five(5) diy brushless ESC designs

[Ron van Sommeren]

For a compilation of brushed diy ESC designs have a look at this thread:
http://www.rcgroups.com/forums/showthread.php?s=&threadid=157193

Please report dead links.

Books/theory
http://www.amazon.com/exec/obidos/ASIN/0070668108/electronicformod
An online course on magnetism/flux, motors and ESC's
http://www.consult-g2.com/course.html
http://www.innovatia.com/
http://www.innovatia.com/Design_Center/Power_Electronics.htm
Sensored
http://homepages.paradise.net.nz/bhabbott/sensored.html
Sensorless

OSMC project kits:
www.robotpower.com
Discussion group:
www.yahoogroups.com/group/osmc
Discussion groups
http://groups.yahoo.com/group/osmc/
-> files section
http://mailman.evtech.org/mailman/listinfo/evtech
Development discussion
http://www.rcgroups.com/forums/showthread.php?t=200567 (very active and excellent)
http://www.rcgroups.com/forums/showthread.php?t=890041&page=2&pp=10
http://www.rclineforum.de/forum/thread.php?threadid=48225&sid= (very good too, 0.45gr brushless controller)
http://www.rcgroups.com/forums/showthread.php?s=&threadid=168476
http://www.rcgroups.com/forums/showthread.php?s=&threadid=181247
http://www.rcgroups.com/forums/showthread.php?t=200567
This design one we all know, Jo Aichingers family of Speedy-BL controllers. Sadly, Jo passed away in april 2006, I don't know if any one else does the firmware IC programming now, maybe Thomas Radetzki? ???
http://www.speedy-bl.com/
http://www.radetzki.info/html/sbl_micro_e.html
http://www.ele.tut.fi/~peni/speedy_sprint/speedy_sprint.html
http://www.aerodesign.de/peter/2001/LRK350/SPEEDY-BL_eng.html
'Mass' production ;)
http://users.cybercity.dk/~ccc16084/
-> electronic page
-> Brushless Speed Controllers
http://plaza29.mbn.or.jp/~sgl02777/ (English/Japanese)
http://www.rcgroups.com/forums/showthread.php?s=&threadid=70373
http://gb97816.bei.t-online.de/ (German)
-> projekte
http://www.2mslbldc.g4g-server.com/
A group design
http://www.bldc.de (German/English)
Rod Hower's design
http://www.rcgroups.com/forums/showthread.php?postid=1838041#post1838041
http://home.versanet.de/~b-konze/ (English & German)
http://www.turbinemuseum.de/Modellbau/BLMC__UK_/blmc__uk_.html (English)
http://people.freenet.de/khruehlow/
Takao Shimizu's design, source code and schematics
http://www.rcgroups.com/forums/showpost.php?p=2565567&postcount=153
TVE
http://www.hanfordsite.com/
French diy sites
http://frederic.brame.free.fr/variateur%20pour%20moteur%20brushless/variateur%20pour%20moteur%20brushless.htm
http://www.silicium628.fr/
-> electronique
Ezone diy electronics subforum
http://www.rcgroups.com/forums/forumdisplay.php?f=199
'Elektor' magazine design (also published in it's French, German, Dutch and Italian pendants)
http://www.elektor-electronics.co.uk/Default.aspx?tabid=97&ProductID=2721
-> 'Brushless Motor Controller'
For underwater robot
http://aquaticus.info/bldc_controller
http://groups.yahoo.com/group/lrk-torquemax/message/10239
http://jetcontrol.de/Bastelstube/d2pack.html
micro motor controller
http://www.rcgroups.com/forums/showthread.php?t=261316
1.57gr brushless controller
http://home.foni.net/~c-schlabitz/Floh/
http://home.versanet.de/%7Eb-konze/blmc_flea/blmc.htm
Wiki
http://bldc.wikidot.com/
with reverse
http://www.rcgroups.com/forums/showthread.php?p=8056614#post8056614
Demo's and tutorials on www.freescale.com, e.g.
http://www.freescale.com/files/microcontrollers/doc/train_ref_material/motorbldctut.html
high voltage
http://rmmx.gmxhome.de/bldchv/english/start.html
Brushless controller/timer for Control Line:
http://www.pek.nu/pekproj/proj/el/sc/
Discussion:
http://www.svensktmodellflyg.se/forum1.asp?viewmode=1&msgid=195747&page=&CurrentMainTopic=2
Vriendelijke groeten ;) Ron

[Markz]

Thanks Ron

I've always been contemplating a challenge like this. This is a great compilation of designs - too bad I can't read german, but I'll see what the web translators can come up with

Marc

[KreAture]

Mine will be very much like number 4 I think.

