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 yhat took long time to optimise 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 alway sopped tests at around 70 to 75C and it was taking 5 to 10 minutes to get there at cruise setting and 45 secondes 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
My motor is a Neu 8057-100KV
I need 220A / phase peak needed for 120 secondes
110 A continous 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 togheter.
20S25P samsung battery AC Ir is 14 milliohms
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 detectables 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