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REV ION Brushless

The Brushless Revolution

In the fall of 2018, the NEO Brushless Motor and SPARK MAX Motor Controller became the first brushless motor and compatible ESC (Electronic Speed Controller) designed to meet the unique demands of the FRC community. Since then, REV Robotics has been working to continue the Brushless Revolution by releasing products and software features based on our customer's most popular feedback.

The Next Generation of Motors and Controllers

NEO Vortex Brushless Motor

The NEO Vortex Brushless Motor is a high-power, high-performance, and high-resolution sensored brushless motor from REV Robotics. It features a dockable controller interface that can be mounted directly to a SPARK Flex Motor Controller or a NEO Vortex Solo Adapter allowing control from any brushless motor controller, like the SPARK MAX. Its through-bore rotor is the heart of its unique interchangeable shaft system, facilitating easy integration with various robot mechanisms.

SPARK Flex Motor Controller

The SPARK Flex Motor Controller is a new smart motor controller from REV Robotics. Its dockable form factor allows direct mounting onto a NEO Vortex to simplify wiring and maintain flexibility. Improving upon the foundation of the SPARK MAX, new features of the SPARK Flex Motor Controller include 3-phase current sensing, reverse polarity protection, and an expanded data port with additional interfaces. When docked to an adapter, the SPARK Flex can control any existing NEO or compatible brushless/brushed DC motor.

Incredible Power Density and Integrated USB Control

SPARK MAX Motor Controller

The SPARK MAX Motor Controller is your first step for getting advanced brushed and brushless DC motor control in a small, easy-to-use package. SPARK MAX is a true all-in-one controller that will push the envelope for FRC teams. Test prototypes and tune parameters without needing the full control system, only using a computer running the REV Hardware Client and a USB C Cable!

NEO V1.1 Brushless Motor

The NEO V1.1 Brushless Motor offers an incredible power density due to its compact size and reduced weight. As it is designed to have similar performance characteristics and matching mounting features, NEO V1.1 can be a drop-in replacement for CIM-style motors. This motor is perfect for your FRC Robot, Industrial platform or Warehouse robot, Electric skateboards, and more! The NEO V1.1 has been optimized to work with the SPARK MAX Motor Controller to deliver best-in-class performance and feedback.

NEO 550 Brushless Motor

The NEO 550 Brushless Motor is the smallest member of the NEO family of brushless motors. Its output power and small size are designed to make NEO 550 the perfect motor for intakes and other non-drivetrain robot mechanisms. Mounting holes and pilot match a standard 550 series motor, making it natively compatible with many existing off-the-shelf gearboxes.

If there is a question that is not answered by this space, send our support team an email; support@revrobotics.com. We are always happy to help point you in the right direction!

Quick Links

SPARK Motor Controllers

SPARK Flex Links

General Resources

Getting Started with the SPARK Flex
Troubleshooting
- Status LED Patterns
SPARK Flex Specifications
- SPARK Flex Data Port Pinout

Software Resources

SPARK MAX Links

General Resources

Getting Started with the SPARK MAX
Troubleshooting
- Status LED Patterns
SPARK MAX Specifications
- SPARK MAX Data Port Pinout
Using Encoders with the SPARK MAX

NEO Brushless Motors

Motor Comparison and Testing

Motor Comparison
- NEO Vortex Comparisons
- NEO V1.1 Comparisons
Dynamometer Testing

NEO Vortex Links

NEO Vortex Overview
NEO Vortex Specifications
- Motor Curves - NEO Vortex
Docking a SPARK Flex
Installing a shaft

NEO V1.1 Links

NEO V1.1

NEO V1.1 Overview
NEO V1.1 Specifications
- Motor Curves - NEO V1.1
Pinion Pressing Guide

NEO V1

NEO V1 Overview
NEO V1 Specifications
- Motor Curves - NEO V1
Pinion Pressing Guide

NEO 550 Links

NEO 550 Overview
NEO 550 Specifications
- Motor Curves - NEO 550
Pinion Pressing Guide

Frequently Asked Questions

NEO Vortex

What are some best practices for using the NEO Vortex in a build?

NEO Vortex Tips and Tricks

When seating your Vortex with a SPARK Flex or Solo Adapter make sure your have aligned the bullet connectors and data connectors. They should seat near completely with hand pressure then secured with screws. Do not over tighten.
Do not over tighten the the shaft screw when using a Vortex Shaft.
The Vortex is an outrunner, so make sure there are not wires or components that can touch the spinning rotor.
If the Vortex is used in an application that you are not using a shaft screw, make sure cover the shaft opening on the top of the Vortex to prevent dust and debris from falling into the Vortex spindle.

What Smart Current Limit should I set for my NEO Vortex?

The default Smart Current Limit is 80A, which is acceptable for most applications when driven by a SPARK Flex however...

We recommend utilizing our motor curves and specifications to help calculate what the best current to torque ratio for your application will be.

SPARK Flex

Are there any quick tips for getting the most from a SPARK Flex?

SPARK Flex Tips and Tricks

Be sure to clean the SPARK Flex's surface with compressed air and remove any dirt or metal debris from the surrounding wire connections. If particulates find their way into the wire connectors you may experience intermittent connection issues.
Maintain sufficient wire management to avoid critical wires from being strained and ripped out. Before your team puts the robot on the field, give all wires one last smart tug to ensure everything is secure for the match.
Remember to update your SPARK Flex to the latest firmware when connecting your robot through the REV Hardware Client.

SPARK MAX

What is your best advice for using a SPARK MAX?

SPARK MAX Best Practices

Ensure the firmware installed on your SPARK MAXs is the latest version! You can do this using the REV Hardware Client.
Ensure you've set a proper Smart Current Limit for your motor and what it will be driving.
Keep your wire management neat. Wires need to be protected and organized so they are can not be clipped by mechanisms or become an entanglement risk.
Protect the SPARK MAX from debris and impacts. Use the included port covers or tape over the data port when not in use.
Regularly inspect your SPARK MAX and its wires for a secure connection and damage.

How do I run an encoder with the SPARK MAX?

We have a documentation page that can help!

Check out Using Encoders with the SPARK MAX!

My SPARK MAX isn't working, where do I start?

Don't panic! Take a step back and assess the current situation.

A good place to start isolating the root issue would be to go through our Troubleshooting - SPARK MAX documentation.

What does the LED on my SPARK MAX indicate?

The Status LED indicates the operation mode or fault status of your SPARK MAX

See our reference table on the SPARK MAX Status LED Patterns to find the LED behavior that matches your SPARK MAX. Both color and speed of the blinking pattern are important to note!

Should I change the factory default setting for Smart Current Limit?

Your Smart Current Limit will depend on the motor being controlled and what it is driving.

A new SPARK MAX's Smart Current Limit default setting is 80A, but may need to be less. We recommend utilizing our locked-rotor testing data or the table below to decide what to set your Smart Current Limit to for your robot: Locked-Rotor Testing for the NEO (REV-21-1650) and NEO 550 (REV-21-1651).

Generally, the following ranges work well:

NEO V1.1: 40 A - 60 A
NEO 550: 20 A - 40 A

Can I run a NEO Vortex with a SPARK MAX?

You will need to purchase one of our NEO Vortex Solo Adapters (REV-11_2828)

Check out our documentation on the NEO Vortex Solo Adapter and the SPARK MAX for more information.

Why don't the settings save on my SPARK MAX?

Be sure to always click Burn Flash to save the settings through the REV Hardware Client!

A SPARK MAX's parameters can also be overwritten within your code, so ensure you also burn flash after any changes in your program too. Any settings that had been modified and not burned to flash will reset when the SPARK MAX is power cycled.

NEO V1.1

What are general best practices for the NEO V1.1?

REV's NEO V1.1 Tips and Tricks

Use care when removing the sensor wire from a SPARK MAX. Firmly gripping all 6 of the wires as close to the JST connector as possible and pulling evenly generally gives best results. If needed you can also use a small tool to pry or grab the plastic notches of the JST Connector.
Periodically check the NEO's phase and data wires for noticeable damage to the wire insulation or connectors. Exposed wire on your robot runs the risk of a possible short to your system.
Keep the NEO clear from any debris, especially those that could get caught in the mechanism it is driving or affect your wiring.
Route all wires with proper strain relief to avoid damage or unintentional disconnects from tension.
MAXPlanetary Gearbox Cartridges are pre-lubricated and sealed. If during maintenance you find that a cartridge needs more grease, we recommend using a Molybdenum Grease to apply more lubrication such as Synthetic NLGI #2 Molybdenum Grease or MOLYKOTE® G-2008 Synthetic Tool Gear Grease.

What Smart Current Limit should I set for my NEO V1.1?

How do I make a NEO V1.1 compatible with the new SPARK FLEX Motor Controllers?

We have a solution coming soon! The SPARK Flex Dock will...

