I'm working on a high voltage version of VESC6. Schematics.
Main parts used:
- IPB044N15N5 150 V 174 A 4.4mR MOSFET https://eu.mouser.com/datasheet/2/196/Infineon-IPB044N15N5-DS-v02_00-EN-...
- UCC27714 600 V 4 A half bridge driver http://www.ti.com/lit/gpn/ucc27714
- ACS758 +-200 A hall current sensor https://www.farnell.com/datasheets/2629295.pdf
- WP-SHFU REDCUBE PRESS-FIT Terminals M6 250 A https://katalog.we-online.de/en/em/WP-SHFU_FULL_PLAIN
- 4.7 uf 200 V x7r ceramics
- 560 uf 160V aluminum capacitor
Each phase is for now decoupled with 2x 560uF aluminum capacitors and 6x 4.7 uf 200V x7r ceramics. Gate drivers go up to 600V. Fets breakdown at 150V. Nothing else is connected to high voltage because I'm using hall current sensors - similar design as electric cars. For now the driver needs external 12V power supply for the logic. The driver also supports low power (sleep) mode to eliminate external high current high voltage switch - the driver stays connected to the battery even when electric vehicle is turned off.
I already made most of the layout. It has four layers and its size is 177x78 mm.
Orange and green towers are M6 screw terminals for input and phases. They can handle 150A continious.
Orange bars are copper bus bars. They are actually standard size (3x10 mm) copper profiles cut to correct length so no laser processing is needed just a handsaw. Their second function is to conduct heat away from mosftes and PCB traces. A layer of heat conductive silicone (or ceramics) will be placed on top of the bars to insulate them electrically. The PCB will be then placed in an aluminum housing. The whole device will be mounted on external heatsink if required by high loads.
I might over engineer this whole thing for my e-bike (84V 80A phase current) but there's never enough power when it comes to ebikes ... PS. B in BESC stands for beefed.