1/3 Scale Car - setup Flipsky motor controller

[jruths]

The motor controller needs to be configured to work with the stock motor on the 1/3 scale car.

[5408Andy]

09/16/2024 Update:

• Status: Delayed. There is an issue with downloading the software for configuration
• Next Steps: Send email to site to figure out why download is not appear in inbox
• Projected Completion: TBD
• Update: We tried checking our junk mail for motor configuration setup but nothing semblance of the motor configuration software appears. We still need to look for the Youtube videos that show us how to configure a motor. While we have been waiting for response from the website as to why the software is not showing up in our email, Ryan has been studying schematic trying to understand how it works. I also had him help me with the Orin and ZEDX Camera setup.

[jruths]

This youtuber hobbyist has a bunch of videos on modding the car we have. He used a different controller (not the Flipsky), but I think in principle they are very similar. So the setup tools might be a bit different, but I bet you need to enter in pretty much the same information... so if there is something that you can't figure out on your own, I think this video might touch on it: https://www.youtube.com/watch?v=GHt-mKDFR-g

[5408Andy]

09/24/2024 Update:

• Status: Got a response back and was able to download the configuration software
• Next Steps: Learn how the configuration software works and check specifications of our motor on third scale car.
• Projected Completion: TBD
• Update:

[5408Andy]

10/13/2024 Update:

• Status: Tested VESC Motor Controller Software [FAILED]
• Next Steps: Talk to Dr. Ruths about what is wrong. And try again...
• Projected Completion: TBD
• Update: Appears to be some kind of under voltage issue? I followed the spec of the battery we have on the car but its not working. I can make a video of myself going through all the steps.

[5408Andy]

We have determined the issue of the undervoltage fault. It appears that for some unusual reason that that the controller is pulling its voltage from the DC/DC converter which outputs around 15V. The operating range of the controller is around 14V to 84V (4-20S).

The issue of the undervoltage fault is I think might be because we are barely within the operating voltage of the controller. Either way I think it is better to directly hook up the controller to the battery since the Lithium-Iron battery is within the 84V.

[5408Andy]

11/04/2024 Update:

• Status: Issue Identified.
• Next Steps: We will be directly wiring the motor controller to the battery, but first we will check if the other pins of the controller are functioning correctly. Planning to start work on this Monday morning to get it ready for the parade.
• Projected Completion: TBD
• Update: We determined that the undervoltage fault was due to the controller drawing power from the DC/DC converter, which outputs around 15V. Since the operating range of the controller is between 14V and 84V (4-20S), it appears we were operating on the lower boundary of its range, potentially causing the issue. To avoid this, we'll connect the controller directly to the Lithium-Iron battery, which is well within the required range of 84V. Ryan has also been studying the schematic while waiting for a response from the site regarding the software download issue.

[5408Andy]

11/10/2024 Update:

• Status: Testing Underway.
• Progress: The direct wiring of the motor controller to the battery was completed successfully. We conducted preliminary tests and confirmed that the undervoltage issue is resolved. All controller pins were also checked, and no faults were identified.
• Next Steps: Complete testing and validate all functions. Once verified, we'll proceed to integrate everything and perform a full system test in preparation for the parade. Additionally, we'll continue pursuing a resolution with the software provider.
• Projected Completion: TBD

Recommendations & Alternatives:

1. Power Source Stability:

   • Considering the undervoltage issue previously encountered, it may be beneficial to use a DC power stabilizer between the battery and the motor controller. This will help maintain a stable voltage, especially during load changes, avoiding operational disruptions.

2. Anti-Spark Switch Installation:

   • Since the motor controller is now directly wired to the battery, it is recommended to add an anti-spark switch between the battery and controller. This will prevent sparks when disconnecting or reconnecting power, protecting both the controller and wiring from damage.

     Examples: https://www.amazon.com/Amass-Connector-Anti-Spark-Battery-Charger/dp/B074PTHZ3M?th=1

3. Monitoring and Safety:

   • Adding a voltage monitoring circuit or undervoltage cutoff relay could help automatically protect the controller from dropping below its operational voltage range in the future, ensuring safe operation and extending its life.

We now also have an unused DC/DC converter because originally for some reason that converter was dedicated for the motor controller but in my opinion that is overkill.

[5408Andy]

Demonstration of the throttle: https://github.com/user-attachments/assets/d6851d0b-c39e-4602-bd95-cd78ec4f6258

Problem that we need to fix with hooking up motor controller directly to battery: https://github.com/user-attachments/assets/600dd9db-ec58-4d82-b048-41a72754a305