Hi,

I just finished a new controller for my electric scooter project.

The current is limited to 50Amp but it can sustain at least 80Amp.

It is also based on Mc33035 IC and it is capable to decode signal from the hall sensors.




 

 

Now i`m also building a new Go kart controller.I will use the same logic board as the scooter.

The board was designed in Eagle Cad:

The Brushless motor Controller Schematic: (command module)

 

I used photo resist PCB to make the circuit :

 

 

 

After that i used  Ferric Chloride etchant to remove all the unnecessary cooper.


And the result was :


Here is a picture of my Homemade Electric Go Kart:

 

 

 

  1. This is wicked sick. I’d like to build a 4.8 kw kart for racing purposes.

    Thanks for sharing your knowledge and expertise!

  2. Andrei says:

    Imi poti da pe mail toate schemele electrice dar si cateva detalii si sfaturi necesare pentru a realiza un kart ca al tau(respectiv de unde ai achizitionat motoarele,pret,etc? Multumesc.

  3. mat says:

    What type of dc motor you used. and where can i buy this motor.

  4. Thong says:

    Hi, my name Thong
    Im from Viet Nam
    I have project with BLDC
    I used MC33035 to control its. But i always get problem
    so i will happy when u send me logic circuit diagrams u used
    Thanks u so much

  5. Jorge Eriberto Lopes says:

    Hi,

    Congratulations for project.

    I live in the city of Florianópolis, southern Brazil, we have a difficulty to buy eletric motor scooter. His kart design, can also be used in a scooter.
    G

  6. sagar says:

    why have you created JMP5, JMP4 outputs??
    and where are they connected??

  7. iulian207 says:

    Is the same as above AM-1D1212 ( it`s a searated DC – DC suply voltage)

  8. Craig says:

    Nice work and thanks for sharing. I’ve just started researching what it would take to make a self-balancing robot using brushless motors and found your project. I’m wondering if you would be able to tell me if your controller might be suitable. I think the main feature that is needed is torque control in either direction. So if it is moving forward but needs to slow down rapidly to maintain balance, a reverse torque signal would be given (ideally this would result in the charging of the battery). The switching of directions would have to be able to happen fairly rapidly to maintain a static balance.

    • iulian207 says:

      The switching of the direction will occur instantaneous. you can maintain a certain speed regarding the load. Using the other IC in the schematic.

  9. luca says:

    hi,

    I would make brushless controller for my electic car with 10kw motor.
    can I have original file of eagle?

    why you used dc-dc?necessary?and for monitoring current u1(what is this?) transducer but I can’t see good the image

    tks

  10. Hello, i love your controller and if it is not a problem then i am gonna use your plan for a electric bike. But why do you use so many mosfets, are they parallel and working in sync to spread the load, or do they work separate. And in your plan there is component IC4 7815 what is it,i don’t get any result when i google it. And IC3 4049D, also what is it. sorry for my ignorance i am just a novice. And is it possible to get a complete part list of the 24 Mosfets plan, if you please. Thanks…

  11. Silviu D says:

    Salutare, de curiozitate ai o schema completa la proiectelul asta? Vreau sa-mi fac singurel un ESC care sa duca vreo 100 A (doar puls vreo 40 continuu – pentru un hexacopter mai solid) si poate ar fi un punct de pornire. Avand in vedere ca ai un load inductiv cum de nu ti-ai prajit MOSFETII , nu de alta dar nu vad diode la iesire care sa previna aparitia fenomenului de “avalansa”. Vad ca ai multi tranzistori in paralel, nu afecteaza in vreun fel timpii de rise/fall pentru ca practic ii maresti gate capacitor-ul? Oricum felicitari :) si astept un raspuns pe mail daca ai timp.

    • iulian207 says:

      Salut. Mosfeturile au nativ intre drena si sursa o dioda, asa ca nu e nevoie pentru back EMF.
      Ai dreptate capacitatea de grila a mosfeturlor se aduna si creste timpul timerise si timpefall. Dar nu influinteaza cu nimic. Oricum mai am o rezistenta de 20 de ohmi care adauga si ea un timp suplimentar de incarcare.

      Cu toate acestea la frecvente mici de pana in 16khz e complet neglijabil timpul. La 24Khz mosfetii se incalzesc un pic, dar asta la 100A aproape continuu. la 12Khz nu se incalzesc aproape deloc la 80A continuu.

      Am mers cu controllere chinezesti care la 70A nu se incalzeau deloc. si vezi ce radiator minuscul aveau. de 4x4cm.

