>
<foc_motor_l>2.209e-05</foc_motor_l>
<foc_motor_ld_lq_diff>9.7e-06</foc_motor_ld_lq_diff>
<foc_motor_r>0.0089</foc_motor_r>
<foc_motor_flux_linkage>0.00696</foc_motor_flux_linkage>
<foc_observer_gain>8e+07</foc_observer_gain>
<foc_observer_gain_slow>0.05</foc_observer_gain_slow>
<foc_observer_offset>-1</foc_observer_offset>
<foc_duty_dowmramp_kp>50</foc_duty_dowmramp_kp>
<foc_duty_dowmramp_ki>1000</foc_duty_dowmramp_ki>
<foc_start_curr_dec>1</foc_start_curr_dec>
<foc_start_curr_dec_rpm>2500</foc_start_curr_dec_rpm>
<foc_openloop_rpm>350</foc_openloop_rpm>
<foc_openloop_rpm_low>0</foc_openloop_rpm_low>
<foc_d_gain_scale_start>0.9</foc_d_gain_scale_start>
<foc_d_gain_scale_max_mod>0.2</foc_d_gain_scale_max_mod>
<foc_sl_openloop_hyst>0.1</foc_sl_openloop_hyst>
<foc_sl_openloop_time_lock>0</foc_sl_openloop_time_lock>
<foc_sl_openloop_time_ramp>0.1</foc_sl_openloop_time_ramp>
<foc_sl_openloop_time>0.05</foc_sl_openloop_time>
<foc_sl_openloop_boost_q>0</foc_sl_openloop_boost_q>
<foc_sl_openloop_max_q>-1</foc_sl_openloop_max_q>
<foc_hall_table__0>255</foc_hall_table__0>
<foc_hall_table__1>255</foc_hall_table__1>
<foc_hall_table__2>255</foc_hall_table__2>
<foc_hall_table__3>255</foc_hall_table__3>
<foc_hall_table__4>255</foc_hall_table__4>
<foc_hall_table__5>255</foc_hall_table__5>
<foc_hall_table__6>255</foc_hall_table__6>
<foc_hall_table__7>255</foc_hall_table__7>
<foc_hall_interp_erpm>500</foc_hall_interp_erpm>
<foc_sl_erpm>4000</foc_sl_erpm>
<foc_sample_v0_v7>1</foc_sample_v0_v7>
<foc_sample_high_current>1</foc_sample_high_current>
<foc_sat_comp_mode>3</foc_sat_comp_mode>
<foc_sat_comp>0.15</foc_sat_comp>
<foc_temp_comp>1</foc_temp_comp>
<foc_temp_comp_base_temp>25</foc_temp_comp_base_temp>
<foc_current_filter_const>0.1</foc_current_filter_const>
<foc_cc_decoupling>2</foc_cc_decoupling>
<foc_observer_type>1</foc_observer_type>
<foc_hfi_voltage_start>20</foc_hfi_voltage_start>
<foc_hfi_voltage_run>4</foc_hfi_voltage_run>
<foc_hfi_voltage_max>6</foc_hfi_voltage_max>
<foc_hfi_gain>0.3</foc_hfi_gain>
<foc_hfi_hyst>0</foc_hfi_hyst>
<foc_sl_erpm_hfi>3000</foc_sl_erpm_hfi>
<foc_hfi_start_samples>5</foc_hfi_start_samples>
<foc_hfi_obs_ovr_sec>0.001</foc_hfi_obs_ovr_sec>
<foc_hfi_samples>1</foc_hfi_samples>
<foc_offsets_cal_on_boot>1</foc_offsets_cal_on_boot>
<foc_offsets_current__0>2061.78</foc_offsets_current__0>
<foc_offsets_current__1>2061.96</foc_offsets_current__1>
<foc_offsets_current__2>2061.77</foc_offsets_current__2>
<foc_offsets_voltage__0>-0.0048</foc_offsets_voltage__0>
<foc_offsets_voltage__1>0.0046</foc_offsets_voltage__1>
<foc_offsets_voltage__2>0.0002</foc_offsets_voltage__2>
<foc_offsets_voltage_undriven__0>0</foc_offsets_voltage_undriven__0>
<foc_offsets_voltage_undriven__1>0</foc_offsets_voltage_undriven__1>
<foc_offsets_voltage_undriven__2>0</foc_offsets_voltage_undriven__2>
<foc_phase_filter_enable>1</foc_phase_filter_enable>
<foc_phase_filter_disable_fault>1</foc_phase_filter_disable_fault>
<foc_phase_filter_max_erpm>4000</foc_phase_filter_max_erpm>
<foc_mtpa_mode>1</foc_mtpa_mode>
<foc_fw_current_max>0</foc_fw_current_max>
<foc_fw_duty_start>0.9</foc_fw_duty_start>
