I'm back with second generation of my BESC controller. I took a few different approaches this time.
This monstrosity is a 24 FET design. It uses 135V TO-220 mosfets and is designed for input voltages up to 100V. It's primary use case are light electric vehicles and bikes. It features integrated high efficiency 12V 5A dcdc power supply and custom input connectors to ensure easy throttle connection. Because of high voltage it doesn't use phase shunts but rather three low side 0.2 mOhm shunts. It was designed up to 400A phase current but we'll see about that. PCB is standard thickness 4 layer board. Busbars soldered on bottom and top carry high current. Board is also ready for high voltage modification. With suitable capacitors and mosfets it is possible to turn this board into higher voltage / lower current controller up to 150V input voltage.
To sum it up:
- 20S LiPo safe
- 400 A phase current
- 12V 5A integrated dcdc
- Easy throttle connection
- 250€ BOM from Mouser/Farnell
Project is of course open hardware and can be found in my github repository: https://github.com/galpavlin/BESC-G2
You can find pdf of schematic, 3d step files and BOM in documentation folder. Gerbers are also available.
I ordered PCBs few days ago. I'l have a few extra. If you'd like to have one write me a PM. I'll be assembling the first unit sometime next week.