      O zi buna

  12. Marco says:

    Hello, I’m Marco from Italy. I’m building an electric downhill bike with a Turnigy 80-100. Your controller is very interesting, I wanted to ask if you can send me the eaglefiles or pcb layout pdf files with the part list. Thanks in advance for your any response, good job!

  13. nick says:

    Hi Julian,

    Is it possible to sent it also to me?

    many thanks, nick

  14. david says:

    Hi,
    Thank you for you work, very interresting!
    Can you share or send my your eagle files please?
    David

  15. Aynna says:

    Hi Julian, your work very interesting , do you mind if you can send it also to me ? Thank you very much :)

  16. Aynna says:

    also can I have your email please ?

  17. Fernando says:

    Dear Julian,

    Tannk you for share of a very good work.

    Can you send me the Eagle files ?

  18. Bharat Gupta says:

    Hey..

    the go-kart looks super cool.. great work… (y)

    Also i was working with MC33035 for a small 250W motor.. where i was having some problems regarding the current sense input of the MC33035.
    It’d be really helpful if you could tell me how you have used the current sensing

    also if you can please send me the eagle files it’ll be of great help

  19. Salut. Imi place ce-ai construit pe acolo, in special controllerul de burshless. Crezi ca ai putea sa imi faci si mie unul?

  20. Kukuh says:

    Hi mr. Berca Julian,
    my name is Kukuh Saworo from Jakarta – Indonesia.
    thank u for this experise sharing…wow.

    I am doing electric car conversion right now. done built DC motor controller (brushed DC) 144V – 500A….
    now, this is the time to start work with brushless DC and want to built the controller, I wil try to build the controller base on your design..
    do you mind to share the program/firmware for the microcontroller?
    is it possible to increase the current capabilities by adding some more mosets or IGBTs? is it also possible to increase working voltage?

    I want to donate, can I send it throug pay pal?
    thank you,
    warm regards from Indonesia.
    Kukuh Saworo
    [email protected]

  21. Ian says:

    Hi! I’m Ian Ratio from the Philippines. First of all, your work had inspired me even greater in my study of engineering. I am actually planning to create an electronic cart and do you mind if you send me your eagle files of your project “brushless motor controller”. Your help will be very much appreciated. Thank you in advance

  22. C. William Peterson says:

    Hi Great build. I’m building a motor/generator to charge batteries and I need a controller (3 Phase). I would greatly appreciate it if you could send me the files to build your controller.

    Thanks in advance

  23. ionut says:

    Salut,
    Montajul Dv. poate controla si pune in miscare un motor de modelism( brushles sensorless). Intentionez sa il folosec ca si motor de frezare la un CNC.
    Multumesc, si daca se poate va rog sa ajutati si pe mine cu schema completa.

  24. cristi says:

    Buna!
    Poti sa ma ajuti cu o schema ptr un motor de 26v, 250 W, are 3 fire, si se roteste doar intr-un sens, cand il invart cu mana.Este de la o bicicleta electgrica, hub motor, in roata din fata.Multumesc!

  25. Tony Nguyen says:

    Would you please detail how to buil go cart step by step
    Thanks
    Tony

  26. Tony Nguyen says:

    Would you please detail how to built go cart step by step
    Thanks

  27. Jackylee75 says:

    I have 48v 500watt brushles motor but I can’t buy controller in vietnam please Can you send me the Eagle files ? Thank you so so much . I want to diy it

  28. Juan says:

    Good afternoon. my name is john and I’m from Mallorca.
    I’m working on the construction of a self-balancing electric unicycle
    your design is the most suitable driver (I think) for my purpose,
    Can you send me the schematic or files to build me one like yours?.
    thanks

  29. Trung Chi Ho says:

    hello every boy.
    I am learning about control sensorless brushless motor DC 3 phase.
    you can simulate signal BEMF from motor.
    thanks.

  30. Amri says:

    It’s crazy, that was me to make it but always fail.

    By the way, that really purpose and i’ll take go to make that thing.
    Please permit to DIY this driver.

    by the way, could we make a discuss. can you teach me about driver.

  31. George says:

    Hello Iulian !!!

    Congratulation for your excellent electronic projects
    an for the way that you share your achievements on the web.
    I’m not and electronic engineer but I build many small electronic
    circuits, this time I’m interested in build an electric car with BLSM
    using inverter made with IGBT modules (80 to 100 KW).
    Could you please tell me if you know where can I found schematics
    that can handle these sort of power?.
    Kind regards
    George from Australia