500W DC Motor Controller Design
Budget: $30 – $250 USD
I’m ready to hand over the full schematic of my 36 V / 500 W brushed-motor controller so you can put it under the microscope. The design is built around three power-side MOSFETs driven by a four-comparator PWM stage, and it also ties into a throttle, a 36 V battery pack, and a basic lighting circuit.
Your brief is to confirm that every part of the schematic is electronically sound, that the gate-drive and comparator timing will let the MOSFETs switch cleanly at load, and that the surrounding devices (throttle hall sensor, battery protection, head- and tail-lights) remain within safe operating limits in all modes. Along the way, flag any weak points—trace width, thermal bottlenecks, wrong footprints, missing fly-back paths, logic-level mis-matches—and propose fixes directly in the design file. I work in Autodesk EAGLE, so I’ll send you the .sch file; please return the updated version in the same format. If you prefer to prototype a section in LTspice or a similar simulator to justify changes, feel free to do so and include the plots in your hand-over notes.
I’ll also need a clean, purchase-ready bill of materials. A simple spreadsheet with manufacturer part numbers, supplier SKUs, voltage/current ratings, package, and pricing columns is perfect. Focus on parts that are immediately available through the usual channels (Digi-Key, Mouser, LCSC, etc.) so I can hit the ground running once the design is signed off.
Deliverables:
• Revised EAGLE schematic/board files with all corrections applied
• Simulation or calculation notes that prove the circuit will drive 36 V @ 500 W continuously without thermal or electrical overstress
• Spreadsheet BOM as described above
• Short verification report summarising what was checked, what was fixed, and any optional improvements I might consider for a future spin
If this scope is clear, let me know your expected turnaround and any questions you might have about the current design constraints.
Your brief is to confirm that every part of the schematic is electronically sound, that the gate-drive and comparator timing will let the MOSFETs switch cleanly at load, and that the surrounding devices (throttle hall sensor, battery protection, head- and tail-lights) remain within safe operating limits in all modes. Along the way, flag any weak points—trace width, thermal bottlenecks, wrong footprints, missing fly-back paths, logic-level mis-matches—and propose fixes directly in the design file. I work in Autodesk EAGLE, so I’ll send you the .sch file; please return the updated version in the same format. If you prefer to prototype a section in LTspice or a similar simulator to justify changes, feel free to do so and include the plots in your hand-over notes.
I’ll also need a clean, purchase-ready bill of materials. A simple spreadsheet with manufacturer part numbers, supplier SKUs, voltage/current ratings, package, and pricing columns is perfect. Focus on parts that are immediately available through the usual channels (Digi-Key, Mouser, LCSC, etc.) so I can hit the ground running once the design is signed off.
Deliverables:
• Revised EAGLE schematic/board files with all corrections applied
• Simulation or calculation notes that prove the circuit will drive 36 V @ 500 W continuously without thermal or electrical overstress
• Spreadsheet BOM as described above
• Short verification report summarising what was checked, what was fixed, and any optional improvements I might consider for a future spin
If this scope is clear, let me know your expected turnaround and any questions you might have about the current design constraints.