The SPARK Flex Dock will allow a SPARK Flex to control any existing NEO or compatible brushless/brushed DC motor by converting it to a standalone motor controller!

Stay tuned to our website for updates on its release!

Can I run a NEO V1.1 on 24V?

NEO 550 FAQ

What are general best practices for the NEO 550?

REV's NEO 550 Tips and Tricks

Use care when removing the sensor wire from a SPARK MAX. Firmly gripping all 6 of the wires as close to the JST connector as possible and pulling evenly generally gives best results. If needed you can also use a small tool to pry or grab the plastic notches of the JST Connector.
Periodically check the NEO 550's phase and data wires for noticeable damage to the wire insulation or connectors. Exposed wire on your robot runs the risk of a possible short to your system.
Keep the NEO 550 clear from any debris, especially those that could get caught in the mechanism it is driving or affect your wiring.
Route all wires with proper strain relief to avoid damage or unintentional disconnects from tension.
UltraPlanetary Gearbox Cartridges are pre-lubricated and sealed. If during maintenance you find that a cartridge needs more grease, we recommend using a Molybdenum Grease to apply more lubrication such as Synthetic NLGI #2 Molybdenum Grease or MOLYKOTE® G-2008 Synthetic Tool Gear Grease.
When pressing a pinion on your NEO 550 shaft, taken care to not over press the pinion or dislodge the motor's shaft. Take a look at our Pinion Pressing guide for assistance.

What Smart Current Limit should I set for my NEO 550?

NEO Brushless Motors

Brushless DC Motor Basics

DC Motors consist of two major parts, the part that rotates, or the “rotor”, and the part that is stationary, or the “stator”. A DC motor uses these parts to convert electrical energy into rotational mechanical energy using electricity and permanent magnets. Two types of DC motors are used in FIRST Robotics Competition: Brushed DC Motors and Brushless DC motors. Both types are useful in various robot applications, and both have their trade-offs.

Brushless vs. Brushed Motor Basics

Operating a brushed DC motor is simple; provide DC electrical power and the motor spins. In a brushed motor, the rotor consists of electrical winding wires and the stator consists of permanent magnets. Since the electrical part is spinning, there needs to be a way to connect the external power wires to the spinning rotor. This is accomplished through conductive “brushes” that make contact with the stator, automatically sequencing the power to make the rotor spin. Brushes make it easy on us, but they produce extra friction which reduces the efficiency of the motor.

Brushless DC motors don’t have brushes. They still have both electrical winding wires and permanent magnets, but the locations are flipped. The stator now consists of the electrical parts, and the spinning rotor consists of the magnets. This means there is no more brush friction within the motor, making a brushless motor more power-efficient. However, you can’t just give it DC power and expect it to spin. Without the brushes doing the sequencing for us, you must use a specialized motor controller that is designed for brushless motors to properly sequence the power and get the rotor spinning.

The REV NEO Brushless Motor runs an 8mm keyed output shaft which allows for an easy transition from CIM-style brushed motors into brushless.

Swap a set of NEO Brushless Motors into your drivetrain or use one in an elevator to save weight and maintain peak performance. When paired with the SPARK MAX, you can use the integrated hall-effect sensors to calculate incremental position or speed from the NEO.

Key Terms

Stall Torque is measured when the motors RPM is zero and the motor is drawing its full Stall Current. This value is the maximum torque the motor is ever capable of outputting. Keep in mind the motor is not capable of outputting this torque for an indefinite period of time. Waste energy will be released into the motor as heat. When the motor is producing more waste heat than the motor body is capable of dissipating the motor will eventually overheat and fail.

Stall Current is the maximum amount of current the motor will draw. The stall current is measured at the point when the motor has torque that the RPM goes down to zero. This is also the point at which the most waste heat will be dissipated into the motor body.

Free Speed is the angular velocity that a motor will spin at when powered at the Operating Voltage with zero load on the motor’s output shaft. This RPM is the fastest angular velocity the motor will ever spin at. Once the motor is under load its angular velocity will decrease.

Operating Voltage is the expected voltage that the motor will experience during operation. If a robot is built using a 12 volt battery the Operating Voltage of the motor will be 12 volts. When controlling the RPM of the motor the DC speed controller will modulate the effective voltage seen by the motor. The lower the voltage seen by the motor the slower it will spin. DC motors have a maximum rated voltage if this voltage is exceeded the motor will fail prematurely.

The key metrics defined above are interrelated. Take some time to familiarize yourself with the definitions and how they connect together.

General Application Information

In order to ensure that an electric motor lasts as long as possible a few rules of thumb should be kept in mind:

Smooth loading - large torque spikes or sudden changes in direction can cause excess wear and premature failure of gearbox components. This is only an issue when the torque spike exceeds the rated stall torque of the motor. When shock loading is necessary, it is best to utilize mechanical braking or a hard stop that absorbs the impact instead of the motor.
Overheating - when a motor is loaded at near its maximum operating torque it will produce more waste heat than when operating at a lower operating torque. If this heat this allowed to build up the motor can wear out prematurely or fail spontaneously.
Poorly supported output shaft, most motor output shafts are not designed to take large thrust forces or forces normal to the shaft. Bearings need to be used to support the axle when loads in these directions are expected.

NEO Vortex

NEO Vortex Overview

The NEO Vortex Brushless Motor (REV-21-1652) is a high-power, high-performance, and high-resolution sensored brushless motor from REV Robotics. It features a dockable controller interface that can be mounted directly to the SPARK Flex Motor Controller (REV-11-2159) or a NEO Vortex Solo Adapter (REV-11-2828) allowing control from any brushless motor controller, like the SPARK MAX. Its through-bore rotor is the heart of its unique interchangeable shaft system, facilitating easy integration with various robot mechanisms.

Features

High-resolution encoder
Integrated motor parameter and calibration memory
Through-hex bore with taper for numerous quick-change shafts
No motor wires - reliable and robust docking connections for motor phases and sensor
Dual sensor, direct contact winding temperature sensing
560KV (RPM per volt)
640 Watts (375 @ 40A)
#10-32 threaded holes on a 2in bolt circle
The motor and motor controller's silhouette fits behind a standard 2in rectangular tube
1/2in hex through-bore rotor compatible with any length hex shaft or application-specific Vortex Shafts:
- 8mm keyed
- Falcon compatible spline
- MAXSwerve with integrated key
- 7-tooth 20DP gear
- MAXPlanetary input
- Others to be announced

NEO Vortex Anatomy

Motor Specifications

Mechanical Specifications

NEO Vortex Motor Curve

All of our motor testing was performed on our in-house dynamometer.

Docking a SPARK Flex

When docked with a SPARK Flex the NEO Vortex's phase and sensor connections are kept securely together. This eliminates intermediate wiring that can fail if not secured properly.

Docking Materials

Docking the NEO Vortex with the SPARK Flex is simple and only requires the following materials and tools:

NEO Vortex Brushless Motor
SPARK Flex Motor Controller
Docking Hardware
- 4 - M3 x 25 mm Socket Head Screws (included with SPARK Flex)
2.5 mm Hex Key

Docking Procedure

Follow these steps to ensure a secure and proper docking:

Ensure that power is disconnected from the SPARK Flex.
Align the motor phase bullets between the NEO Vortex and SPARK Flex.
Allowing the bullets to guide the two together, press the NEO Vortex and SPARK Flex together until their bodies meet. There may be a small gap between the motor and the controller opposite the bullets. This is normal.
Insert the included docking screws into the counterbored Docking Screw Clearance Holes on the SPARK Flex.
Using the 2.5 mm Hex Key, tighten the four screws evenly in a crisscross pattern until the screws are tight and secure. The screw heads should be sub-flush from the mounting face of she SPARK Flex. If you have a torque wrench, the ideal torque is 11.5 ±0.9 in-lb (1.3 ±0.1 Nm).

DO NOT run the motor without the docking screws installed. These screws ensure a robust and secure electrical connection, and doing so may cause damage to the system.

Undocking Procedure

Follow these steps to undock the NEO Vortex and SPARK Flex:

Ensure that power is disconnected from the SPARK Flex.
Completely remove the four docking screws from the assembly.
Gently pull the NEO Vortex and SPARK Flex apart until the bullets release. Try to maintain their relative orientation to each other while pulling them apart.

Vortex Shafts

NEO Vortex Shaft Features

Vortex shafts feature a 1/2 in hex section for transferring torque, and a locating taper section for effortless self-centering. When the shaft is secured with a #10-32 Shaft End Screw, the taper keeps your shaft perfectly centered as it's drawn in and locked into place within the NEO Vortex Spindle.

NEO Vortex Shaft Anatomy

NEO Vortex Shaft Options

NEO Vortex Solo Adapter

The NEO Vortex Solo Adapter (REV-11-2828), allows teams to seamlessly integrate the NEO Vortex Brushless Motor with a SPARK MAX. This adapter breaks out the motor sensor connector and phase wire connections for simple backward compatibility.