[Mark Sanders]

Thanks Ron - keep up the good work / mark

[Mr DIY]

Continuing on with Brushless designs, I am close to finalizing mine and have progressed to my second PCB version that now incorporates the sensor circuitry. I have managed to get a HD motor running without a problem, but when I attempted my Mega motor, I promptly burned out the high side FETs. There seems to be limited information relating to the method of drive and I do not have a commercial one at my disposal that would answer all my questions.

Now this may sound like a very stupid question to those that know, but what I need to know is … when starting the motor, a PWM signal is applied. But once up and running, then what? Is the PWM discarded and short pulses triggered at the start of each new phase? In other words, fire the “controlled” pulse, which accelerates the motor, and then wait for “crossing” feedback whilst motor decelerates. The controlled pulse width then determines the final speed. Is this the way it is done, or is the PWM signal being used all the time? I am finding that an extended duration PWM signal is the cause of my FETs going bang. They are being driven via a FET driver IC.

My controller at present is an overkill as far as the digital stuff goes. Wanted to play with a logic device, so added it in order to make controller more flexible and allow very high speeds. Will post pic as soon as I get a motor running.

[Takao Shimizu]

Mr DIY,

>wait for “crossing” feedback

You must wait the feed back signal for next switch to start and run, for sure.
So far, My new program generates "preset duty" drive phase signal applying sequently until next 1/2Vcc cross signal detection, under no information of magnet rotor position.

http://www.rcgroups.com/forums/showthread.php?postid=1676789#post1676789

Also, "Too slow condition" as over load can be detected while running by timer. This condition is also caused at starting.Then,my program has no-output timer as starting duty control when the system does not start.

FET works CD-ROM RC motor, because of the coil winding wire is not so thick as low resistance compared to RDS(On):On Resistance between Drain and Source. FET does not heat up at all on my winding.

The problem is "preset duty" setting value to protect FETs when the motor coil is wound with very a few turns and with very low registance thick wire.

You may sense the starting rush current by RDS(On) on FET or one of current sense hall device on power line by A/D for best solution.

[FlyByMike]

Originally posted by Markz
Thanks Ron

I've always been contemplating a challenge like this. This is a great compilation of designs - too bad I can't read german, but I'll see what the web translators can come up with

Marc This site will translate words, phrases, and even URLs: http://babel.altavista.com/translate.dyn
I use it a lot :)
-Mike

[Ron van Sommeren]

Or
http://www.google.com/language_tools?hl=en

[FlyByMike]

Thanks Ron, I've bookmarked that one too.
-Mike

[mr_wood]

Hi,

I am looking for a sensored design. I want to use the hall sensors on the CD board I have. Surely this can't be too difficult ??

Anyone have any ideas ?

Thanks
Tim

[FlyByMike]

Sensorless is simpler than sensor type, parts-wise that is :)
-Mike
edit: Posted after Takao's post to clarify it. Which he deleted and re-posted. Maybe I should delete this as it is confusing. :confused:
BTW, controller software is much easier w/ a sensored motor.

[Takao Shimizu]

Tim,

Sensored type is useful to get the starting torque for RC car application.

Sensore less circuit is simpler than sensored type.

Takao

[mr_wood]

this is very complex,

I was hoping it would be easy like the circuit for the 2-phase motor in http://www.rcmicroflight.com/library/motor1.asp . Incidently would a 2 phase motor be powerful enough for RC - the controller is certainly simple !

