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Revolution Models . CarbonXtreme . Midland Helicopters

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e-Electric Conversions > Ever tried to modified ESC for a higher voltage?
 
 
Islander
Heliman
Location: Stanford, CA

Has anyone tried to modify the ESC for a higher rating? since a 50V+ ESC is so expensive, is it possible to modofy a JETI77A ESC for 50V?

the prime limitation of operation voltage would be:
1. FET - this is primarily limited by Vds
2. FET driver - the driver would have to output a voltage higher than the DC bus(battery DC value) for at least 10V
3. battery capacitor - this is the one which cause the big spark for your battery connector
4. CPU's power supply - LDO(known as low drop out regulator), should withstand upto 50V
5. S/W - the sensorless sensing circuit/algorithm may not operate right at too high a voltage
6. ???



for a JETI 77 3P-O
1. FET - it is a SI4850, which has a Vds of 60V, should be OK to handle 12S - around 50V
2. FET driver - it is a IR2103S, which can operate up to 600V, should be OK to operate at 50V
3. battery capacitor - this one is rated as 330uF/50V, two in parallel. - It would be better to replace them with two 330uF/100V parts, and these caps are no difficult to get.
4. CPU power LDO - it is a two-stage design which gets each stage a lower voltage to "dropout", one regulator is a NS LM2931, which can withstand 26V. the other is unknown. SO I don't know if it can withstand upto 50V. I think I can find some replacements which would be able to handle 30V, and this would make the whole reguting circuit able to operate upto 56V
5. S/W and sensorless circuit - I have no info about it, but I think it should not be a problem since the circuits is consisted with only a few resistor network.
6. ???


comments and suggestions?
01-16-2005 Over year old.
 
 
rroback
Key Veteran
Location: Irvine (UCI), Ca

well, with my basic knowledge... it seems possible. the problem would end up being the max power running through the esc. some components could not handle the power.. and would heat up too much. if you could solve this problem.. I'd pay for you to convert a few escs for me : )

Rhett... I can't fly, luckily the HC Profi Can!
01-19-2005 Over year old.
 
 
Islander
Heliman
Location: Stanford, CA


Hi:
after some tests, I am now pretty confident that the only risk to run JETI77A @ 50V is the input capacitors and maybe the heat @ high current. I've replaced the input cap with two 330uF/63V caps and run a light test w/o problem. However I am not so sure if it will fry out at load. Maybe some of you can do this test.

rroback:
I think it would ease up a bit the heat @ high current if you set the ESC to run only 8KHz as this would significantly reduce the "switching loss" induced by each switching movement of the FET.
01-19-2005 Over year old.
 
 
Islander
Heliman
Location: Stanford, CA

some further inspections reveal that this ESC can only work upto 55V, theoretically - because the sensorless circuits would be overvoltage for a DC-bus voltage higher than 55V.
01-19-2005 Over year old.
 
 
rroback
Key Veteran
Location: Irvine (UCI), Ca

55 volts would be 13s! even 51 volts would cover 12s.. and would be plenty. Any chance you can run a semi load test? given it passes some basic tests, I'd test it for you : ) I'd pay for shipping from you to me, and we'd set an amount, like a week to test, and I'd send it back...

r

Rhett... I can't fly, luckily the HC Profi Can!
01-19-2005 Over year old.
 
 
Islander
Heliman
Location: Stanford, CA

rroback:
I haven't found the method to restore the plastic heat shrink cover of the ESC. That's the problem. And It would be too damn expensive to ship this thing back and forth between US and Taiwan. If you could find someone who can do the soldering work for you, then it would be much easier as I can tell you the steps to modify it.
01-20-2005 Over year old.
 
 
rroback
Key Veteran
Location: Irvine (UCI), Ca

I didn't even see you were in taiwan. do you have pictures? I'm moderatly capable at soldering, but I know people who are very good. pictures would be better, although I suppose I could give them some sort of direction list. I would just cover this thing in kapton.. as it will need to have a lot of good heat conduction away from the board.

r

Rhett... I can't fly, luckily the HC Profi Can!
01-20-2005 Over year old.
 
 
1 page671 viewsPOST REPLY
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e-Electric Conversions > Ever tried to modified ESC for a higher voltage?
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