Heavyweight Brushless Speed controllers: VESCs for sale- Hi amperage version.

[EventorizonIan]

Hi Folks
‘Mangles’ VESC’s – Making Brushless Heavyweight Drive a Reality
Professionally produced in static controlled environment.

For the new series of Robotwars, in partnership with Rory Mangles of Team Nuts, we have developed a High-Amperage version of a new type of Electronic Speed controller, the VESC.

Originally developed as an open source design for use on Electric Long Boards by Benjamin Vedder, these uprated ‘Mangled’ versions are designed for use in Combat Robot weapon and drive systems. Two robots in the new series already make use of these controllers; you will find out who when the new series airs.

Until now, sensorless brushless motors have suffered from limited start up torque, and sensored systems are susceptible to failure if any sensors move or get damaged. VESC’s remove this problem by ‘integrating the magnetic flux after the zero crossing instead of adding a delay based on the previous speed’. ‘When the motor is rotating while the controller is off, the commutations and the direction still tracked. The duty-cycle to get the same speed is also calculated. This is to get a smooth start when the motor is already spinning’.

To improve current handling over the VESC’s the following changes were made:

• Upgraded to higher current IRFS7530 MOSFETs
• Width of high power tracks increased
• Current shunts were changed from 1mOhm to 0.5mOhm
• Increased decoupling capacitance from 1680 to 3000uF
• Improved mounting points to allow heatsinks to be added more easily.

This results in a current rating of ~80A, 130 max (100A Cont. may be possible with active cooling) at 8 – 50V (Safe for 3S to 12S LiPo).

The only thing that was removed from the original design was the CAN Bus, which allowed for real-time telemetry while the controller was running, but that is still possible using UART (Universal asynchronous receiver/transmitter).

Now for the difficult part…

Unlike Brushed controllers, Brushless controllers are not ‘Plug n Play’. They require settings that will be unique to each motor and drive set up to get the most out of them. While you can just upload a generic profile and go for a drive you will find that the vehicle/robot will most likely not be giving everything it can. These controllers are so new, both the Original and ‘Mangled’ variants, that you best option is to just spend time messing with the settings until you find what makes the VESC drive how you want. While it takes time it does ultimately mean that you have a lot more control over the drive in your robot, from acceleration, to breaking, maximum speed, current limiting and even battery regen.

While the technology is still new it shows great promise and the more people that adopt and try it out the better it will get. You can check out some of the links and testing videos for the original VESC’s below, along with some other videos showing off what VESC’s can do.

Official VESC Website - http://vedder.se/2015/01/vesc-open-source-esc/
VESC Forum - http://vedder.se/forums/
VESC Firmware and Config Tutorial -
Early VESC testing -
VESC Longboard Fitting and Testing -
4X VESC’s & NTM5060’s Pull a Car -
Longboard test + Data Logging Overlay -

Special for FRA members (profit neutral for us) Each VESC is £150 ex VAT, including postage to Mainland UK.
We hope to be at Gadget Show Live running from the 31 of March to the 3^rd of April so you can pick them up there if you prefer.
Since this was the first run, availability is limited so we have to operate on a first come first served basis.


‘Mangled’ VESC Technical Specifications –

• The hardware and software is open source. Since there are plenty of CPU-resources left, the customization possibilities are almost endless.
• Voltage: 8V – 50V (Safe for 3S to 12S LiPo).
• Current rating ~80A, 130A peak. (100A may be possible with active cooling)
• Sensored and Sensorless operation
• PPM Signal output for use with RX’s, Raspberry Pi’s and Android devices.
• Full software GUI with lots of configuration parameters
• Improved start up torque over other brushless speed controllers in sensorless mode (and obviously in sensored mode too)
• USB port for programming and telemetry
• Adjustable protection against: Low Voltage, High Voltage, High Motor Current, High Input Current & Regenerative breaking, all of which can be set independently.
• RPM Limiting with soft back off strategy.
• NOTE – there is no CAN Bus on the ‘Mangled’ VESC.

(Stats and information that hasn’t changed between the original VESC and Mangled VESC was compiled from http://vedder.se/forums/ and http://www.enertionboards.com/electr...or-controller/. Check both links for further information.)

[typhoon_driver]

You guys are VAT registered?

[maddox10]

Pity I don't have the money around, but a pair sound very interesting. Also, not UK based.

[Eventorizon]

You guys are VAT registered?

Our company ConkerIT, who paid for the VESC's manufacture, is VAT Registered.

Pity I don't have the money around, but a pair sound very interesting. Also, not UK based.

They are pretty small and light (part of the reason they are so appealing to us). When you get the money just give us a bell (here or you can check the company website for contact details) and we will work something out.

[typhoon_driver]

Ah right, makes sense. Just jumped out as being rather odd.

Best of luck guys. I'll be sitting on the sidelines using my old trusty vantec.....as long as it still works.....really need to round to testing that again......

[supernova]

Would be good to get it tested in the live events. Building a new supernova and considering brushless. With brushless motors running at a higher rpm, would the weight saving in the motors and esc be lost in the higher mechanical gear reduction?

[Shakey]

You can get some very low kv brushless motors in the 100-300kv range for heavy drive.

[terry]

They look awesome great work , what motors would work with them I was thinking of beast toro around the 780kv but they are sensor less and I know big nipper team have been having problems with that type what would you suggest ?

[Eventorizon]

Hi Terry

We paired ours with Scorpion 5020 450KV motors with a 9:1 reduction on 100mm wheels, the RW team used 50CC RotoMax's; I'm not sure of the wheel and reduction. Both were sensorless and had current limiting set to just 50A. Both drove just like brushed setups.

Big Nipper were using massive ESC's for 1:5th scale RC cars (I can't remember the exact model right now). What problems they were having I am not sure but being Sensored or Sensorless doesn't matter given that the VESC's can calculate a motors position without sensors.

Its still very early days but it seems the larger motors work better as they will give more torque and are easier to start turning than smaller ones. A helpful coincidence is that larger motors also tend to have lower KV ratings which means less reduction.

[Jeroenl]

PM send..