While the NEO Vortex Solo Adapter allows you to use the motor independently, it may not fully support certain advanced functionalities of the NEO Vortex Brushless Motor.

Specifications

Kit Contents

The following items are included with each NEO Vortex Solo Adapter

NEO V1.1

NEO V1.1 Overview

The REV NEO Brushless Motor V1.1 (REV-21-1650) is the initial update on the first brushless motor designed to meet the unique demands of the FIRST Robotics Competition community. NEO V1.1 offers an incredible power density due to its compact size and reduced weight, and it's designed to be a drop-in replacement for CIM-style motors, as well as an easy install with many mounting options. The built-in hall-effect encoder guarantees low-speed torque performance while enabling smart control without additional hardware. NEO V1.1 has been optimized to work with the SPARK MAX Motor Controller (REV-21-2158) to deliver incredible performance and feedback.

Features

Drop-in replacement for CIM-style motors
Shielded out-runner construction
Front and rear ball bearings
High-temperature neodymium magnets
High-flex silicone motor wires
Integrated motor sensor
- 3-phase hall sensors
- Motor temperature sensor

New to NEO V1.1

A tapped #10-32 hole on the end of the shaft, allowing teams to retain pinions on the shaft without using external retaining rings
A tapped #10-32 hole on the back housing of the motor, making it no longer necessary to remove the motor housing to press pinions
Additional holes on the front face of the motor for added mounting flexibility

Wiring Connections

Connecting the NEO V1.1 Brushless motor is fairly straightforward. Follow the guide at Wiring the Spark Max, and don't forget to connect your sensor wire; the motor will not spin without it!

CAUTION: Improperly wiring the connectors can cause severe motor damage and is not covered by the warranty. DO NOT connect the motor directly to the battery.

Motor Specifications

Mechanical Specifications

NEO V1.1 Motor Curve

All of our motor testing was performed on our in-house dynamometer.

Check out the NEO Motor Data Sheet for additional information! Please read the NEO Motor Locked Rotor Testing and ensure you understand how to set an appropriate Smart Current Limit before using your NEO Brushless Motor.

NEO V1

NEO V1 Overview

The REV NEO Brushless Motor (REV-21-1650) is the first brushless motor designed to meet the unique demands of the FRC community. Offering an incredible power to weight ratio along with it's compact size it's designed to be a drop-in replacement for CIM-style motors as well as an easy install with mounting options.

Features

Drop-in replacement for CIM-style motors
Shielded out-runner construction
Front and rear ball bearings
High-temperature neodymium magnets
High-flex silicone motor wires
Integrated motor sensor
- 3-phase hall sensors
- Motor temperature sensor

Wiring Connections

CAUTION: Improperly wiring the connectors can cause severe motor damage and is not covered by the warranty. DO NOT connect the motor directly to the battery.

Motor Specifications

Mechanical Specifications

NEO V1 Motor Curve

The only difference between the NEO V1 and NEO V1.1 are external changes to the motor's housing.

All of our motor testing was performed on our in-house dynamometer.

Pinion Pressing Guides

NEO V1.1 Pinion Pressing Guide

Needed Materials

NEO V1.1 (REV-21-1650)
1 - 10-32 x 3/8in long Socket Head Screw
Press Fit Pinion
Arbor Press

Steps

Do not attempt to run the NEO while a screw is still attached to the back of the motor. Not removing the screw will damage the motor and/or shaft.

NEO V1.0 Pinion Pressing Guide

Needed Materials

NEO V1.0 (REV-21-1650)
A high-quality 1.5mm Allen Key (i.e. WERA Tools, Bondhus)
Loctite 242
Arbor Press

Steps

NEO 550

NEO 550 Overview

The REV NEO 550 Brushless Motor (REV-21-1651) is the newest member of the NEO family of brushless motors. Its output power and small size are specifically designed to make NEO 550 the perfect motor for intakes and other non-drivetrain robot mechanisms. Mounting holes and pilot match a standard 550 series motor, allowing it to natively mount to many existing off-the-shelf gearboxes.

The REV NEO 550 Brushless Motor runs a 0.12in output shaft which, when combined with its 550-style mounting features, allows for easy installation in many off-the-shelf gearboxes.

Its small size and weight make it easy to put power where you need it, whether that is on intakes, end-effectors, or other weight-sensitive mechanisms. However, keep in mind that this motor has a lower thermal mass than a NEO, CIM, or Mini CIM, and thus it may not be ideal for some drivetrain applications.

Wiring Connections

Connecting the NEO 550 Brushless motors is fairly straightforward. Follow the guide at Wiring the Spark Max, and don't forget to connect your sensor wire; the motor will not spin without it!

CAUTION: Improperly wiring the connectors can cause severe motor damage and is not covered by the warranty. DO NOT connect the motor directly to the battery.

Features

Mounting features match other 550 series DC motors
Out-runner construction (i.e. Rotor housing is compatible with REV Motion Pattern; you can mount metal Gears, Sprockets, and Pulleys)
Front and rear ball bearings
High-temperature neodymium magnets
High-flex silicone motor wires
Integrated motor sensor (3-phase hall sensors)
Motor temperature sensor

Motor Specifications

Mechanical Specifications

NEO 550 Motor Curve

Updated testing from our in-house dynamometer coming soon!

Check out the NEO 550 Motor Data Sheet for additional specifications and charted motor curves. Please read the NEO 550 Motor Locked Rotor Testing and ensure you understand how to set an appropriate Smart Current Limit before using your NEO 550 Brushless Motor.

Pinion Pressing Guide

NEO 550 Pinion Pressing Guide

Needed Materials:

Press Fit Pinion
Arbor Press

Steps

Dynamometer Testing

Dynamometer Characterization

The data for Motor Curves provided in our documentation is generated with an inertia-type dynamometer, or dyno, and then further analyzed by our engineers.

Parts of a Dynamometer

The dynamometer REV Robotics uses consists of the following major components mounted directly to the main shaft:

Flywheel - A weighted flywheel supported by ball bearings
Encoder - An encoder that collects data during the test
Motor Mount - An adjustable system where the motor is equipped with a coupling so its output lines up with the rotational axis of the dynamometer
Motor and ESC - The motor and ESC (Electronic Speed Controller or Motor Controller) are always tested as a unit. Some examples of this are the SPARK MAX and NEO or the Falcon 500 Motor and Talon FX ESC
Power Supply - A high current power supply system capable of supplying 12V at 200A with minimal voltage sag while handling voltage spikes and braking conditions.

Testing Process

A test starts at rest and consists of applying a constant throttle setting to the motor and motor controller. Generally, this value is 100%, but any value can be used. The motor is allowed to accelerate the flywheel while data is recorded with timestamps.

The data recorded during testing includes:

The speed and position of the flywheel encoder
The DC current at the input of the ESC
The bus voltage at the input of the ESC
Any data provided by the ESC, this may vary from controller to controller
- This is generally collected over CAN

Data Analysis

Using the speed and position data, the acceleration of the flywheel can be calculated throughout the timespan of the test. The moment of inertia of the rotating portion of the dyno is known to a high degree of precision. This includes the flywheel, shaft, hub, motor rotor, couplings, etc. Using the acceleration and moment of inertia, the torque produced by the motor can be calculated.

Calibration

At thousands of RPM, the flywheel and shaft system can generate enough drag to affect the results of the test significantly. To determine the drag in the system from air movement and viscous friction, the dyno is spun up to a very high speed and allowed to freely rotate until it comes to a stop. During this process, speed and position data are recorded and then used to calculate the drag torque. The drag torque is added to the motor torque calculated from each acceleration measurement during a motor test so that our results are calibrated for our specific dyno setup.

Current Limiting

At low speeds, a motor will typically draw more current than the set current limit on its ESC. Current limiting may affect the duty cycle and commutating of the motor, causing the data to deviate from “raw” motor performance. Current limiting processes within an ESC's software can also cause excess noise in current, voltage, and acceleration data collected by the dyno. For these reasons, the low-speed section where current limiting is in effect is usually removed from the data set before characterizing the motor.

Data Characterization

Characterization is accomplished by correlating torque and current with velocity. These relationships are usually extremely linear and a best fit can be used to approximate and extrapolate the motor’s performance outside of the test region. Additional processing can be applied to compensate for voltage drop in the power supply lines at high currents.

REV's in-house Dynamometer

REV Robotics has designed a dynamometer that we are working to make open source and available to the public. In creating this dynamometer, we have focused on using as many off-the-shelf components as possible in an effort to make this design easy for members of the community to build.

Below are some photos of our progress!

Motor Comparison

This page is intended to highlight the relative comparison between REV ION motors and similar motors from other vendors.

