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Make your own Sensored ESC || Electric Bike Conversion (Part 1)



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Parts list (incomplete, see Instructables for more, affiliate links):
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1x Arduino Nano:
1x 10k Potentiometer:
1x 74HC14 Hex Inverter Schmitt Trigger:
3x TC4427 MOSFET Driver:
3x IRF5305 P-Channel MOSFET:
3x IRFZ44N N-Channel MOSFET:
6x MUR460 Diode:
1x LM7805 5V Regulator:
1x LM7815 15V Regulator:
Ebay:
1x Arduino Nano:
1x 10k Potentiometer:
1x 74HC14 Hex Inverter Schmitt Trigger:
3x TC4427 MOSFET Driver:
3x IRF5305 P-Channel MOSFET:
3x IRFZ44N N-Channel MOSFET:
6x MUR460 Diode:
1x LM7805 5V Regulator:
1x LM7815 15V Regulator:

In this video I will show you how a sensored BLDC Motor from an electric bike works and how we can create our own sensored ESC in order to let it rotate.

Thanks to JLCPCB for sponsoring this video
Visit to get professional PCBs for low prices

Music:
2011 Lookalike by Bartlebeats
Killing Time, Kevin MacLeod
(incompetech.com)

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Written by lena

Foodie, Performer, Water Protector, Avid Baker, Syndicate Aggregator. I probably still live in my mom's basement.

45 Comments

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  1. You aren't going to close this one off with.. Well that didn't work. BUT BE AWSOME! 😀 Cuz Digikey is tired of taking back my opened component packages.

  2. can you please tell me from where you learnt programming for those arduino boards. Is there any official site of arduino which teaches about arduino programming .Other sites take too much money for teaching programming .I mean how do you know syntax of each hardware you bring. Of course datasheets does not help in programming.
    please tell me

  3. wouldn't it make more sense making a controller that creats 3 sine waves with 120° phase shift instead of turning a pwm signal on and of?

  4. GreatScott, your driver has one serious problem – if you only use inverters to switch between the FETs, there is no dead time. The transistors don't turn off instantaneously, so you are going to have very nasty current spikes (shoot-through) because for a short moment both transistors are on, causing a short circuit across the power rails. That's bad both because it will cause the FETs to get hot (or even blow them up), because you are generating a ton of EMI with it and also because it wastes energy, which is important if you want to run this from a battery on a bike.

    That's why proper FET drivers for half bridges have an option to set dead time. Many microcontrollers designed for driving motors/bridges have an option to generate programmable dead time too. If you are using an Arduino (ATMega328 and similar), you will have to generate this dead time in software by inserting a delay between switching one FET off and the other from the pair on. You will pretty much never see a simple inverter used in this kind of application.

  5. Why did my esc now broke? The resistor gets really hot and nothing worked but why did this happen any idea? ( i couldnt see and smell a short circut and the shunt was fine.

  6. Hi great Scott! This was a great video, you are a genius! There is one thing I really want to point out to you for your own good. I have made many ebikes, I purchased a hub motor for the front just like you. When I put it on my bike the hub motor the second I put power to it on the ground the mounting taps broke on the forks. I don’t know what it is but the magnesium alloy is very brittle to the motors torque. I really hope you see this because I have broken 3 forks like that and had to get steel ones. I think it’s a huge safety hazard and don’t want it to happen to you!!!

  7. I might be missing something !!
    Why aren't you just change the battery into a stronger one . .that will solve the problem right?

  8. Hi Scott, another thing I would like to see. Could you make some deep approach showing the relationship between number of poles of stator and rotor. Where to place the magnets and when to commute phases. I don't see, for example, a motor with same number of poles in stator and rotor. Thanks a million

  9. great video, tanks for explaining the hall effect sensor in a good practical way, keep up the great work.

  10. Yeah, I wouldn't do that if efficiency is something you care about (6:45)… If you wanna use a PWM-ish approach to control the speed, by only applying voltage for a limited amount of time, be sure to leave the phases floating while not applying voltage (except during regenerative braking of course).

  11. i am wanting to look into some electronics engineering and i was wondering if you or anyone else could recommend a good place to start with it. i thought about find schematics online and learning how they work then build them or if buying a kit would be a better route?

  12. Hi great Scott, is it possible to increase the rotation speed of the engine? I have an electric bike and I would like to make it go faster.

  13. you should set up a generator, so when you move on the bike the wheel rotates the generator and powers the batterie

  14. Lately, I am struggling to make prototypes on a piece of pcb. I really love your technique of making solder traces, but I really don't succeed in making traces? How do you do them?

  15. I dont understand a heck about what you are talking about, but i like your videos, what is this called (the carrer)?

  16. Hey, i have a project i'd like your help in, I need an audio amplifier with 100w on one mono channel, but i need to be able to mount the volume knob through an enclosure. I have not been able to find an off the shelf amp that lets me do these things, is there any service i could use to have one custom made? or even have you design a circuit that i could assemble?? or is there a two channel amplifier that i could bridge??

  17. Have you ever given any thought to making a video on a diy smps to turn mains power into 5vdc, so it can be used to power a micro controller. I've looked all over but I can't seem to find a decent video or tutorial on the subject.

  18. Is it possible to create a sine wave controller with regen braking that can handle high voltage and output high amount of watts?

  19. Hi there. I've created an ESC control and I would like to comment some things. I'm using 16.5KHz AND the potentiometer only control the PWM which starts with 5%. The next step will happens when the hall sensors to change. This way you don't need to wait. You will be always in sync, even in low or high speeds. Sorry my poor English.

  20. Sorry,I have a question. The TC4427 chip's operating range 4.5V to 18V,why you use LM7815 15V regulator? why don't use the LM7805 5V regulator ? Could the three pieces of TC4427 & one 74HC14 Hex Inverter Schmitt Trigger share the output of LM7805 5V regulator?

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