I've been planning to start my controller thread for a long time, now here it is. It's about my latest build that I made for development and testing purpose, started sometime in the spring last year and still in progress.
It was designed to fit in the hammond 1590U or the gainta G0474 box (almost the same, external dimensions: 120x120x59mm):
https://eu.mouser.com/ProductDetail/Hammond-Manufacturing/1590U?qs=lxPAlgZqN%2FxeTOQJUYeowQ==
https://www.tme.eu/hu/en/details/alu-g0474/multipurpose-enclosures/gainta/g-0474/
The circuit consists of 3 boards stacked: power, gate driver and CPU. I planned this way to make it easier to change to another gate driver or CPU board without redesigning the whole unit.
I made the design in an older software (Accel), so instead of the source files I just share pdf and screenshots. No spectacular 3D views.
The schematics are 3 pages, each for one board:
View attachment 10kW BLDC motor controller sch rev01.pdf
PCB drawings:
all boards top
View attachment 01 all top.png
all boards bottom
View attachment 02 all bottom.png
power board bottom
View attachment 03 power bot.png
power board top
View attachment 04 power top.png
power board output nodes in magenta (cut from 0.5mm copper sheet and soldered on the top layer with thin insulation boards above +VBAT (white rectangles in the middle))
View attachment 05 power outputs.png
snubber modules (small PCB-s soldered between the MOSFET legs)
View attachment 06 snubbers.png
driver board top
View attachment 07 driver top.png
driver board bottom
View attachment 08 driver bot.png
CPU board top
View attachment 09 cpu top.png
CPU board bottom
View attachment 10 cpu bot.png
Originally I started to design this controller for this bike (dark green box inside the frame on the bottom plate):
View attachment bike2024.png
But I'm not going to build this frame in the near future, so I will install it on my current bike.
The gate driver circuit is a bit more complex than usual because I wanted to adjust all phases of the MOSFET switching transients separately as much as possible, such as the Vgs rise and fall times, length of the Miller-plateau (Vds edges), length of the current transients for both the turn-on and turn-off, and the high frequency oscillations.
I'm using this controller also to develop my FOC firmware with full torque sensorless start, that is also in progress.
So at the moment I'm building only a single unit for development purposes, maybe later I'll design a simplified version for sale with only 2 boards.
The boards are already built and mostly tested, I will post photos and waveforms later.
Some resistors/capacitors on the schematics may still change.
It was designed to fit in the hammond 1590U or the gainta G0474 box (almost the same, external dimensions: 120x120x59mm):
https://eu.mouser.com/ProductDetail/Hammond-Manufacturing/1590U?qs=lxPAlgZqN%2FxeTOQJUYeowQ==
https://www.tme.eu/hu/en/details/alu-g0474/multipurpose-enclosures/gainta/g-0474/
The circuit consists of 3 boards stacked: power, gate driver and CPU. I planned this way to make it easier to change to another gate driver or CPU board without redesigning the whole unit.
I made the design in an older software (Accel), so instead of the source files I just share pdf and screenshots. No spectacular 3D views.
The schematics are 3 pages, each for one board:
View attachment 10kW BLDC motor controller sch rev01.pdf
PCB drawings:
all boards top
View attachment 01 all top.png
all boards bottom
View attachment 02 all bottom.png
power board bottom
View attachment 03 power bot.png
power board top
View attachment 04 power top.png
power board output nodes in magenta (cut from 0.5mm copper sheet and soldered on the top layer with thin insulation boards above +VBAT (white rectangles in the middle))
View attachment 05 power outputs.png
snubber modules (small PCB-s soldered between the MOSFET legs)
View attachment 06 snubbers.png
driver board top
View attachment 07 driver top.png
driver board bottom
View attachment 08 driver bot.png
CPU board top
View attachment 09 cpu top.png
CPU board bottom
View attachment 10 cpu bot.png
Originally I started to design this controller for this bike (dark green box inside the frame on the bottom plate):
View attachment bike2024.png
But I'm not going to build this frame in the near future, so I will install it on my current bike.
The gate driver circuit is a bit more complex than usual because I wanted to adjust all phases of the MOSFET switching transients separately as much as possible, such as the Vgs rise and fall times, length of the Miller-plateau (Vds edges), length of the current transients for both the turn-on and turn-off, and the high frequency oscillations.
I'm using this controller also to develop my FOC firmware with full torque sensorless start, that is also in progress.
So at the moment I'm building only a single unit for development purposes, maybe later I'll design a simplified version for sale with only 2 boards.
The boards are already built and mostly tested, I will post photos and waveforms later.
Some resistors/capacitors on the schematics may still change.