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Thread: 300A VESC in the works, feature suggestions wanted

  1. #1
    TechAUmNu's Avatar
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    I am working on designing a 16s 450A VESC. Called the A450S.
    As a leapfrog to this, I am first doing a smaller version the A200S.

    Estimated Pricing for A200S as of 5th Dec 2017:
    £350 with 8AWG silicone wire and 8mm bullets
    Repairs cost the price of parts and shipping.

    In comparison a 15s 400A MGM controller costs £800
    12s VESC6 costs £300 and only does ~80A

    So far I have chosen to use OptiMOS fets and TI 4A discrete gate drivers.
    FETs: FDBL86361_F085
    Gate Drivers: UCC27211A-Q1

    The first version will have:
    • 3 Fets per phase leg (18 total)
    • 1 Gate driver per phase (3 total)
    • CNC machined aluminium case
    • STM32f405 Cortex M4
    • 2x 100v 1000uF Chem-Con Capacitors EKZN101ELL102MM40S
    • TVS protected 5v rail, suppied from receiver (OPTO)
    • 16s LiPo maximum (Rating at 80v on the mosfets and current shunt amps, so need a bit of margin to account for ringing/transients
    • 200A continuous
    • 400A burst
    • All standard VESC features (CAN, SPI, Encoder/Hall support)
    • Same amazing VESC performance with sensorless motors.
    • Designed specifically for combat use. Absolutely no heavy components on the boards which might fall off with shock.
    • Each unit is hand built and will be rigorously tested before sale using a range of motors. (100W, 2200w, 5300w, 9800W) If I have the motor you will be using then I can set it up for you before sending it.


    Progress so far:
    • Power stage components chosen
    • Power stage schematic complete
    • Logic side schematic complete
    • Power dissipation calculations complete
    • Power supply selection complete
    • Buck converter design complete
    • Switched gate drivers to UCC27211A-Q1
    • power stage rework complete
    • Switched MOSFETS to FDBL86361_F085 to reduce cost and power dissipation
    • Power board layout complete
    • Power board ordering complete
    • Logic board layout complete
    • Logic board ordering complete
    • Power board testing in complete
    • Logic boards shipped
    • Power board design v2 complete
    • A200S V1.1 design complete
    • A200S V1.1 boards ordered...


    This thing is overkill in every way possible. Hopefully that makes it very reliable in the arena.
    Last edited by TechAUmNu; 5th December 2017 at 23:48.

  2. #2
    typhoon_driver's Avatar
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    Features - cost less than a tenner. You'll be very popular

  3. #3
    overkill's Avatar
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    A potted case is a REALLY bad idea! I tried that on a number of IFI Victors a few years ago and they all eventually died. It was traced back to the potting resin expanding at a different rate to the PCB and causing solder joints to crack. A thin conformal coating is a better bet. Room to add our own shock mounts is a good idea.

  4. #4
    TechAUmNu's Avatar
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    Quote Originally Posted by overkill View Post
    A potted case is a REALLY bad idea! I tried that on a number of IFI Victors a few years ago and they all eventually died. It was traced back to the potting resin expanding at a different rate to the PCB and causing solder joints to crack. A thin conformal coating is a better bet. Room to add our own shock mounts is a good idea.
    Good to know! Its probably best to not have any coating then to make it easier to replace parts.

    As for pricing I don't want it to be over £300 current BOM is ~£120 + board.

  5. #5
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    There's a couple of us trying to build 300A ESCs now.

    Personally I'm not a fan of directFETs, can't inspect joints, package is unique to Infineon and they seem to discontinue them quickly. HSOF packages seem much better to me, it's what they use in the Vex BB controllers.

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    Not sure on the integrated shock mounts. Prefer some flexibility on mounting e.g. mount into a shock mounted electronics box

    I'm looking to drive 8019 Neumotors - http://neumotors.com/80xx-series-electric-motors/

  7. #7
    TechAUmNu's Avatar
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    Quote Originally Posted by shakesc View Post
    Not sure on the integrated shock mounts. Prefer some flexibility on mounting e.g. mount into a shock mounted electronics box

    I'm looking to drive 8019 Neumotors - http://neumotors.com/80xx-series-electric-motors/
    I will make the mounting points on the board with plenty of room around them instead, then it gives people mounting flexibility.

    So about 350A peak on those motors, I might end up making another board with 6 or 8 fets per phase if there is demand. It really bumps the price up though.

  8. #8
    TechAUmNu's Avatar
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    Quote Originally Posted by Pinski1 View Post
    There's a couple of us trying to build 300A ESCs now.

    Personally I'm not a fan of directFETs, can't inspect joints, package is unique to Infineon and they seem to discontinue them quickly. HSOF packages seem much better to me, it's what they use in the Vex BB controllers.
    I was thinking that too, only real reason I was going with them was for the ability to stick a heatsink directly onto them, but looking at the HSOF I am going to use this one instead.
    http://www.mouser.com/ds/2/196/Infin...-en-767648.pdf
    Has almost half the on resistance and bumps the current rating way up for a very small price increase.

    Thanks!

  9. #9
    TechAUmNu's Avatar
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    Would people prefer it to be

    A) Smaller with no 5v Dc-DC. i.e. OPTO
    B) Larger with integrated 5v Dc-Dc about 2A (also makes it £10-20 more expensive)

    I think its best to be OPTO since people will likely already have a 5v dc-dc and if they don't they can easily add one.

  10. #10
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    My vote would be OPTO

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