Extended BLDC-TOOL with Watt Control Mode, PPM Cruise Control, individual Throttle-Curve and Android App

General Discussion
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697

@ackmaniac I have a friend with the same setup as me, 2 VESC, 2 6355 190KV motors, 100mm wheels, 10S4P with Samsung 25R, but instead of 16/36T he has 13T/36T pulley kit.

Whenever the battery charge is between 90-100%, if he applies brakes on high speed, regen sends amps to the battery until it overcharges more than 57V and throws an overvoltage fault code:

Fault : FAULT_CODE_OVER_VOLTAGE Current : -14.2 Current filtered : -14.3 Voltage : 57.35 Duty : 0.27 RPM : 21833.1 Tacho : 453339 Cycles running : 10841 TIM duty : 3498 TIM val samp : 1748 TIM current samp : 8175 TIM top : 12854 Comm step : 5 Temperature : 48.62

Fault : FAULT_CODE_OVER_VOLTAGE Current : -20.3 Current filtered : -15.9 Voltage : 57.41 Duty : 0.20 RPM : 17775.2 Tacho : 464138 Cycles running : 4798 TIM duty : 3221 TIM val samp : 1610 TIM current samp : 9744 TIM top : 16268 Comm step : 2 Temperature : 46.49

Fault : FAULT_CODE_OVER_VOLTAGE Current : -11.4 Current filtered : -11.5 Voltage : 57.45 Duty : 0.23 RPM : 17776.1 Tacho : 486449 Cycles running : 6651 TIM duty : 3358 TIM val samp : 1677 TIM current samp : 8969 TIM top : 14583 Comm step : 3 Temperature : 47.65

Fault : FAULT_CODE_OVER_VOLTAGE Current : -23.3 Current filtered : -16.5 Voltage : 57.63 Duty : 0.14 RPM : 14073.5 Tacho : 505408 Cycles running : 4414 TIM duty : 2848 TIM val samp : 1426 TIM current samp : 11865 TIM top : 20877 Comm step : 2 Temperature : 48.48

Fault : FAULT_CODE_OVER_VOLTAGE Current : -34.5 Current filtered : -22.3 Voltage : 57.68 Duty : 0.10 RPM : 11553.5 Tacho : 522941 Cycles running : 3915 TIM duty : 2513 TIM val samp : 1264 TIM current samp : 13767 TIM top : 25007 Comm step : 1 Temperature : 51.99

and VESC reboots itself, I’m guessing if the battery is fully charged at 42V there’s no place for the regen current to go, so system crashes, he looses all remote control and brakes, really scary to ride this way.

I the battery is below 90% the board rides perfect and braking works flawlessly

1393×905

We tried:

  1. Reducing the Batt Min (regen) from -8.00 to -5.00A (same problem, overcharge, less braking)
  2. Reducing the batt Min (regen) to -2.00A (no cutting out, but almost no brakes)
  3. Increasing Maximum Input Voltage from 57V to 58V (same problem, overcharge, voltage spike now 58.7V instead of 57.6V)

I’m pretty sure it must have something to do with the pulley kit 13T/36T as it spins the motor a lot more and charges will too much current.

698

I guess he has another BMS or you have no BMS and he has one. Sounds to me that his BMS shuts down and the VESC doesn’t know where to put that power.

699

As @Ackmaniac said, probably the BMS is detecting an overcharge of the battery The easy way to figure it out is bypass the charge and use it only for charging

700

Both boards, mine and his, have the Battery Supports 10S 60A BMS. VESC doesn’t know where to put that regen power

701

@Pedrodemio if BMS would be detecting a battery overcharge then why would the VESC detect a overcharge and store the fault?, if VESC cutsoff 5 times there would be 5 overcharge stored faults.

Would this have anything to do with the fact I have 100mm wheels, 13T/36T pulley ratio?

Same braking speed, very big wheel diameter, very small motor pulley, a lot of rpms on the motor pulley side during braking, a lot of current being produced by the motor and flowing back to the battery = VESC cutsoff and reboots.

702

When the BMS detects a overcharge it shuts off. So where should the VESC send the power now? If you would have 12S battery it might can reach the 57V if you have very very bad batterys. But with a 10S you should not face that issue. So i think it’s the BMS. And if the Motor spins faster with the lower motor gear it also produces a higher current. But still it shouldn’t be a issue for a 10S Battery. Just try to bypass the BMS and i think the problem will be solved.