For more information please see the section below -

NEO Vortex - Quick Comparison

NEO Vortex & Kraken X60 Motor Curves

NEO Vortex & Kraken X60 Data

NEO Vortex & Falcon 500 V2 Motor Curves

NEO Vortex & Falcon 500 V2 Data

NEO Vortex & NEO V1.1 Motor Curves

The data shown for NEO V1.1 is also valid for the NEO V1

NEO Vortex & NEO V1.1 Data

NEO V1.1 - Quick Comparison

The data shown for NEO V1.1 is also valid for the NEO V1

NEO V1.1 & Kraken X60 Motor Curves

NEO V1.1 & Kraken X60

NEO V1.1 & Falcon 500 V2 Motor Curves

NEO V1.1 & Falcon 500 V2 Data

NEO Vortex & NEO V1.1 Motor Curves

NEO Vortex & NEO V1.1 Data

Interpreting this Data

Values of motor data may vary from manufacturer to manufacturer because of variances in the dynamometer used to test each motor and how that data is analyzed. With each motor shown on this page, REV Robotics performed the same dynamometer testing and analysis of the data collected.

Absolute vs. Relative Data

Absolute Values for a specification are determined independently of each similar motor made by other manufacturers. Each of the specifications are determined by a manufacturer's individual testing procedures and methods of analyzing test data.
Relative Values for a specification are found by running the same test and analysis on a motor. While the values provided may not match a motor's listed Absolute Values for a given specification, this kind of data helps us compare the motors as fairly as possible.

Motor Curves

NEO Vortex - REV Robotics

NEO V1.1 - REV Robotics

Kraken X60 - WestCoast Products

Falcon 500 V2 - VEX Robotics

SPARK Flex Motor Controller

SPARK Flex Overview

The SPARK Flex (REV-11-2159) is a new smart motor controller from REV Robotics. Its dockable form factor allows for direct mounting onto a NEO Vortex (REV-21-1652), simplifying wiring while maintaining flexibility. Improving upon the foundation of the SPARK MAX, new features include 3-phase current sensing, reverse polarity protection, and an expanded Data Port with additional interfaces. When docked to an adapter, the SPARK Flex can control any existing NEO or compatible brushless/brushed DC motor.

Feature Highlights:

Docking interface for motor phases and sensors
USB type C configuration and control
PWM and CAN communication
Fully integrated power and control wires
Enhanced data port with more power, latching connector, and additional serial interfaces
Advanced motor control modes include:
- Velocity
- Position
- Current
- New modes with future firmware updates
#10-32 threaded holes on a 2in bolt circle
Motor and motor controller's silhouette fits behind a standard 2in rectangular tube

SPARK Flex Resources

General Resources

Getting Started with the SPARK Flex
Troubleshooting
- Status LED Patterns
SPARK Flex Specifications
- SPARK Flex Data Port Pinout

Software Resources

SPARK Flex Dock

SPARK Flex Dock Overview

When connected to a SPARK Flex Dock (REV-11-2858) the SPARK Flex can control any existing NEO or compatible brushless/brushed DC motor.

SPARK Flex Dock Features & Specifications

Coming soon!

SPARK Flex Specifications

The following tables provide the operating and mechanical specifications for the SPARK Flex Motor Controller.

DO NOT exceed the maximum electrical specifications. Doing so will cause permanent damage to the SPARK Flex and will void the warranty.

Main Electrical Specifications

Parameter

Min

Typ

Max

Units

PWM Input Specifications

Parameter

Min

Typ

Max

Units

Data Port Specifications

Mechanical Specifications

SPARK Flex Feature Description

The SPARK Flex Motor Controller is a fully featured smart motor controller designed to be robust and easy to use yet fully capable of advanced motion control. The following sections describe each feature in detail.

SPARK Flex Connections

USB-C Port

Allows for seamless firmware updates and code uploads, facilitating quick and efficient software management through the REV Hardware Client

Locking Data Port

Allows for integration of additional sensors such as the Through Bore Encoder, analog sensors, absolute encoders, and limit switches.

Ultra-flexible, and Silicone-coated Wires

Supply Input Power and Control Signals through 45cm long high-quality wires. Twisted Control wires also feature two standardized connectors to make wiring the SPARK Flex easy for PWM or CAN control.

Status LED Indicator

Displays the operational status and error codes, ensuring easy troubleshooting and real-time monitoring

SPARK Flex Docking Interface

Precisely engineered clearance holes for docking screws provide stable and secure attachment of the SPARK Flex and NEO Vortex to your Mechanism
High-current Bullet Connectors facilitate quick and secure connections to the NEO Vortex's phases, ideal for high-performance and high-power applications
Robust Motor Interface Connector mates to the NEO Vortex's control systems to ensure efficient, secure, and reliable electrical connections and communication

SPARK Flex Mounting Holes

The SPARK Flex features six #10-32 threaded mounting holes on a 2 in bolt circle

Power and Motor Connections

SPARK Flex is designed to drive 12V brushed and brushless DC motors at current up to 60A continuously. It features a unique Docking Interface that ensures secure and reliable motor phase and sensor connections, reducing the chance of intermittent or poor connections affecting the commutation of the attached motor.

Power Input

Power input wires are labeled as + and - with red and black wires, respectively, and consist of two 12 AWG ultra-flexible silicone-coated wires extending 45 cm from the motor controller case.

SPARK Flex is intended to operate in a 12 V DC robot system, however it is compatible with any DC power source between 4.5 V and 24 V.

Please note that the 5 V power output of the Data Port requires a 6 V minimum input voltage.

DO NOT exceed the maximum supply voltage of 30 V. Doing so will cause permanent damage to the SPARK Flex and will void the warranty.

When used in high power applications, it is recommended to use a power source that is capable of handling large surge currents, e.g. a 12V lead-acid battery. If the supply voltage drops below 4.5 V the SPARK Flex will brown out, which can result in unexpected behavior. It is also highly recommended to add a fuse or circuit breaker in between your SPARK Flex and its power source to prevent exceeding the maximum current rating.

DO NOT exceed the maximum current ratings:

60A for 3 minutes
100A for 2 seconds

Doing so will cause permanent damage to the SPARK Flex and will void the warranty.

Docking Interface

SPARK Flex is specifically designed to dock with the NEO Vortex Brushless Motor. Docking eliminates the extra connections between the motor and motor controller that are prone to fail due to assembly issues and rough environments.

When docked into a SPARK Flex Dock (coming soon), the motor controller can also drive virtually any 12 V brushed DC motor and the existing NEO & NEO 550 brushless motors.

Instruction on how to dock a SPARK Flex can be found within the documentation of the applicable device:

SPARK Flex Dock Instructions - Coming Soon

Be sure to fully install the Docking Screws when docking the SPARK Flex. These screws ensure a robust and secure electrical connection. Operating the SPARK Flex and its attached motor or dock without these screws can cause unintended behavior and damage to the system.

Always dock and undock the SPARK Flex with both main power and USB power disconnected.

Control Connections

The SPARK Flex can be controlled by three different interfaces: servo-style PWM, Controller Area Network (CAN), and USB. The following sections describe the physical connections to these interfaces. For details on the operation and protocols of the PWM, CAN, or USB interfaces, please see .

CAN/PWM Connections

CAN and PWM control connections share a set of four integrated 26 AWG twisted wires extending 45 cm from the case of the motor controller. Each wire is color coded according to its function:

The wires are terminated with two 1 x 3, 0.1 in pitch, rectangular connectors, both excluding the center pin. One connector is pinned and the other socketed to facilitate daisy-chaining between multiple CAN devices on the bus when using the CAN interface.

Each matching wire pair is physically connected to its functional counterpart within the device. Even if the SPARK Flex loses power, the CAN bus remains unbroken, leaving downstream devices unaffected.

Pay close attention when daisy-chaining devices, and make sure that the colors match from connector-to-connecter along the entire CAN bus. Mismatched connections can cause difficult-to-diagnose communications issues along the entire bus.

When using the PWM interface, only one of the two connectors should be used. In most systems this will be the socketed connector. Therefore, it is best practice to secure the unused wires and protect the exposed pins by covering them with electrical tape.

USB-C Port

The USB-C Port is located above the CAN/PWM wires of the SPARK Flex. It supports USB 2.0 and can provide 5 V power for the SPARK Flex's internal microcontroller.

While you can configure the SPARK Flex under USB-only power, you will not be able to spin a motor unless main power is also connected.

More information about what can be configured and operated through the USB port can be found in the USB Interface section.

Data Port

Located next to the SPARK Flex's power and control input wires, the Data Port allows for extra sensor input and future feature expansion. Connector details can be found below.

Data Port Pinout

SPARK Flex Data Port Break Out Cable

The keyed and locking Data Port connector ensures a secure and aligned fit when plugged into the SPARK Flex Motor Controller. Its JST-PH 6-pin connector is designed to plug directly into the REV Through Bore Encoder, connecting both the quadrature and absolute encoder outputs to the appropriate SPARK Flex Data Port pins. Additional inputs, like Limit Switch and Analog inputs, are broken out to shrouded, 1 x 3 pinned, 0.1in pitch, PWM-style connectors that provide both power and ground in addition to the input signal.

