Dual-Channel Controller PCB Replication
Budget: $750 – $1,500 AUD
I’m holding an ageing but still functional dual-channel, 80 A DC reverse controller that was built for industrial truck-tarp systems about fifteen years ago. The original supplier is long gone and all I have left is the bare hardware in my hands—no CAD files, no schematics.
To get this product back into reliable production I need you to capture the existing board and deliver a fresh manufacturing package that any modern fab house can use. I’ll supply high-resolution photographs of both sides, detailed close-ups of critical sections, and shots that include vernier-scale references so dimensional data can be extracted accurately.
Scope of work
• Reverse-engineer the circuitry into a clear single-line diagram that reflects the dual-channel, high-current H-bridge topology.
• Produce a complete, labelled schematic and a clean PCB layout matching the original footprint and mounting holes.
• Compile a current, supplier-ready material list noting exact part numbers or modern equivalents that are still in distribution.
• Generate standard Gerber/Excellon outputs alongside pick-and-place and centroid files so I can drop everything straight into my board house workflow.
Acceptance
I’ll run the outputs through my DFM checks and order a prototype. Full sign-off comes once the board powers a tarp motor at 80 A continuous without thermal or functional issues.
If you’re experienced with high-current routing, wide copper pours, and mining-grade protection components, this should be a straightforward yet rewarding project. Looking forward to seeing how quickly you can breathe new life into this controller.
To get this product back into reliable production I need you to capture the existing board and deliver a fresh manufacturing package that any modern fab house can use. I’ll supply high-resolution photographs of both sides, detailed close-ups of critical sections, and shots that include vernier-scale references so dimensional data can be extracted accurately.
Scope of work
• Reverse-engineer the circuitry into a clear single-line diagram that reflects the dual-channel, high-current H-bridge topology.
• Produce a complete, labelled schematic and a clean PCB layout matching the original footprint and mounting holes.
• Compile a current, supplier-ready material list noting exact part numbers or modern equivalents that are still in distribution.
• Generate standard Gerber/Excellon outputs alongside pick-and-place and centroid files so I can drop everything straight into my board house workflow.
Acceptance
I’ll run the outputs through my DFM checks and order a prototype. Full sign-off comes once the board powers a tarp motor at 80 A continuous without thermal or functional issues.
If you’re experienced with high-current routing, wide copper pours, and mining-grade protection components, this should be a straightforward yet rewarding project. Looking forward to seeing how quickly you can breathe new life into this controller.