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Reprogramming Brushless ESCs - Complete - No Support Offered
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marto
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Reprogramming Brushless ESCs - Complete - No Support Offered

Brushless ESC are now a very cheap device which can be bought from our friend hobbyking. These ESCs are great for planes but they don't quite fit what we need. So lets reprogram them to do what we want. Very Happy

Controllers are now using Atmel and Silicon Labs microcontrollers. Both can be reprogrammed, however silicon labs MCU requires a different programming adapter.

For Code See
www.launchpad.net/brushed

Brushed Motor ESC
The brushless ESC consists of 3 half bridges. It should be possible to repurpose two of these to make a single H-bridge. This is similar to a brushed motor mode which is available in some high end controllers. This should be able to be done with most HK controllers.

Goals for Brushed Controller
This TODO list is much more complex in reality due different code for SiLabs and Atmel MCUs

    Proof of Concept - Complete
    Fully Functional Controller - Complete
    - Add max slew rate - Complete
    - Exponential rates - Complete
    - Programmable mode - Complete
    Identify suitable controllers for classes - Complete

    Controller State
    Special 2in1 Antweight Controller -Complete
    Battle Tested in Antweight - Complete
    Battle Tested in Beetle - Complete
    Battle Tested in Feather- Complete

    Battle Tested in Lightweight - Under Development
    Battle Tested in Middleweight - Under Development
    Tutorial - Complete - http://www.robowars.org/forum/viewtopic.php?t=1609


Compatible Controllers
TZ85A - Proven in Feather
F20A - Tested in Beetle & 2in1
Sentilion HV 100A (only tested on old version) - Testing with 12S on 100W scooter motors
Plush10 - Tested - Proven In Ant
TZ12A - requires soldering to MCU
HK10 - Proven in ant
Turnigy TI-PY 25A - Proven in Beetle, and still running @ 6S on drills in feather


Controllers Under Development
No more opensource development is current being undertaken.

For further development please see
http://www.facebook.com/botbitz or http://robowars.org/forum/viewtopic.php?t=1642

Reversible Brushless Motor - Not currently under development
This would involve reprogramming and removing the delay with reverse. Some initial investigations have been made into this and it is definitely possible. For drive train applications it would almost certainly require sensored motors and controller. I could develop this but at this point in time I don't have time.


I am no longer providing support for those trying to program their own controllers. If you want pre-programmed controllers goto botbitz.com
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Steven Martin
Twisted Constructions
http://www.botbitz.com

Last edited by marto on Fri Aug 07, 2015 9:25 pm; edited 32 times in total

Post Sat Feb 05, 2011 9:57 pm 
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marto
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Joined: 08 Jul 2004
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Location: Brisbane, QLD


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The Quest for cheap ESCs begins.

My first aim is to be able to 2x Plush 30s to run scooter motors in a feather. The ESCs should be able to take it.

Here is a picture.


You can see the 6 programming pins. Just tracing them now.

http://dl.dropbox.com/u/815267/IMG_1008.JPG

Steve
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Last edited by marto on Sat Feb 05, 2011 11:35 pm; edited 2 times in total

Post Sat Feb 05, 2011 10:10 pm 
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Knightrous
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As per discussions on MSN, I suggest looking at Turnigy Brushless ESC 85A w/ 5A SBEC ( TZ85A ). This looks like a more combat ready controller physically and the amperage and voltage ranges should be suitable for the featherweight class. The size, weight and price of the TZ85A are very attractive.

I'm prepared to purchase a couple of these to put towards development.
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Post Sat Feb 05, 2011 10:10 pm 
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marto
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So from left to right in the above picture.