SPARK Flex Data Port Pigtail Cable

Data Port Connector Information

The SPARK Flex Data Port is a 0.05 in pitch, 2 x 5 pin, keyed and locking connector. Custom cables can be made with the following parts:

Mounting Holes

The mounting face of the SPARK Flex features six #10-32 threaded mounting holes on a 2 in bolt circle. Each hole has an absolute maximum depth of 0.25 in.

DO NOT exceed the maximum mounting screw depth of 0.25 in when mounting the SPARK Flex. Doing so will result in permanent damage to the SPARK Flex and will void the warranty.

Depth gauges are laser-etched into each side of the SPARK Flex body to make it easy to check that the chosen screw length will not violate the maximum depth.

Simply check the screw length against the intended stack-up of structure and motor controller, and verify that it does not violate the maximum depth.

Control Interfaces

The SPARK Flex can be controlled by three different interfaces: servo-style PWM, Controller Area Network (CAN), and USB. The following sections describe the operation and protocols of these interfaces. For more details on the physical connections, see .

PWM Interface

The SPARK Flex can accept a standard servo-style PWM signal as a control for the output duty cycle. Even though the PWM port is shared with the CAN port, SPARK Flex will automatically detect the incoming signal type and respond accordingly. For details on how to connect a PWM cable to the SPARK Flex, see .

The SPARK Flex responds to a factory default pulse range of 1000 µs to 2000 µs. These pulses correspond to full-reverse and full-forward rotation, respectively, with 1500 µs (±5% default input deadband) as the neutral position, i.e. no rotation. The input deadband is configurable with the REV Hardware Client or the CAN interface. The table below describes how the default pulse range maps to the output behavior.

If a valid signal isn't received within a 60 ms window, the SPARK Flex will disable the motor output and either brake or coast the motor depending on the configured Idle Mode. For details on the Idle Mode, see Idle Mode - Brake/Coast Mode.

CAN Interface

The SPARK Flex can be connected to a robot CAN network. CAN is a bi-directional communications bus that enables advanced features within the SPARK Flex.

SPARK Flex must be connected to a CAN network that has the appropriate termination resistors at both endpoints. Please see the FIRST Robotics Competition Robot Rules for the CAN bus wiring requirements.

Even though the CAN port is shared with the PWM port, SPARK Flex will automatically detect the incoming signal type and respond accordingly.

Each device on the CAN bus must be assigned a unique CAN ID number. Out of the box, SPARK Flex is assigned a device ID of 0. This ID is considered "unconfigured" and must be assigned to a unique number from 1 to 62. CAN IDs can be changed by connecting the SPARK Flex to a Windows computer and using the REV Hardware Client.

Additional information about the CAN accessible features and how to access them can be found in the SPARK Flex API Information section.

USB Interface

The SPARK Flex can be configured and controlled through a USB connection to a computer running the REV Hardware Client.

More information coming soon!

Mode Button

The mode button can be used to activate basic operating modes within the SPARK Flex. For information on those modes, please see the section.

Pressing the SPARK Flex Mode Button

The Mode Button is specifically designed to be difficult to press inadvertently. Therefore, please follow the steps below to press the mode button successfully.

Using a small and blunt tool, like a straightened paper clip, gently press the Mode Button. You should feel and hear a soft click. If you are in a noisy environment, you may only be able to feel the click through the tool.

DO NOT use a sharp tool to press the Mode Button.

Safety pins, thumbtacks, pinbacks buttons, and other sharp tools will cause damage to the Mode Button's material.

If you do not feel the click, ensure the tool is aligned with the button.

DO NOT press with excessive force.

You should feel the click of the button with relatively gentle pressure. Pressing with excessive force can permanently damage the button.

Some early batches of SPARK Flex Motor Controllers have variances in the alignment of the Mode Button and the case hole. Misaligned buttons can still be pressed and the alignment does not affect the functionality of the SPARK Flex Motor Controller as a whole.

If your button is misaligned, please pay close attention and avoid the gap between the button and the printed circuit board (PCB):

Again, DO NOT use a sharp tool to press a misaligned Mode Button. It can easily be inserted into the indicated gap above, and permanently damage the button. Generally, a sharp tool should never be used to press the Mode Button.

Please reach out to us at support@revrobotics.com if you are still having difficulty pressing your Mode Button after following this guide.

Operating Modes

Brushed/Brushless Mode - Motor Type

This mode is only compatible with the SPARK Flex Dock (coming soon). More information about this mode will be available once the dock is available.

Brake/Coast Mode - Idle Behavior

When the SPARK Flex is receiving a neutral command the idle behavior of the motor can be handled in two different ways: Braking or Coasting.

When in Brake Mode, the SPARK Flex will effectively short all motor wires together. This quickly dissipates any electrical energy within the motor and brings it to a quick stop.

When in Coast Mode, the SPARK Flex will effectively disconnect all motor wires. This allows the motor to spin down at its own rate.

The Idle Mode can be configured using the Mode Button, CAN, and USB interfaces.

Mode Button Configuration

Follow the steps below to switch the Idle Mode between Brake and Coast with the Mode Button.

Please follow the before continuing.

Use a small straightened paper clip or other small blunt tool to press the button. Never use a sharp tool or any type of pencil, as the pencil lead can break off inside the SPARK Flex.

Connect the SPARK Flex to main power, not just USB Power.
The Status LED will indicate which Idle Mode is currently configured by blinking blue or cyan for Brake and yellow or magenta for Coast depending on the motor type.
Press and release the Mode Button
You should see the Status LED change to indicate the selected Idle Mode.

USB Configuration

Follow the steps below to switch the Idle Mode between Brake and Coast with the USB and the REV Hardware Client application. Be sure to download and install the REV Hardware Client application before continuing.

Connect the SPARK Flex to your computer using a USB-C cable.
Open the REV Hardware Client application and verify that the application is connected to your SPARK Flex.
On the Basic tab, select the desired mode with the Idle Mode switch.
Click Update Configuration and confirm the change.

CAN Configuration

Please see the API Information for information on how to configure the SPARK Flex using the CAN interface.

Recovery Mode

In the rare case where a firmware update has been interrupted or corrupted, it may be necessary to boot the SPARK Flex into Recovery Mode. This can be done by following the steps below. Have a computer running the REV Hardware Client and a USB cable ready in order to reload the device firmware once the device is in Recovery Mode.

Use a small straightened paper clip or other small blunt tool to press the button. Never use a sharp tool or any type of pencil, as the pencil lead can break off inside the SPARK Flex.

Start with all power disconnected from the SPARK Flex.
Press and hold the Mode Button.
While still holding the Mode Button, connect power by either turning on main power or connecting the USB cable between the SPARK Flex and the computer.
Once powered, you may release the Mode Button. The LED should stay dark. The SPARK Flex is now in Recovery Mode.

If the firmware is not booting properly, it may not be easy to know if the device has entered Recovery Mode since the LED will be dark in both cases. To confirm that the SPARK Flex is in Recovery Mode:

Connect the USB cable between the SPARK Flex and computer if not already connected.
In the REV Hardware Client, the SPARK Flex should show up as a Recovery Mode Device when scanning for devices.

If the device doesn't show up, please repeat the process, ensuring that the power and button holding sequence is followed exactly. If the device still doesn't show up, please contact REV Support.

SPARK Flex Getting Started

SPARK Flex Anatomy

Side View

Outside

Inside

The SPARK Flex is a motor controller with many features allowing it to control a host of brushless and brushed motor controllers. Out of the box, the Flex can be docked directly with a NEO Vortex Brushless Motor and drive it with the Flex's PWM interface. This Getting Started guide will assume that you are driving NEO Vortex and includes steps to get the motor spinning using the REV Hardware Client as well as information on how to configure your SPARK Flex. Driving other motors requires the SPARK Flex Dock (coming soon) and will be covered in its own separate guides.

Before You Start

Before following this guide, the REV Hardware Client should be installed before continuing. It is the best way to verify that the device up to date and configured correctly. Configuration through the Hardware Client is required before using the CAN interface.

Wiring the SPARK Flex

Required Materials

12 V battery
120 A circuit breaker
Power Distribution Hub
SPARK Flex
NEO Vortex
Associated wiring and a "test bed" described below
USB type-C cable
A Computer Running the REV Hardware Client

Prepare the Components

Test Bed

Using a "test bed" is an easy way to get started with the SPARK Flex and to verify connections and code. For the initial bring-up of the SPARK Flex, a test bed with a single Flex, NEO Vortex, and a is recommended.

Wiring the SPARK Flex to the Power Distribution Hub is just like wiring a SPARK MAX.

