First post - so if my question is completely stupid, tell it politely ;)
Most of the failures seem to happen on the power side. that means blown FETs or gate drivers (whichever that might be).
The control signals to and from the main MCU is more or less the same no matter how the power side is built, so my question would be - why isn't anyone building the power side separately and leave the MCU on a different board? I knw that will most likely increase the size a bit but IF you blow the power stage you can just pop another one in (and don't repeat whatever you were doing) and you will keep the settings from before.
I'm thinking about building a power stage with IRF7749 FETs and the DRV8323. In another post it was suggested that the 8323 might not perform as good as the 8301 with external current sensors but it might simplify the design process a bit.
And if it don't work out - then I would only need to make a new power stage.
Another idea could be to have an EEPROM on the board so the main MCU could identify safe values for that specific stage.
Is this the worst idea ever?