Thanks
Tim

[Takao Shimizu]

Tim,

This is my simplest flying single phase motor.

http://www.rcgroups.com/forums/showthread.php?postid=594518#post594518

Takao

[Ron van Sommeren]

Added development discussions:
http://www.rcgroups.com/forums/showthread.php?s=&threadid=168476
http://www.rcgroups.com/forums/showthread.php?s=&threadid=181247

[aeropenguin]

There are so many links here I am quite confused. Is there a place where I can get a KIT (not completely DIY as I can't program and not enough experience, etc, and not completely assembled as that's too expensive) of any esc taht's good for a 2s or 3s lipo, and can handle up to ~16A? So far the best motor for this is the Jeti, it's $60. Trying to find something cheaper. If the price and weight aren't affected too much, then a slightly bigger esc would be fine too (25A?).
Thanks!
-Michael
P.S. I don't speak German ;) If it's a sketchy site and not much info, perhaps the email address of the right person would be better. Thanks.

[Ron van Sommeren]

I know only German kit suppliers.

[aeropenguin]

Still, do any of the German suppliers carry a product that fits the above specifications? Surely one of them can speak English too.
Thanks!
-Michael

[Ron van Sommeren]

Thomas Radetzki does, on a non-commercial basis:
http://www.radetzki.info/html/sbl_micro_e.html

And Megra:
http://www.megra-elektronik.de/

[aeropenguin]

Thank you!!! I'll be getting a hold of them soon...
Thanks!
-Michael

[jschrader]

Anybody who likes some detailed information or translated contact to Megra Elektronik, manufacturer of the SpeedStar kit may write pm to me.

[Ron van Sommeren]

Added Rod Hower's design.

Groeten ;) Ron

[Ron van Sommeren]

Added to item one, the Speedy BL controller, Thomas Radetzki's page (English):
http://www.radetzki.info/html/sbl_micro_e.html

Groeten ;) Ron

[Mr DIY]

Ron ... these additions are commercially driven controllers. No circuits available without paying for them. They are of little value to somebody that wants a schematic to learn how the system works. I will admit my frustration in following a link from here only to find the information I am hoping to find is not available. Just my 2c.

[Ron van Sommeren]

Every now and then, Thomas Radetzki does a Speedy-BL kit run a.k.a. collective order. Not commercial, next one is due end of April:
http://www.ikarus-modellbau.de/ubbthreads/showflat.php?Cat=&Number=350183&page=0&view=collapsed&sb=5&o=21&fpart=1

[Ron van Sommeren]

Added:
http://www.rcgroups.com/forums/showthread.php?t=200567
and
http://home.versanet.de/~b-konze/

[Ron van Sommeren]

Added:
http://www.rcgroups.com/forums/showthread.php?t=200567

[quax]

Hi Ron,

I did my very best :) and added an English version of my BLMC on my homepage.

Can be found starting from here:
http://home.versanet.de/~b-konze/

2b|!2b ;)

QUAX

[Ron van Sommeren]

Danke Bernard, I changed the first post accordlingly. Keep up the good work.

Cu, Ron

[Ron van Sommeren]

Takao Shimizu's design, source code and schematic:
http://www.rcgroups.com/forums/showpost.php?p=2565567&postcount=153

[Takao Shimizu]

I have tons of question e-mails for BL-ESC control technique description.
The attached file shows the step by step programming of my BL-ESC design.
Also, C8051F330 mixed signal processor function block diagram of BL-ESC control is attached.
Basically, I use a comparator with software select input multiplexer with 100nS responce for BL-ESC control.