Motor Connections and Mounting

Mount the docked SPARK Flex and NEO Vortex assembly to a piece of structure to keep it secured when it spins up. The motor has a lot of inertia and upon spin-up it can jump off the table.

The SPARK Flex's mounting face includes six #10-32 threaded mounting holes that are on a 2 in bolt circle. This bolt pattern is compatible with many structure types available, including REV ION System. However, two 0.196 - 0.201 in holes, spaced 2 in apart can easily be drilled into a piece of wood to rigidly mount the assembly.

Power Connections

The power wires are permanently connected to the SPARK Flex and are not replaceable. Take care not to cut these wires too short. It is highly recommended to install connectors on these wires to allow for reconfiguration as you experiment and design your robot. WAGO 221 Inline Splicing Connectors (REV-19-2491-PK50) and Anderson Power Pole connectors are commonly used for this purpose.

Make sure the power is disconnected or turned off before making any electrical connections on your test bed or robot.

Connect the integrated SPARK Flex power leads labeled + (red) and - (black) to an available channel on the Power Distribution Hub. If you need to extend the length of the integrated wires, it is recommended to use 12 AWG wire or larger (a lower gauge number).

Make it Spin!

Power On

Now that the device is wired, and the connections carefully checked, power on the robot. You should see the SPARK Flex slowly blinking its for a new device the color will be Magenta. If the LED is dark, or you see a different blink pattern, refer to the guide for troubleshooting.

If you are using a brushed motor, you may see a sensor error. This is expected until you configure the device to accept a brushed motor in the following steps.

Connect to the SPARK Flex

Plug in the USB cable and start the REV Hardware Client. Select the SPARK Flex from the Connected Hardware

If you cannot see the SPARK Flex, make sure that the SPARK Flex is not being used by another application . Then unplug the SPARK Flex from the computer and plug it back in.

Basic Setup and Configuration

Before any parameters can be changed, you must first assign a unique CAN ID to the device. This can be any number between 1 and 63. After setting a unique CAN ID, the user interface will refresh and allow you to change other parameters.

Eventually you may set up a CAN network on your test bench or robot. Be sure each device on the network has a unique CAN ID. It is helpful to label each device with its ID number to aid in troubleshooting.

Set the Motor Type

If you are using a NEO Vortex, NEO, or NEO 550, verify that the motor type is set to REV NEO Brushless, Sensor Type is Hall Effect, and the LED is blinking Magenta or Cyan.

If you see a Sensor Fault blink code, make sure the Motor Interface Connector is properly seated.

The ability to run a Brushed motor using a SPARK Flex will not be available until the release of the SPARK Flex Dock.

Suggested Current Limits

Your ideal current limit may vary based on your specific application, but these values can be used as a starting point to reduce the chance of an overload on your motor as you begin tuning your specific mechanism's Smart Current Limit.

Warning: Setting current limits outside of the suggested ranges listed above may cause unintended overload and severe damage to components that are not covered by warranty.

Save the Settings

The settings must be saved for the SPARK Flex to remember its new configuration through a power cycle. To do this, press the Burn Flash button at the bottom of the page. It will take a few seconds to save, indicated by the loading symbol on the button.

Any settings saved this way will be remembered when the device is powered back on. You can always restore the factory defaults if you need to reset the device.

Spin the Motor

Before running any motor, make sure all components are in a safe state, that the motor is secured, and that anyone nearby is aware. FRC motors are very powerful and can quickly cause damage to people and property.

Keep the CAN cable disconnected throughout the test. For safety reasons, the REV Hardware Client will not run the motor if the roboRIO is connected. If the roboRIO was connected, power cycle the SPARK Flex.

To spin the motor, go to the Run tab, keep all of the default settings and press Run Motor. The setpoint is 0 by default, meaning that the motor is being commanded to idle (0% power). When you press Run you should see the LED go from slow blinking to solid, indicating that the motor is idling.

Slowly ramp the setpoint slider up. The motor should start to spin and you should see a green blink pattern proportional to the speed you have set to the motor. Slowly ramp the slider down. The motor should spin in reverse, and you should see a red blink pattern proportional to the speed you have set to the motor.

Basic Configurations

SPARK Flex has many operating modes that can be configured through its CAN and USB interfaces.

Coming soon!

SPARK Flex Operating Modes

Brake/Coast Mode - Idle Behavior

When the SPARK Flex is receiving a neutral command the idle behavior of the motor can be handled in two different ways: Braking or Coasting.

When in Brake Mode, the SPARK Flex will effectively short all motor wires together. This quickly dissipates any electrical energy within the motor and brings it to a quick stop.

When in Coast Mode, the SPARK Flex will effectively disconnect all motor wires. This allows the motor to spin down at its own rate.

The Idle Mode can be configured using the Mode Button, CAN, and USB interfaces.

Mode Button Configuration

Follow the steps below to switch the Idle Mode between Brake and Coast with the Mode Button.

Use a small screwdriver, straightened paper clip, pen, or other small implement to press the button. Do not use any type of pencil as the pencil lead can break off inside the SPARK Flex.

Connect the SPARK Flex to main power, not just USB Power.
The Status LED will indicate which Idle Mode is currently configured by blinking blue or cyan for Brake and yellow or magenta for Coast depending on the motor type.
Press and release the Mode Button.
You should see the Status LED change to indicate the selected Idle Mode.

Please see the guide for information on how to identify the Idle Behavior configuration by the color of the Status LED!

USB Configuration

Follow the steps below to switch the Idle Mode between Brake and Coast with the USB and the REV Hardware Client application. Be sure to application before continuing.

Connect the SPARK Flex to your computer using a USB-C cable.
Open the REV Hardware Client application and verify that the application is connected to your SPARK MAX.
On the Basic tab, select the desired mode with the Idle Mode switch.
Click Burn Flash and confirm the change.

CAN Configuration

SPARK MAX Motor Controller

SPARK MAX Specifications

The following tables provide the operating and mechanical specifications for the SPARK MAX Motor Controller.

DO NOT exceed the maximum electrical specifications. Doing so will cause permanent damage to the SPARK MAX and will void the warranty.

Main Electrical Specifications

Parameter

Min

Typ

Max

Units

*Continuous operation at 60A may produce high temperatures on the heat sink. Caution should be taken when handling the SPARK MAX if it has been running at higher current level for an extended period of time.

If using a battery to power SPARK MAX, make sure the fully charged voltage is below 24V allowing for sustained operation. Some battery chemistries and configurations, including 6S LiPo packs, have a charge voltage above the maximum operating voltage for SPARK MAX.

PWM Input Specifications

Parameter

Min

Typ

Max

Units

Data Port Specifications

Encoder Port Specifications

Mechanical Specifications

REVLib

Tips and Tricks

Legacy Documentation

Migrating to REVLib 2025

Only SPARK MAX and SPARK Flex are affected by the REVLib 2025 release. Color Sensor V3 is unaffected.

Summary

The 2025 version of REVLib introduced a series of breaking changes from the previous year. These changes include:

An overhauled configuration system
Updated import paths
Renamed classes

For a more complete changelog, please see our 2025 beta release notes on GitHub.

Below shows how to migrate certain common tasks from previous versions of REVLib to the 2025 release.

Including the library and creating a SPARK object

In the 2025 version, all SPARK related classes moved to a spark package in Java and a spark namespace in C++.

In addition, some of the classes were renamed:

CANSparkMax is now SparkMax
CANSparkFlex is now SparkFlex
CANSparkLowLevel is now SparkLowLevel
SparkPIDController is now SparkClosedLoopController

Before

import com.revrobotics.CANSparkMax;
import com.revrobotics.CANSparkFlex;
import com.revrobotics.CANSparkLowLevel.MotorType;
import com.revrobotics.SparkPIDController;

CANSparkMax max = new CANSparkMax(1, MotorType.kBrushless);
CANSparkFlex flex = new CANSparkFlex(2, MotorType.kBrushless);
SparkPIDController maxPid = max.getPIDController();

After

import com.revrobotics.spark.SparkMax;
import com.revrobotics.spark.SparkFlex;
import com.revrobotics.spark.SparkLowLevel.MotorType;
import com.revrobotics.spark.SparkClosedLoopController;

SparkMax max = new SparkMax(1, MotorType.kBrushless);
SparkFlex flex = new SparkFlex(2, MotorType.kBrushless);
SparkClosedLoopController maxPid = max.getClosedLoopController();

Before

#include <rev/CANSparkMax.h>
#include <rev/CANSparkFlex.h>

using namespace rev;

CANSparkMax m_max{1, CANSparkMax::MotorType::kBrushless};
CANSparkFlex m_flex{2, CANSparkFlex::MotorType::kBrushless};
SparkPIDController m_maxPid = m_max.GetPIDController();

After

#include <rev/SparkMax.h>
#include <rev/SparkFlex.h>

using namespace rev::spark;

SparkMax m_max{1, SparkMax::MotorType::kBrushless};
SparkFlex m_flex{2, SparkFlex::MotorType::kBrushless};
SparkClosedLoopController m_maxPid = m_max.GetClosedLoopController();

Configuring a SPARK

Instead of imperatively configuring parameters of the SPARK by calling methods directly on it and its auxiliary objects (sensors, closed loop controller, etc.), configuration parameters are set in a more declarative way through configuration objects and applying that configuration to the SPARK.

