tag:blogger.com,1999:blog-66378686907599318222024-02-06T21:28:44.453-08:00DIY Brush-less DC Motor Controllerdo it yourself brush-less DC motor controller for e-bike & e-scootersD. C. Boycehttp://www.blogger.com/profile/02757828960588762188noreply@blogger.comBlogger3125tag:blogger.com,1999:blog-6637868690759931822.post-69084053364703349292010-11-14T07:46:00.000-08:002010-11-14T07:46:19.038-08:00YouTube Videos<a href="http://www.youtube.com/watch?v=nL8sW3Dh0Ig">Home-made e-bike Motor Speed Controller Project-Dashboard LCD Display Menu</a>D. C. Boycehttp://www.blogger.com/profile/02757828960588762188noreply@blogger.com0tag:blogger.com,1999:blog-6637868690759931822.post-8117653691134833122010-11-05T11:48:00.000-07:002010-11-05T11:48:09.225-07:00Do It Yourself Brushless DC Motor Controller<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;">Hammond Case to put your DIY Brushless Controller into<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPTIfuaYN-3iEs12TdlqgziNxxndYjWgKtLJCrUQuBkeHBiDK4Xz8AvL87hIhIMic7UyTnm0ib75RfGOL4DMGWd5NIaxmUUzkWbK7hlvkXNdnPkfW30VCM1TAS3PWImOM8o2MrH_m1mjI/s1600/Hammond+1455N1601+Case.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPTIfuaYN-3iEs12TdlqgziNxxndYjWgKtLJCrUQuBkeHBiDK4Xz8AvL87hIhIMic7UyTnm0ib75RfGOL4DMGWd5NIaxmUUzkWbK7hlvkXNdnPkfW30VCM1TAS3PWImOM8o2MrH_m1mjI/s1600/Hammond+1455N1601+Case.jpg" /></a></div>D. C. Boycehttp://www.blogger.com/profile/02757828960588762188noreply@blogger.com0tag:blogger.com,1999:blog-6637868690759931822.post-85895830085464173652010-09-05T12:58:00.000-07:002010-11-14T07:57:06.804-08:00Build Your Own BLDC Motor Controller for your e-Bike or e-ScooterThere is no greater satisfaction then completing a project you started and knowing you built the whole thing.<br />
Introducing the most robust e-bike/e-scooter motor speed controller system available for the hobbyist market today.<br />
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Here is the ultimate do-it-yourself 3-phase brush-less DC motor speed controller you could ever sink your time and money into.<br />
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My home-made 3-phase BLDC motor controller is cheap and easy to build.<br />
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The idea behind this 9 month R&D project build was to design a simple but useful robust EV controller system that others would want to build and learn from.<br />
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I based my controller design on PIC16F87X series micro-controllers. The software I developed using a in-circuit programmer/in-circuit debugger.<br />
This two controller system has one dedicated to motor control and the other a simple user interface and programming/diagnostic tool I called the "Dashboard".<br />
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The minimal system is designed to require just the motor controller. Any programming changes are done through the PC software interface.<br />
With the optional "Dashboard" connected to the motor controller, programming changes can be done where ever you are.<br />
While driving LCD Display will show battery voltage, discharge current, wattage, speed, throttle, RPM, ride-time and much more.<br />
The "Dashboard" has a data-logging function that stores 4095 samples into a EEPROM chip. Logged data can be retrieved, saved and graphically display on the PC Interface software.<br />
There is also a built-in hardware diagnostic screen that shows hall effect sensors, brake & reverse inputs and more for quick and easy hardware troubleshooting.<br />
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What was my design criteria? <br />
1st of all it has to be easy to assemble so I did not use any surface mounted components. Anyone can put this together.<br />
2nd must be made from off-the-shelf parts. All components are commonly available at Mouser or Digi-Key.<br />
3rd have you learn more about this technology. If you build it then you can fix it right! All you problems solved in one project.<br />
4th make it easy to modify for other battery and motor technologies.<br />
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What popular features did I include in my motor controller design?<br />
3 Switch Selectable Throttle Control Limits<br />
Programmable Battery Pack Low Voltage CutOff (LVC)<br />
Adjustable Hardware DC Current Limiter<br />
Programmable Software Phase Current Limiter<br />
Regenerative Braking Recharge Voltage & Current Limiting<br />
Programmable Cruise Control Options<br />
Brake Switch & Reverse Commutation Switch Input<br />
Reverse Throttle Limit<br />
Open Throttle Protection<br />
Hardwired 120°/60° Phase & Motor Direction jumpers<br />
Hall Sensor Failure Detection<br />
Data-Logger function with Programmable Interval Timer (4095 samples x 16 bytes)<br />
Adjustable LCD Display Color & Brightness<br />
RGB LED Back-lit 16x2 LCD Display with 4 Key User Interface<br />
Dealer/Build/Owner Text Message Splashes in LCD every minute in standby<br />
Built-In Hardware Diagnostics LED<br />
Made for use with Hall Effect Sensor-ed 3-Phase BLDC motors<br />
Multi-Wheeled Drive capabilities (1 to 4 BLDC controllers running on one throttle/brake wire thru digital link)<br />
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Specs: 12 MOSFET PC board, Battery Voltage Up to 102.3V, Current Sensing Up to 100A, Discharge/Regen Recharge Current sensing, Reverse Commutation, Regenerative Braking, Cruise Control Twist Throttle<br />
Battery: Sealed-Lead Acid, VRLA, SLA, Up to 24S lipo (100V)<br />
Most popular TO-220 MOSFET devices P75NF75, IRFB4110, IRFB4115, IRFB4310 to build with<br />
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In the Owner's Manual the schematic, parts list, component placement, printed circuit board layout are included. The end user can program the controller features through a simple software interface which connected to a serial or USB port.<br />
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This controller was developed and is intended to be an <u>OPEN </u><u>SOURCE </u><u>HARDWARE</u> project you can build at home.D. C. Boycehttp://www.blogger.com/profile/02757828960588762188noreply@blogger.com15