MAD FOC IGBT 90A 80-440V Drone ESC

Overview

The MAD FOC IGBT 90A ESC is a high-performance Electronic Speed Controller (ESC) designed for UAVs, underwater propellers, electric vehicles, and other industrial applications. Featuring an IGBT three-phase full-bridge inverter topology, this ESC delivers a maximum peak output current of 200A, ensuring efficient power delivery to DC brushless motors, permanent magnet synchronous motors, and AC motors.

Engineered for durability, it incorporates a robust heat dissipation structure with external forced air cooling, enhancing reliability in demanding environments. With an 80-440V DC input range, sensor-less FOC (Field-Oriented Control) technology, and multiple safety protections, this ESC ensures superior performance and longevity.

Key Features

• Wide Input Voltage Range: DC80V to DC440V with built-in overvoltage and undervoltage protection.
• High Power Capability: Continuous output current of 90A, peaking at 180A, ensuring stable performance.
• Advanced Control Algorithm: Sensor-less FOC technology for precise and efficient motor control.
• High Frequency Modulation: SVPWM with a 12kHz carrier frequency, optimizing efficiency.
• Versatile Compatibility: Supports PPM/PWM input signals with frequency ranging from 50Hz to 400Hz.
• Multiple Communication Interfaces: TTL232 and CAN for real-time monitoring of voltage, current, speed, and temperature.
• Durable and Efficient Cooling: Features an external forced air cooling system for effective thermal management.
• Robust Protection Mechanisms:
  • Overvoltage & Undervoltage protection to prevent system damage.
  • Throttle detection for safety.
  • Overtemperature protection with automatic adjustment at 90°C and 100°C.
  • Sensor zero-point detection for accurate phase current control.
• Rugged Build Quality: High-grade materials with an efficient thermal design for extended durability.

Specifications

Protection Mechanisms

1. Undervoltage Protection

• The ESC enters a protection state if the supply voltage falls below the set threshold.
• Output resumes once the voltage stabilizes.

2. Overvoltage Protection

• If the input voltage exceeds the set threshold while idle, the ESC enters protection mode.
• If the motor is running, an alarm notification is triggered instead.

3. Throttle Detection

• Ensures throttle loss detection and return-to-zero detection for added safety.
• Audible alarm triggers upon failure.

4. Sensor Zero-Point Detection

• The ESC automatically detects phase current zero points upon startup.

5. Overtemperature Protection

• If the ESC temperature reaches 90°C, it limits input current based on temperature.
• At 100°C, the system reduces output throttle to prevent overheating.

6. Communication Protocol

• Uses IG-UART_V1.2 at 19200 baud rate, with periodic data broadcasting every 255ms.

Control Signal Standard

• Compatible with Aircraft Model Remote Controllers.
• Supports 50Hz frequency cycle, with high-level times from 1150 to 1950µs.
• Telecontrol signal is optically isolated for enhanced safety.

Throttle Calibration Steps

1. Connect ESC PWM signal to the receiver.
2. Turn on the remote control and set the maximum throttle position.
3. Power on the ESC; confirmation tones indicate successful detection.
4. Set the throttle rocker to the preset starting position.
5. Confirmation tones indicate maximum and minimum throttle calibration.
6. Turn off power to save settings.

Connection Description

• Power Cord: Positive & Negative Input.
• Throttle Signal Cable: PPM/PWM signal input.
• Serial Communication Cable: TTL data transmission.
• CAN Communication Cable: CAN-H and CAN-L signals.

Compatibility

• Compatible with all DC Brushless Motors.
• If compatibility issues arise, debugging support is available.

Recommended Motors & Propellers

Dimension Drawing

• Overall size: 244mm x 110mm x 74.5mm
• Detailed measurements available in the technical diagram.

AMPX 90A ESC features premium materials, rugged design, and good heat dissipation. It supports DC brushless motors with a peak output current of 200A. The hardware includes isolated throttle control and data communication signals. Software uses self-researched FOC angle observer and feedforward PLL controller for efficient motor control.

ESC Protection mechanism details include undervoltage, overvoltage, throttle detection, sensor zero-point, and overtemperature protection. Communication protocol is IG-UART_V1.2 with 19200 baud rate. ESCs are compatible with most DC Brushless Motors. Throttle calibration steps involve connecting PWM signal, setting maximum and minimum throttle, and saving settings.

ESC Connection diagram illustrates motor, PWM, ESC, and battery setup. Dimension drawing provides measurements. AMPX ESC recommendations include electric regulation, motor types, voltage, and propeller sizes.