703

Thanks Nico, I’ll try to do that tonight and report back the results

704

Exactly what @Ackmaniac said, the BMS cut the conection between the VESC and battery, but there still a current wanting to flow, all energy goes into the capacitors and the voltage rise quickly since they can’t store much charge, triggering the cut off.

I would say to stop riding in this condition, if the conditions are right (or wrong in this case) the VESC may react to slow to the rising voltage and something might blow

705

@The_Dude was so nice and provided a new Version for MAC. Thanks again, much appreciated.

I added it already to the Dropbox link. Hopefully the problems are now fixed for all operating systems.

1 Like
706

This new version doesn’t work with macOS Sierra 10.12.3 for me.

“BLDC-Tool_2.53 cannot be opened because of a problem.”

707

Works for me now (Yosemite 10.10.5). Thank you very much @The_Dude !!!

708

Strange - I also gave it to @mrplaygood and it worked for him. As far as i know, he’s also with OSX Sierra. I will see, if I can get access to a Mac with Sierra to check.

709

Can you post a screenshot of the error? That would help.

710

Wasn’t there some issue with newer Macs that you have to allow “sideloaded” applications. Maybe that’s the case…

711

Of course :

Process: BLDC_Tool [2017] Path: /Applications/BLDC-Tool_2.53.app/Contents/MacOS/BLDC_Tool Identifier: com.yourcompany.BLDC-Tool Version: ??? Code Type: X86-64 (Native) Parent Process: ??? [1] Responsible: BLDC_Tool [2017] User ID: 501

Date/Time: 2017-02-09 22:09:42.438 +0100 OS Version: Mac OS X 10.12.3 (16D32) Report Version: 12 Anonymous UUID: AFABF4B5-5A46-F9CE-8C3B-576757210306

Sleep/Wake UUID: 15F18420-A086-4009-A58B-314C4EC275DB

Time Awake Since Boot: 7700 seconds Time Since Wake: 39 seconds

System Integrity Protection: enabled

Crashed Thread: 0

Exception Type: EXC_CRASH (SIGABRT) Exception Codes: 0x0000000000000000, 0x0000000000000000 Exception Note: EXC_CORPSE_NOTIFY

Termination Reason: DYLD, [0x1] Library missing

Application Specific Information: dyld: launch, loading dependent libraries

Dyld Error Message: Library not loaded: @rpath/QtPrintSupport.framework/Versions/5/QtPrintSupport Referenced from: /Applications/BLDC-Tool_2.53.app/Contents/MacOS/BLDC_Tool Reason: image not found

Binary Images: 0x10a736000 - 0x10a891ff7 +com.yourcompany.BLDC-Tool (???) /Applications/BLDC-Tool_2.53.app/Contents/MacOS/BLDC_Tool 0x10e133000 - 0x10e170267 dyld (421.2) <947FC440-80F9-32F7-A773-6FC418FE1AB7> /usr/lib/dyld

Model: iMac13,2, BootROM IM131.010A.B0A, 4 processors, Intel Core i7, 3,4 GHz, 16 GB, SMC 2.11f14 Graphics: NVIDIA GeForce GTX 680MX, NVIDIA GeForce GTX 680MX, PCIe, 2048 MB Memory Module: BANK 0/DIMM0, 8 GB, DDR3, 1600 MHz, 0x80AD, 0x484D5434314753364D465238432D50422020 Memory Module: BANK 1/DIMM0, 8 GB, DDR3, 1600 MHz, 0x80AD, 0x484D5434314753364D465238432D50422020

712

713

Hi, I tried @The_Dude s software on Mac OSX Sierra 10.12.3 and it worked fine. I had not installed QT which he said could solve the problem but I have installed Xcode. If you don’t want to install this because it is about 5 GB you can also install the Xcode command line tools which are free and much smaller. I hope that helps.

714

I have all updates done, but I have Xcode Version 8.0 (8A218a).

I’m downloading Version 8.2.1 to see if it helps.

The problem is : “dyld: Library not loaded: @rpath/QtPrintSupport.framework/Versions/5/QtPrintSupport”

715

What is the size of your pkg-file you downloaded and used for the installation?

716

It’s 852 858 bytes.

Updating Xcode didn’t help.

I’m installing QT now… Maybe that was the problem? :blush: