High-power brushless motor controller compatible with VESC®6.0: Ping FOCer Lite V2.0

⚠WARNING⚠

• This project has not been extensively tested, and hardware or firmware defects may still exist and affect use. Users are advised to do so at their own risk!
• Improper use of high-voltage and high-power motors may cause personal injury or even death. The author of this project does not bear any responsibility for this!
• This project does not allow commercial use for profit without permission (especially selling information). Please contact the author for any commercial use. There is no restriction on selling small batches at cost price.

Acknowledgments:

• This design software is entirely due to the best open source ESC on the planet: Benjamin Vedder's VESC® Project ( https://github.com/vedderb/bldc ). Please consider donating to him: https://vesc-project.com/donations.
• Due to copyright issues, the host computer VESC® Tool is not uploaded here. Please click on the official download https://vesc-project.com/vesc_tool . You need to register an account and click checkout. All software prices are the same. Different prices just represent different amounts of money donated to the author. If you don't want to donate, just choose the free version.

(PS VESC is a registered trademark of Benjamin Vedder himself. Only high-quality brands that meet his review can use vesc as a certification. Most of the VESC and keil source codes on xbao are illegal infringements)

• The hardware is modified based on Sharman's Cheap FOCer 2 ( https://github.com/shamansystems/Cheap-FOCer-2 ) schematic. His excellent design made me interested in VESC and finally completed this design. Thanks for his detailed design and instructions.
• JLC has sponsored free prototyping and SMT placement services for this project. Thank you for your company on the road to open source.

Features:

• High power: output power exceeds 1.5KW (actually measured)
• Small size: size 50*70*8mm (excluding wires and electrolytic capacitors)
• Easy to order and install: the PCB body can be sampled for free (6 layers), all SMD components are on the same side of the PCB, JLCSMT’s economical patch service can (and is recommended) be used.
• Using USB typeC.
• Three-phase phase current sampling, mute HFI function can be used.
• I/O with ESD protection.
• USB does not draw power and needs to be connected to power to operate.

Electrical specifications

• Phase current: 60A continuously (tested, additional heat sink required and forced heat dissipation), instantaneous current >75A, sampling current range: ±82.5A.
• Maximum input voltage: 80V (absolute value, should not be exceeded at any time)
• Recommended input voltage: <65V (When using a switching power supply, you need to derate it according to the situation, and set the Battery Current Max Regren to -0.1A, otherwise your power supply and driver will go up together with a brake)

Shortcoming

• To use custom firmware that is not currently supported by the VESC project, you need to compile it yourself.
• Not consistent with standard VESC hardware connectors, requires soldering.
• No CAN function (can’t put it down)

Physical pictures

Other things to note

• The current amplifier is compatible with INA240 and AD8418. Note the packaging and amplification factor.
• The MOS used is IST 019N08NM5AUMA1 (80V 1.9mR) sold by LC. You can choose to disassemble the components, such as IUAA250N08 (80V 1.8mR). There should be no fakes of this kind of package for the time being.
• The BOM does not include a large bus filter capacitor (diameter 10mm). High-frequency, low-resistance electrolytic capacitors must be used, and solid capacitors are recommended.
• The verification board uses 6 layers of 2OZ thick copper, which is more expensive. The free sample 1OZ/0.5OZ has a slightly worse heat-removing ability, but it is cheap, so you need to make your own choice. (You can consider group buying to keep the price down)