A more complete guide on the new configuration system will soon be available.

For simplicity, only an example for SPARK MAX is provided. The following will still be valid for a SPARK Flex object.

Before

CANSparkMax max = new CANSparkMax(1, MotorType.kBrushless);
RelativeEncoder enc = max.getEncoder();
SparkPIDController pid = max.getPIDController();

max.restoreFactoryDefaults();

max.setInverted(true);
max.setIdleMode(IdleMode.kBrake);
enc.setPositionConversionFactor(1000);
enc.setVelocityConversionFactor(1000);
pid.setFeedbackDevice(enc);
pid.setP(1.0);
pid.setI(0.0);
pid.setD(0.0);

max.burnFlash();

After

SparkMax max = new SparkMax(1, MotorType.kBrushless);
SparkMaxConfig config = new SparkMaxConfig();

config
    .inverted(true)
    .idleMode(IdleMode.kBrake);
config.encoder
    .positionConversionFactor(1000)
    .velocityConversionFactor(1000);
config.closedLoop
    .feedbackSensor(FeedbackSensor.kPrimaryEncoder)
    .pid(1.0, 0.0, 0.0);
    
max.configure(config, ResetMode.kResetSafeParameters, PersistMode.kPersistParameters);

Before

using namespace rev;

CANSparkMax m_max{1, MotorType.kBrushless};
SparkRelativeEncoder m_enc = m_max.GetEncoder();
SparkPIDController m_pid = m_max.GetPIDController();

m_max.RestoreFactoryDefaults();

m_max.SetInverted(true);
m_max.SetIdleMode(IdleMode.kBrake);
m_enc.SetPositionConversionFactor(1000);
m_enc.SetVelocityConversionFactor(1000);
m_pid.SetFeedbackDevice(enc);
m_pid.SetP(1.0);
m_pid.SetI(0.0);
m_pid.SetD(0.0);

m_max.BurnFlash();

After

using namespace rev::spark;

SparkMax m_max{1, SparkMax::MotorType::kBrushless};
SparkMaxConfig config{};

config
    .Inverted(true)
    .SetIdleMode(SparkMaxConfig::IdleMode::kBrake);
config.encoder
    .PositionConversionFactor(1000)
    .VelocityConversionFactor(1000);
config.closedLoop
    .SetFeedbackSensor(ClosedLoopConfig::FeedbackSensor::kPrimaryEncoder)
    .Pid(1.0, 0.0, 0.0);
    
m_max.Configure(config, SparkMax::ResetMode::kResetSafeParameters, SparkMax::PersistMode::kPersistParameters);

Retrieving a configuration parameter from a SPARK

With the new configuration system, parameter getters moved to a configAccessor field in the SparkMax and SparkFlex.

For simplicity, only an example for SPARK MAX is provided. The following will still be valid for a SPARK Flex object.

Before

CANSparkMax max = new CANSparkMax(1, MotorType.kBrushless);
RelativeEncoder enc = max.getEncoder();

boolean isInverted = max.getInverted();
double positionConversionFactor = enc.getPositionConversionFactor();
double velocityConversionFactor = enc.getVelocityConversionFactor();

After

SparkMax max = new SparkMax(1, MotorType.kBrushless);

boolean isInverted = max.configAccessor.getInverted();
double positionFactor = max.configAccessor.encoder.getPositionConversionFactor();
double velocityFactor = max.configAccessor.encoder.getVelocityConversionFactor();

Before

using namespace rev;

CANSparkMax m_max{1, CANSparkMax::MotorType::kBrushless};
SparkRelativeEncoder m_enc = m_max.GetEncoder();

bool isInverted = m_max.GetInverted();
double positionFactor = m_enc.GetPositionConversionFactor();
double velocityFactor = m_enc.GetVelocityConversionFactor();

After

using namespace rev::spark;

SparkMax m_max{1, SparkMax::MotorType::kBrushless};

bool isInverted = m_max.configAccessor.GetInverted();
double positionFactor = m_max.configAccessor.encoder.GetPositionConversionFactor();
double velocityFactor = m_max.configAccessor.encoder.GetVelocityConversionFactor();

Setting status periods

Previously, setting status periods required the user to know which periodic status frame a signal belonged to. Now, status signals' periods can be individually configured, and REVLib will handle figuring out which status frame to adjust.

These values can be configured through the new configuration system.

For simplicity, only an example for SPARK MAX is provided. The following will still be valid for a SPARK Flex object.

Before

CANSparkMax max = new CANSparkMax(1, MotorType.kBrushless);

max.restoreFactoryDefaults();
// Adjust periodic status frame 2, which includes encoder position data
max.setPeriodicFramePeriod(PeriodicFrame.kStatus2, 5);
max.burnFlash();

double position = max.getEncoder().getPosition();

After

SparkMax max = new SparkMax(1, MotorType.kBrushless);
SparkMaxConfig config = new SparkMaxConfig();

config.signals.primaryEncoderPositionPeriodMs(5);

max.configure(config, ResetMode.kResetSafeParameters, PersistMode.kPersistParameters);

double position = max.getEncoder().getPosition();

Before

using namespace rev;

CANSparkMax m_max{1, MotorType.kBrushless};

m_max.RestoreFactoryDefaults();
// Adjust periodic status frame 2, which includes encoder position data
m_max.SetPeriodicFramePeriod(CANSparkMax::PeriodicFrame::kStatus2, 5);
m_max.BurnFlash();

double position = m_max.GetEncoder().GetPosition();

After

using namespace rev::spark;

SparkMax m_max{1, SparkMax::MotorType::kBrushless};
SparkMaxConfig config{};

config.signals.PrimaryEncoderPositionPeriodMs(5);
    
m_max.Configure(config, SparkMax::ResetMode::kResetSafeParameters, SparkMax::PersistMode::kPersistParameters);

double position = m_max.GetEncoder().GetPosition();

Device Firmware Changelogs

It is recommended to keep your SPARK MAX up-to-date with the latest firmware. The REV Hardware Client application will automatically download the latest firmware, but you can also download the firmware manually below:

This firmware will not work with SPARK MAX beta hardware units distributed by REV to the SPARK MAX Beta testers. It is only compatible with units received after 12/20/2018.

Version 24.0.1

Improves filtering of invalid PWM signals
- Previously, noise on the signal wires could be occasionally be erroneously interpreted as a PWM signal, causing the motor to spin unexpectedly

Version 24.0.0

Breaking Changes

Moves the IAccum value to periodic status frame 7
- Periodic status frame 7 is new to this release, and by default is sent every 250ms.

Enhancements

Allows changing the CAN ID of a SPARK MAX connected directly via USB without affecting other SPARK devices on the CAN bus with the same CAN ID
Makes changes towards improving the reliability of saving and persisting parameters

Bug fixes

Fixes alternate encoder position accuracy
Fixes the main quadrature encoder position jumping in brushed mode

Version 1.6.3

Fixes issue where changing the inversion mode of the duty cycle absolute encoder with a zero offset specified would cause the physical zero position to change

Version 1.6.2

Fixes critical issue where new parameters introduced in 1.6.0 were not being burned to flash correctly
Fixes issue where new parameters were not being read back correctly despite being set correctly

Version 1.6.1

Fixes duty cycle offset to match the inverted setting
Fixes parameters being NaN after updating to 1.6.0
Fixes burn flash command response

Version 1.6.0

Adds new parameters for configuring hall sensor velocity measurement
Adds support for duty cycle absolute encoders
Adds new parameters to enable and configure position PID rollover

Version 1.5.2

Fixes issue with the kDataPortConfig parameter not enabling Alternate Encoder Mode on a power cycle after it has been configured and saved to flash.
Improves Gate Driver Fault recovery.

Version 1.5.1

Improvements to BLDC commutation timing.
- Most noticeable at high RPMs only achievable by the NEO 550.
Fixes rare case where the SPARK MAX Status LED shows normal driving but no actual output is occurring until a reboot of the controller.