1. Reset
2. VCC
3. Ground
4. SCK
5. MISO
6. MOSI

And we have a programming connector

And apparently this is the schematic.

http://www.rcgroups.com/forums/showatt.php?attachmentid=3693455&d=1293741089
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Post Sat Feb 05, 2011 10:56 pm 
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marto
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The code on the ESC appears to be locked. It can be read but its just a repeated pattern



Here is the code.
http://dl.dropbox.com/u/815267/Plush30/Plush30-Read.hex
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Post Sun Feb 06, 2011 1:04 pm 
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marto
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Ok Fet details for the Plush 30s

4407GM
http://dl.dropbox.com/u/815267/Plush30/4407GM.pdf

IRF 932

http://dl.dropbox.com/u/815267/Plush30/P932M.pdf
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Steven Martin
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Post Sun Feb 06, 2011 3:14 pm 
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Knightrous
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quote:
Originally posted by Jaemus:
fast work! got a video?

http://www.youtube.com/watch?v=h4ts5zWxVuU
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Post Sun Feb 06, 2011 7:55 pm 
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Knightrous
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I've been discussing with Steve on reprogramming various controllers for different weight classes.

Antweight
H-KING 10A @ $5.98
HobbyKing 12A @ $7.81.

Beetleweights
TURNIGY Basic 18A @ $13.99
TURNIGY Basic 25A @ $15.86

Featherweights
Turnigy Brushless ESC 85A @ $36.59
TURNIGY Sentilon100A HV @ $84.01

Research still has to be done into each controller, but if it does prove successful, it might mean a new era for cheap, disposable speed controllers for everyone. Smile
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Post Sun Feb 06, 2011 8:40 pm 
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Knightrous
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Just to add some extra stuff to this project. If you blow up one side of h-bridge (half-bridge) on these controllers, it should be a simple case of reprogramming them to use the spare, 3rd half-bridge instead so the controller works as normal again. Therefore you might get a chance to blow it up twice before throwing it away Laughing
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Post Sun Feb 06, 2011 8:42 pm 
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marto
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Uploading video now with moar reverse just to prove it actually does work.
http://www.youtube.com/user/QRSClub#p/u/0/mAbSaG7nFBQ

As for amps I am not sure. Only way we will know is to test. But odds are for beetles it will still be cheapest option. Even if we can't do feather sized motors.

Also the schematic I uploaded is incorrect High C actually = High A

I am going to start a launchpad repository for the code as revision control is something which I really need. As I have a tenancy to throw away all the code then realise I need it all back....
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Last edited by marto on Sun Feb 06, 2011 9:16 pm; edited 1 time in total

Post Sun Feb 06, 2011 8:58 pm 
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marto
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I am pretty sure it should work. I just probably have bugs in my Code.

I am going to strip it back a little tonight and just see if I can get Bang-Bang with a RC input working. Might also wire up a LED to the spare motor wire for debugging. Finding uses for that extra channel already.

I am still wondering why no one has done this before.....

Steve
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Post Mon Feb 07, 2011 6:04 pm 
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marto
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So latest.

http://www.youtube.com/watch?v=ZhOPOTYCwdk

If you want to see code check out http://www.launchpad.net/brushed

Ah was quite a few stupid mistakes in the code..... No PWM atm but that is to come.

Brett if you see this could use a bit of input on the code particularly for switching the fets.

Steve

Edit: Also updated first post.
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Post Mon Feb 07, 2011 11:41 pm 
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marto
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After quick look at PWM code I think there is something wrong with my timer setup. Sleep will tackle full PWM tomorrow.
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Post Tue Feb 08, 2011 12:28 am 
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dyrodium
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Words do not describe the awesomeness, even proving bang/bang control via RC is enough, the days of grossly overpriced esc's are nearing their end... Laughing Wonder if any of the american guys have seen this yet...
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Post Tue Feb 08, 2011 7:53 am 
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Knightrous
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Good work Steve.
I'll start testing the code on a few of my BESC's when I get back from NSW. I also have a few other ideas to bouce off you with regards to functionality.
Also, cheers for making me the 'Driver' on Launchpad Razz
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Post Tue Feb 08, 2011 8:56 am 
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