<foc_fw_q_current_factor>0.02</foc_fw_q_current_factor>
<foc_fw_ramp_time>0.2</foc_fw_ramp_time>
<foc_speed_soure>1</foc_speed_soure>
<gpd_buffer_notify_left>200</gpd_buffer_notify_left>
<gpd_buffer_interpol>0</gpd_buffer_interpol>
<gpd_current_filter_const>0.1</gpd_current_filter_const>
<gpd_current_kp>0.03</gpd_current_kp>
<gpd_current_ki>50</gpd_current_ki>
<sp_pid_loop_rate>5</sp_pid_loop_rate>
<s_pid_kp>0.004</s_pid_kp>
<s_pid_ki>0.004</s_pid_ki>
<s_pid_kd>0.0001</s_pid_kd>
<s_pid_kd_filter>0.2</s_pid_kd_filter>
<s_pid_min_erpm>900</s_pid_min_erpm>
<s_pid_allow_braking>1</s_pid_allow_braking>
<s_pid_ramp_erpms_s>25000</s_pid_ramp_erpms_s>
<p_pid_kp>0.025</p_pid_kp>
<p_pid_ki>0</p_pid_ki>
<p_pid_kd>0</p_pid_kd>
<p_pid_offset>0</p_pid_offset>
<p_pid_kd_proc>0.00035</p_pid_kd_proc>
<p_pid_kd_filter>0.2</p_pid_kd_filter>
<p_pid_ang_div>1</p_pid_ang_div>
<p_pid_gain_dec_angle>0</p_pid_gain_dec_angle>
<cc_startup_boost_duty>0.01</cc_startup_boost_duty>
<cc_min_current>0.05</cc_min_current>
<cc_gain>0.0046</cc_gain>
<cc_ramp_step_max>0.04</cc_ramp_step_max>
<m_fault_stop_time_ms>500</m_fault_stop_time_ms>
<m_duty_ramp_step>0.02</m_duty_ramp_step>
<m_current_backoff_gain>0.5</m_current_backoff_gain>
<m_encoder_counts>8192</m_encoder_counts>
<m_encoder_sin_amp>1</m_encoder_sin_amp>
<m_encoder_cos_amp>1</m_encoder_cos_amp>
<m_encoder_sin_offset>1.65</m_encoder_sin_offset>
<m_encoder_cos_offset>1.65</m_encoder_cos_offset>
<m_encoder_sincos_filter_constant>0.5</m_encoder_sincos_filter_constant>
<m_encoder_sincos_phase_correction>0</m_encoder_sincos_phase_correction>
<m_sensor_port_mode>0</m_sensor_port_mode>
<m_invert_direction>0</m_invert_direction>
<m_drv8301_oc_mode>0</m_drv8301_oc_mode>
<m_drv8301_oc_adj>16</m_drv8301_oc_adj>
<m_bldc_f_sw_min>3000</m_bldc_f_sw_min>
<m_bldc_f_sw_max>35000</m_bldc_f_sw_max>
<m_dc_f_sw>25000</m_dc_f_sw>
<m_ntc_motor_beta>3380</m_ntc_motor_beta>
<m_out_aux_mode>0</m_out_aux_mode>
<m_motor_temp_sens_type>8</m_motor_temp_sens_type>
<m_ptc_motor_coeff>0.61</m_ptc_motor_coeff>
<m_ntcx_ptcx_res>10000</m_ntcx_ptcx_res>
<m_ntcx_ptcx_temp_base>25</m_ntcx_ptcx_temp_base>
<m_hall_extra_samples>1</m_hall_extra_samples>
<m_batt_filter_const>45</m_batt_filter_const>
<si_motor_poles>16</si_motor_poles>
<si_gear_ratio>1</si_gear_ratio>
<si_wheel_diameter>0.05303</si_wheel_diameter>
<si_battery_type>0</si_battery_type>
<si_battery_cells>20</si_battery_cells>
<si_battery_ah>100</si_battery_ah>
<si_motor_nl_current>1</si_motor_nl_current>
<motor_brand></motor_brand>
<motor_model></motor_model>
<motor_weight>0</motor_weight>
<motor_sensor_type>0</motor_sensor_type>
<motor_description></motor_description>
<motor_quality_bearings>0</motor_quality_bearings>
<motor_quality_magnets>0</motor_quality_magnets>
<motor_quality_construction>0</motor_quality_construction>
<motor_quality_description></motor_quality_description>
<bms.type>1</bms.type>
<bms.limit_mode>3</bms.limit_mode>
<bms.t_limit_start>45</bms.t_limit_start>
<bms.t_limit_end>65</bms.t_limit_end>
<bms.soc_limit_start>0.05</bms.soc_limit_start>
<bms.soc_limit_end>0</bms.soc_limit_end>
<bms.fwd_can_mode>0</bms.fwd_can_mode>
</MCConfiguration>
Thanks