Version 1.5.0

Adds a unique hash key to the firmware. This key is a hashed value based on the unique 96-bit device ID guaranteed to be unique for every STM32 device. The hash value itself is 32-bits to make transmission/reception and on-board comparison easier. It is unlikely for a key collision especially since most buses have only a small number of devices.
Adds ID Query command to have all devices which match the CAN ID sent to return their unique hash key. This is typically used to identify all devices with CAN ID 0 but can be used to identify devices with conflicting CAN IDs.
Adds ID Assign command, which sends a unique hash key and a CAN ID, which is received by any device whose CAN ID matches the ID field. The device whose unique hash matches has their own CAN ID set to the desired value. This is for initial or automatic provisioning, or to re-address devices with the same CAN ID.
Adds identify command which flashes the LED blue/magenta. This command uses the CAN ID, or the unique hash if CAN ID = 0.
Complete overhaul of USB interface, creating a generic USB-to-CAN driver connection to act as the bridge to the interface.
Adds device manufacturing info to firmware frame.
Adds retry frame to CAN bootloader if there is an issue.

Version 1.4.1

Fixes issue where creating a CANSparkMax object would cause the SensorType parameter to be set to NoSensor.

Version 1.4.0

Adds non-competition heartbeat command when not used with a roboRIO.
Adds Raspbian support using official WPILib tools.
Adds locking mechanism to prevent simultaneous USB and CAN commands.
Proportional blink codes now match inversion settings (i.e. positive input is always green, and negative input is always red).
Limit switch and soft limits now follow inversion settings.
Motor controller inversion now in the firmware instead of the API.
Adds a configurable range for absolute feedback devices (currently only applicable to an absolute mode analog sensor), which also prevents users from setting a setpoint out of range.
Adds ability to use both absolute and relative analog sensors as feedback devices
Adds filtering for Analog sensor with settings for velocity moving average filter
Adds ability to configure how errors are tracked and handled by the user.
- Calls can be automatically registered and tracked, with any errors displayed to the DriverStation or users can use the GetLastError() after calls to determine if an error has been thrown. This is done by changing the error timeout through SetCANTimeout(), where a timeout of 0 means that the calls are non-blocking, and errors are checked in a separate thread and sent through to the driver station.
Other minor improvements and bug fixes.

Version 1.3.0

Ability to configure the feedback device for the PIDController.
Addition of CANAnalog which will function as a possible feedback device.
Added API for using encoders with brushed DC motors.
Adds API to enable and set soft limits.
All control modes now reset integrator on limit switch activation for long as the limit switch is held.
Smart Motion now honors acceleration rate after limit switch changes from triggered to not triggered.
Fixes issue where sticky faults can be cleared incorrectly when a new fault is set and the old fault is no longer present.
Adds status 3 periodic frame for analog sensor.
Other minor improvements and bug fixes.

Version 1.2.1

Adds initial CAN bootloading functionality.
- Requires continuous power during update and requires USB recovery if the update fails after erasing the flash (i.e. power is lost during update).
- This is not yet integrated into a formal tool, but is exposed in the API. Future versions will allow recovery over CAN.
- Fix to bus voltage measurement, previous version reported a lower value.
- Additional accuracy improvements to all ADC measurements.
- Adds additional filtering to bus voltage.
- Fix for Follow settings not being reapplied after power cycle.
- Adds ability to change units for arbFF between voltage and percent bus voltage (or percent compensated voltage).

Version 1.1.33

Fixes issue that causes a Gate Driver Fault if the NEO is spinning at a certain speed during power up.
- e.g. while still moving after a breaker trips for more than ~1.4s after breaker recovery.
Fixes issue where configuration data can be corrupted under a unique set of conditions, including loss of power while configuration settings are being saved to flash memory.
- Issue symptoms: Controller cannot be controlled by a normal address and would report a firmware version of 0.0.0 in the Client, even after a successful firmware update. Updating a controller that is in this state to 1.1.33 will recover the controller.

Version 1.1.31

Adds new Smart Velocity mode - uses same constrains as the Smart Motion mode but outputs velocity instead of position. This is not a motion profiling mode, but rather provides acceleration limiting as opposed to simple ramp rates.
Improvements to heartbeat implementation.
CAN ID of 0 now considered 'unconfigured' and will not be enabled.
Changes the default output range for all PID slots to be [-1,1] instead of [0,0]
Changes setpoint commands to 'stick' instead of relying on periodic frames from the controller.
Follow mode can now persists through a power-cycle.
Periodic Status 2 (position data) frame rate default changed from 50ms to 20ms.
Watchdog changed to 220ms.
Proportional blink codes while driving now have a minimum blink rate (minimum is same as 10% applied output blink rate).
Fault flag 'over voltage' replaced with 'IWDT Reset'.
Velocity and Position conversion factors are now used for all internal PID calculations.

Version 1.1.26 (beta)

Adds new Smart Motion mode utilizing trapezoidal motion profiling
Improvements to velocity decoding for low speeds and associated PID control loops requiring control at low speeds
Improvements to gate driver fault handling
Adds voltage compensation mode
Adds ability to set the stored sensor position
Adds ability to set the maximum PID integral accumulator value to prevent integral windup
Adds ability to set the PID I accumulator value
Adds filter function to PID derivative value
Adds closed-loop current control
Adds closed-loop ramp rate separate from open-loop
Adds ability to follow Phoenix 4.11 motor controllers
- Note: This feature depends on the firmware of the Phoenix controllers, and is not controlled by REV. We will do our best to build this functionality, but this is not an officially supported feature.
Adds ability to set a unit conversion for both velocity and position units
Adds ability to reset to factory defaults
Improvements to smart current limits
Improvements to current data sent over CAN
Improvements to internal settings table implementation
Calling the constructor no longer resets the encoder count. This must be done manually by running CANEncoder.setPosition()

Version 1.0.385

Fixes PWM control issue introduced by version 1.0.384.

Version 1.0.384

Fixes GetPosition() randomly returning 0.
Fixes momentary velocity spike when accelerating from 0 speed.
Fixes issue related to rapid control mode switching by the user.
Fixes issue related to extreme low voltage CAN bus operation.
Adds conversion for motor temperature.
Improvement to "Has Reset" flag.
Improvements to brownout fault indicator.
Improvements to brownout behavior.

Factory Images

Version 24.0.8

Fixes bug in velocity calculation when changing the encoder average depth
Fixes issue causing motor EEPROM to occasionally reload fully after disabling the motor, causing brief dropout of status frames

Version 24.0.7

Adds parameters for status frame periods
Performs contextual validation on the sensor type parameter
Always keeps the hall sensor active when in brushless mode, in addition to the specified sensor type
Recalculates the hall angle more frequently to prevent lockup

Version 24.0.6

Fixes issue where an invalid sensor type for a given motor type can cause a sensor fault

Version 24.0.5

Improves handling of errors on the CAN bus
Fixes incorrect EEPROM faults appearing
Reduces boot time
Properly handles the case where a CAN device sends a payload longer than 8 bytes
Improves internal watchdog

Version 24.0.4

Fixes issue where SPARK Flex constantly disables itself while running when certain third-party commands are being sent to the CAN bus

Version 24.0.3

Fixes position data inaccuracy when the position conversion factor is not 1

Version 24.0.2

Improves filtering of invalid PWM signals
- Previously, noise on the signal wires could be occasionally be erroneously interpreted as a PWM signal, causing the motor to spin unexpectedly
Fixes issue where CAN errors would cause the device to switch between brake mode and coast mode, resulting in a clicking sound if you manually turned the motor

Version 24.0.0

Breaking Changes

Moves the IAccum value to periodic status frame 7
- Periodic status frame 7 is new to this release, and by default is sent every 250ms.

Enhancements

Adds Orange/Green blink code to indicate temperature cutoff
Refuses to run in brushed mode when connected to a NEO Vortex
Improves the precision of the main encoder
- Previously, the higher the position value was, the less precise the value would be
- For the NEO Vortex's internal encoder, this change starts making a difference after only ~1,000 rotations
- Requires REVLib 2024.2.0 or later or REV Hardware Client 1.6.2 or later to take advantage of the additional precision
Allows changing the CAN ID of a SPARK Flex connected directly via USB without affecting other SPARK devices on the CAN bus with the same CAN ID
Makes changes towards improving the reliability of saving and persisting parameters

Bug fixes

Fixes analog sensor values when it is configured to be inverted
Fixes setting the NEO encoder's position to values other than zero
Fixes the NEO encoder's position when the motor is inverted

Version 23.0.2

Adds support for updating the firmware via CAN and USB (without Recovery Mode)

Known issues

Setting the NEO encoder's position always resets the position to 0, regardless of the specified value
When the analog sensor is configured to be inverted, its reported values will be incorrect

Version 23.0.0

Initial version with intent to support equivalent features to SPARK MAX

Features requiring the SPARK Flex Dock (coming soon) are not yet supported, e.g. brushed motor driving and NEO/NEO550 brushless motor driving
Alternate Encoder Mode is not necessary for SPARK Flex, therefore it is replaced by the External Encoder Data Port feature:
- Can be used simultaneously with the internal encoders in NEO class motors
- Can be used simultaneously with an absolute encoder and limit switches
- Virtually no RPM limit
- No special configuration