Originally by Rory Mangles
For drive, we used duty cycle in BLDC mode (FOC may also work fine but needs investigating when not an hour before a fight). For weapon, current no reverse in FOC mode.
ABS Current Limit faults in the new firmware in FOC mode can be tuned out by adjusting Current Kp and Current Ki in the FOC general menu. For us we doubled the Kp and halved the Ki. This may also work in BLDC mode, as some settings in FOC menu effect other features. Also make sure ABS current limit is set as high as possible.
If you want to mitigate the effect of legitimate ABS current faults, turn off both Safe start and Median filter, and if you're on the latest software, you can also reduce the fault recovery time from 500ms down to something like 100ms. This ensures it recovers automatically and quickly from faults.
To improve sensorless spinup with high inertia loads in FOC mode try increasing flux saturation compensation. May also help improve top speed under load.
There are issues with hybrid mode in sensored FOC. The transition between sensored and sensorless mode doesn't really work under high inertial loads. Haven't found a decent solution to this yet, currently just turn the sensored/sensorless crossover ERPM value up to something above the max speed of the motor to essentially run it in sensored only mode. Works fine for low kv motors, but need a better solution at higher speeds where sensors become less effective. (reply to this: we found that having the 2 motors switchover at different eprm made it work (one motor powers the other through it). However, without CAN we'd end up with one motor taking all the air resistance load at full speed, and the other coasting at 1-2 amps. We ended up just going to full sensored mode since we could max out the RPM in that mode anyway. )
Increasing switching frequency can help smooth things out, but increases switching losses so use sparingly.
Don't set braking current to 0, as the controller may not stop spinning the motor. Also avoid setting the battery braking current to much more than -10A as the batteries won't like it. We used -10A on drive and - 5A on weapon.