;-----------------------------------
; Copyright (C) 2004 by Takao
; All rights reserved.
; FILE NAME : BL_ESC_01.ASM
; DESCRIPTION : Simple MOS FET driver test program for motor run as a stepping motor
; NOTES: This test program does NOT have current limitter function.
; : Use the current limitter to protect the motor coil.
; : Do not run over 5 sec. to avoid the over heat.
;-----------------------------------
; FILE NAME : BL_ESC_02.ASM
; DESCRIPTION : Simple MOS FET driver test program for motor run as a stepping motor
; NOTES: This program has current limitter function. The On/Off duty is 1:6(16%), frame = 150uS.
; : But, use the hardware current limitter to protect the motor coil for single step debug.
; : Do not run over 15 sec. to avoid the over heat.
; : Check the round direction while running and correct the motor wire connection.
;-----------------------------------
; FILE NAME : BL_ESC_03.ASM
; DESCRIPTION : Simple MOS FET driver program for BL motor start run as a stepping motor
; NOTES: Improve the start stepping sequence by sweep frame timing control at starting
;-----------------------------------
; FILE NAME : BL_ESC_04.ASM
; DESCRIPTION : BL motor start run + Sampling comparator data drive.
; NOTES: Get comparator data from motor leads while 3-ST timing and drives motor with corresponding drive pattern.
;-----------------------------------
; FILE NAME : BL_ESC_05.ASM
; DO NOT USE this for latest precision zero cross detector circuit schematic.
;
; DESCRIPTION : BL motor start run + Sampling comparator data drive + Zero Cross switching drive.
; NOTES: Improve BEMF pattern detector by noise check routine.
; Stepping start + BEMF run + Zero Cross switching drive

Takao

Takao Shimizu's design, source code and schematic:
http://www.rcgroups.com/forums/showpost.php?p=2565567&postcount=153

[CLEMENT]

thx

[rtrujillo]

Ron ... these additions are commercially driven controllers. No circuits available without paying for them. They are of little value to somebody that wants a schematic to learn how the system works. I will admit my frustration in following a link from here only to find the information I am hoping to find is not available. Just my 2c.


Mr. DIY,
How about posting schematics or board layouts of some of your developments?

Best,
R. Trujillo

[Mr DIY]

Mr. DIY,
How about posting schematics or board layouts of some of your developments?

It is my intention to do so. I am trying to create some documentation at present to go along with the design that will explain everything in more detail than what we normally see here. Most people refer to the AN857 app note. I would like to create an alternative document that is more applicable to us.

But .. the main reason I have not posted it yet is because very few people here would be able to duplicate it. I am using a CPLD device that requires special hardware and SW to program it. The CPLD device could be replaced with another micro though, but then a new PCB layout would be required. Hopefully it will not be too long now before something is seen here.

Brian

[Takao Shimizu]

This is my BL-ESC software development tools.
I have designed the BAD Li-Po simulator power supply as almost 4C 700mAh Li-Po.

[Takao Shimizu]

This is the ACW CD-ROM BL-ESC full power drive wave form.

[Ron van Sommeren]

Added:
TVE
http://www.hanfordsite.com/

[Ron van Sommeren]

Added a micro ESC;
http://www.rcgroups.com/forums/showthread.php?t=261316

[funflyRI]

MR DIY
phone me and ill try to anser ur questions Kevin 0723789349 only in the RSA

[Ron van Sommeren]

An online course on magnetism/flux, motors and ESC's:
http://www.consult-g2.com/course.html

[Ron van Sommeren]

Added more motor and controller theory:
http://www.innovatia.com/
http://www.innovatia.com/Design_Center/Power_Electronics.htm

Vriendelijke groeten ;) Ron van Sommeren
• e-motor building tips & tricks (http://www.rcgroups.com/forums/showthread.php?t=240993)
• diy outrunner discussion group (http://www.yahoogroups.com/group/lrk-torquemax)
• int. E fly-in & diy outrunner meet (http://home.hetnet.nl/~ronvans/), September, Nijmegen, the Netherlands

[Ron van Sommeren]

Added this 'Quax' controller link:
http://people.freenet.de/khruehlow/

[PaulPounds]

Hi,

I'm in the midst of completing a brushless speed controller board for a research project. I've found that when I send my motor step commands (ie. go from one set value to another, non-contiguous value) the motor instantaneously demands a large current.

Of course, Li+poly batteries don't like being run down like that. Does anyone know how to stop the cells doing this elegantly, or how commercial units do it?

cheers,

-Paul

[Ron van Sommeren]

Beter give it a separate thread Paul, more people will see it. And I intended this thread to be a compilation thread only.

Vriendelijke groeten ;) Ron

[Ron van Sommeren]

Added:
http://frederic.brame.free.fr/variateur%20pour%20moteur%20brushless/variateur%20pour%20moteur%20brushless.htm

[Ron van Sommeren]

Troll or agent, ignore.

