FF v1.1 and v1.2s Design Files

I'm finally getting around to collecting and organizing the hardware documentation for my two newest motor controller designs. These are the FF line motor controllers, which I've been testing for a few months now. They're small single-board three-phase motor controllers, designed for sensorless field-oriented control. v1.1 is the larger, higher-power version and v1.2s is the smaller, lower-power version.

FF v1.1 (left) and v1.2s (right).

Both versions share the same logic layout. The microcontroller used is the STM32F103C4, although the design should be pin-compatible with many other 48-pin STM32 microcontrollers, including some with floating-point capability. It can be programmed with a 3.3V FTDI adapter or wirelessly over XBee. The firmware is still very much a work-in-progress, but I've also uploaded two different firmware versions (IAR EWARM Kickstart Projects) here, for reference only:

1. Air Firmware (STM32_air.zip): Framework for closed-loop RPM control based on 1000-2000μs RC-style PWM input. Inner loop is field-oriented current control based on sensorless position estimate.
   
2. Ground Firmware (STM32_ground.zip): Framework for torque-controlled electric vehicles using field-oriented current control. The input is an analog throttle signal. There is an optional ramping start-up but it's not perfect.

Note that the firmwares are my working copies, not release versions. I won't even give them version numbers because they're that non-functional. Repeat: This will not run your motor. Each motor needs parameter tuning and the only way to do that right now is using hard-coded constants in the firmware. I'm only uploading them as examples that others can refer to for development. Also note that this hardware cannot do six-step BLDC control. It's designed with sinusoidal commutation / SVM and synchronous rectification in mind.

Both versions of the controller hardware also share the same gate drive solution, based on the Texas Instruments DRV8301. I call this the magic everything chip, because it's much more than just a nice 2A three-phase gate driver. It also has dual low-side phase current amplifiers, integrated gate and logic power supplies, integrated bootstrap diodes, and a completely independent buck controller with internal switch for creating a logic supply for the rest of the board.

Both versions also have the same I/O broken out, including pins for analog throttle, I2C, UART (shared with the FTDI programming port and with the XBee headers), RC-style PWM input, and three auxiliary inputs that can be either timer capture inputs (encoder), hall sensor inputs, phase voltage sensing, or general-purpose analog inputs. 3.3V and 5V supplies are also broken out to pin headers.

The differences between v1.1 and v1.2s are entirely in the power section of the board. v1.1 has a beefier power stage based on D2Pak-7 MOSFETs, while v1.2s has a smaller Super SO-8 MOSFET layout. The details and design files are below:

FF v1.1 [Design Files]

Size (board only): 3.00in x 1.50 in x 0.50in

Size (w/ external cap): 4.20in x 1.50in x 0.50in

Weight (board only): 28g

Weight (w/ wires and cap): 66g

Suggested MOSFETs: IRFS3004-7PPbf, IPB017N06N3 G, IPB010N06N, IRFS3107-7PPbf

Suggested External Capacitor: 680uF, 63V (x2 for high current)

Approx. Power: 48V / 30A (cont.), 75A (peak)
BOM Cost: $96.90 (1x), $74.38 (10x), $53.39 (100x)

This version of the controller was originally designed with large multirotors in mind, but it's also been tested on a number of ground vehicles at up to 75A acceleration current (the maximum phase current at full throttle). The continuous current capability is significantly lower due to the lack of large heat sink. 30A is my best guess with any of the MOSFETs listed above, but with adequate airflow it could be higher. The maximum voltage depends on the capacitors and MOSFETs used, but is limited to 50V by other components.

FF v1.2s [Design Files]

Size (board only): 2.00in x 1.50 in x 0.28in
Size (w/ external cap): 2.79in x 1.50in x 0.32in
Weight (board only): 11g
Weight (w/ wires and cap): 35g
Suggested MOSFETs: BSC016N04LS G, BSC010N04LS, BSC014N06NS
Suggested External Capacitor: 470uF, 35V (x2 for high current)
Approx. Power: 48V / 15A (cont.), 30A (peak)
BOM Cost: $56.89 (1x), $47.14 (10x), $33.32 (100x)

This version was designed with smaller multirotors in mind, although it should be fine on the not-so-heavily-loaded CineStar 6 as well. It's not really suitable for vehicles, but might work fine for robots / RC cars /  small servo-mechanisms. The maximum voltage and current depend on the MOSFETs and external capacitor chosen, but it should have no trouble at 15A continuous and 30A peak, higher with more air flow or heat sinking.

That's it for now. Later I hope to post a lengthy document outlining the sensorless position estimation algorithm at work in the reference firmware. Even later I hope to make a GUI for configuring the firmware for a particular motor. For now, you're on your own with that.