[Ron van Sommeren]

Added a design by the 'Elektor' magazine (it was also published in it's French, German, Dutch and Italian Elektor/Elektuur pendants)
http://www.elektor-electronics.co.uk/Default.aspx?tabid=97&ProductID=2721
--> link 'Brushless Motor Controller'

[amirarsalan110]

how we can find speedy-bl pcb layout
thank

[Ron van Sommeren]

You order the PCB's and programmed IC's from Jo Aichinger, the designer.

[PDK]

Hi,

Does anyone know where Frederic Brame's web page has moved to? I would like to see his BL-esc hardware and code but the site seems to have moved.

Best regards
Phil K

[jeffs555]

Phil,
Don't know where if anywhere the site has moved, but if you go to www.archive.org and put in the url, they have most of the internet archived for many years back. I checked, and his site is archived, including the schematics and code. Here is a direct link to the archived pages. http://web.archive.org/web/20050301042354/http://frederic.brame.free.fr/electron/electron.htm

Jeff

[PDK]

Thankyou very much Jeff,

Thats a very handy bit of information. I will see what I can find


Best regards
Phil

[olliestyles]

pdk - i have found the page with all the links intact

here ' tis

http://silicium628.chez-alice.fr/variateur%20pour%20moteur%20brushless/variateur%20pour%20moteur%20brushless.htm

[PDK]

Many thanks,

That is great. Now all I need to do is learn french!!

Best regards
Phil

[Ron van Sommeren]

Added to the list:
Controller design for underwater robot
http://aquaticus.info/bldc_controller
http://groups.yahoo.com/group/lrk-torquemax/message/10239
http://aquaticus.info/bldc_controller

[kubing]

hi,
i'm looking for homemade BLDC esc that can put in my HB cyclone car. Any link? Im prefer PIC base design :o)

------------------------------------

[Ron van Sommeren]

Added:
http://jetcontrol.de/Bastelstube/d2pack.html

Vriendelijke groeten ;) Ron
• diy motor building tips & tricks (http://www.rcgroups.com/forums/showthread.php?t=240993)
• diy outrunner discussion group (http://www.yahoogroups.com/group/lrk-torquemax)
• int. E fly-in & diy outrunner meet (http://home.hetnet.nl/~ronvans/), Aug.26 2007, Nijmegen, the Netherlands

[Ron van Sommeren]

Sad news that I forgot to mention here, Jo Aichinger, the Speedy BL designer, passed away in April.

[Ron van Sommeren]

Added:
1.57gr brushless controller
http://home.foni.net/~c-schlabitz/Floh/
http://home.versanet.de/%7Eb-konze/blmc_flea/blmc.htm

[quax]

Hi,

meanwhile "veterok" of the German rclineforum realized a flea brushless controller with only 0.8g and has built a brushless PicooZ.

http://home.versanet.de/~b-konze/image/piccoz_brushless.jpg

The topic can be found here:
http://www.rclineforum.de/forum/thread.php?postid=1257314#post1257314

Ciao
Quax

[aboobacker]

This sensered controller CD Rom motor without modification
Real Expert people please post this idea

[faraz101]

This sensered controller CD Rom motor without modification
Real Expert people please post this idea
hello aboobacker
would u please tell us from where we can get the ic.

[AndyKunz]

You can use an EPROM if you are doing a sensored control. The Hall outputs generate an address, the data controls the 6 FETs.

Have fun with shoot-thru, though ;)

A simple micro or FPGA would be adequate.

Andy

[Ron van Sommeren]

Guys, this thread was intended for compilation, not discussion. Better start a new thread.

Prettig weekend ;) Ron

[Bruce Abbott]

hello aboobacker
would u please tell us from where we can get the ic.I doubt that aboobacker can help you, since he just ripped the circuit off my website at http://homepages.paradise.net.nz/bhabbott/sensored.html (http://).

I purchsed the NJM2624 from Digi-Key (http://www.digikey.com).

[Ron van Sommeren]

Development kit
http://www.ibweinmann.de/html/homeeng.html

[phanquang_toan]

Dear Ron Van Sommeren ,
I'm really happy with your prompt answer . On the powercroco.de website I met the think I,m focusing in : the videocassete motor drive thaat is large enough to be converted into a direct drive motor for my heli...andthe only thing I do need now is Neodenium Magnets .
Please may I have another Question about Rare earth magnets :
Do we need to remagnetise them after assembling the motor :if so how do it right ? .... Do rare earth magnets sensitive to temperature rise ? and how to solve it practically ?
Thanks a lot Ron Van Sommeren . I and many Vietnamese friends are really happy to do it by ourself >
Best regards,
Thomas Phan Quang Toan.

[Ron van Sommeren]

Thomas, I answered your question in your original discussion:
http://www.rcgroups.com/forums/showthread.php?t=604270

[roffey]

.........

[Ron van Sommeren]

* http://bldc.wikidot.com/

* BLDC controller with reverse:
http://www.rcgroups.com/forums/showthread.php?p=8056614#post8056614

[Ron van Sommeren]

Demo's and tutorials on www.freescale.com, e.g.
http://www.freescale.com/files/microcontrollers/doc/train_ref_material/MOTORBLDCTUT.html

[Ron van Sommeren]

http://silicium628.chez-alice.fr/variateur%20pour%20moteur%20brushless/variateur%20pour%20moteur%20brushless.htm

[Ron van Sommeren]

"The page describes how to convert a cheap commercial speed controller into a light, easy to use, brushless free flight timer. It is also a good introduction to brushless ESC's and you could even build your own. The conversion requires very little soldering and is lighter than most people will ever be able to build themselves (2g without wires). It uses free software, can run on 1, 2 or 3 lipos and deliver up to 6A."

http://www.flyelectric.ukgateway.net/avr_ff_timer.htm

[Unterhausen]

That's a cool link Ron, thanks

[Ron van Sommeren]

300A, 100V design goal:
http://www.rcgroups.com/forums/showthread.php?t=903307
http://www.rcgroups.com/forums/showthread.php?t=879898

[allibow]

anyone got a pic based bl ESC?

[malibus]

Yes, i have find these in french, pic16f628 based
http://silicium628.chez-alice.fr/variateur_pour_moteur_brushless/variateur_pour_moteur_brushless.html

[Ron van Sommeren]

Added:
http://www.rcgroups.com/forums/showthread.php?t=890041&page=2&pp=10

Prettig weekend ;) Ron

[Ron van Sommeren]

Added Bruce Abbott's sensored design:
http://homepages.paradise.net.nz/bhabbott/sensored.html

[Chippie]

Yes, i have find these in french, pic16f628 based
http://silicium628.chez-alice.fr/variateur_pour_moteur_brushless/variateur_pour_moteur_brushless.html

New link to site...

http://www.silicium628.fr/variateur_pour_moteur_brushless/variateur_pour_moteur_brushless.html

[Ron van Sommeren]

Merci Chippie, j'ai changé le lien :)

[Ron van Sommeren]

Added this HV design:
http://rmmx.gmxhome.de/bldchv/start.html

[rmmx]

Hi,

i made an english translation available.
Please use:
http://rmmx.gmxhome.de/bldchv/english/start.html

@ron could you please change this in the first post

Thanks Ralf

[Ron van Sommeren]

Done :)

[Ron van Sommeren]

Added
Controller discussions
http://mailman.evtech.org/mailman/listinfo/evtech

[Bricobrac]

Good afternoon,

does anybody know where i could find some source code regarding the governor modes ?
I found many nice designs i the lists but no way to find any code for the governor, even something to start with for experimentations :)

Thanks a lot for any answer,

Fabien

[Ron van Sommeren]

Search/ask in this thread Fabien:
http://www.rcgroups.com/forums/showthread.php?t=200567

Vriendelijke groeten ;) Ron

[Bricobrac]

Hi Ron,

thank you very much :)

BEst regards,

Fabien

[Ron van Sommeren]

Added to first post

Brushless controller for Control Line:
http://www.pek.nu/pekproj/proj/el/sc/
Discussion:
http://www.svensktmodellflyg.se/forum1.asp?viewmode=1&msgid=195747&page=&CurrentMainTopic=2

[Ron van Sommeren]

Added

OSMC projekt kits:
http://www.robotpower.com/
Discussion group:
www.yahoogroups.com/group/osmc