Design a PCB for Dual BLDC Motor Control
Budget: $250 – $750 USD
I need a custom single-board solution to replace my current prototype, which controls two 24V brushless DC (BLDC) hub motors with Hall sensors using an RC-style remote with a single thumb transducer for speed control. My prototype currently uses off-the-shelf components (Arduino Nano, two RioRand motor drivers, a 24V battery, and a step-down converter), but I want an integrated PCB that combines all functionality into a compact, efficient design. The board should be powered by a 24V 2Ah battery, include motor drivers, and interface with my existing RC remote and receiver system. I have limited PCB design experience, so I’m relying on you to create a professional schematic, PCB layout, and manufacturing files.
Functional Requirements:
Motor Control:
- Control two independent BLDC hub motors with Hall sensors (3-phase, 24V, current rating TBD—assume 5–10A per motor for now).
- Replace the two RioRand motor drivers (model TBD, likely 30A ESCs) with integrated drivers on the PCB.
- Support Hall sensor feedback for precise speed and position control.
Microcontroller:
- Use an Arduino Nano (or equivalent ATmega328P-based design) as the processor.
- Must process input from the RC receiver and generate PWM signals for the motor drivers.
- Include a programming header (e.g., ISP or USB) for uploading firmware.
RC Interface:
- Interface with my existing RC receiver (brand will be provided upon hiring)
- Receiver takes input from an RC remote with a single thumb transducer (e.g., joystick or throttle) and outputs a PWM/PPM signal.
Power Management:
- Powered by a 24V battery LiPo
- Include a 24V to 5V step-down converter (e.g., buck converter, 3A output) to power the Arduino Nano and RC receiver.
- Add basic protection: a 5–10A fuse on the 24V input and decoupling capacitors.
Connectors:
- Power input: Screw terminal or XT60 connector for the 24V battery.
- Motor outputs: Two 6-pin headers (3 phases + 3 Hall signals) per motor.
- RC receiver: 3-pin header.
- Programming: 6-pin ISP header or USB port.
Design Constraints:
Size: Compact design, ideally no larger than 100mm x 100mm (adjust based on your recommendation, but I need it to fit in a small enclosure)
Mounting: Include 4 mounting holes for securing the board.
Environment: Indoor/outdoor use (e.g., scooter or robot), so consider durability and heat dissipation.
Current Prototype Details:
-Details will be provided upon hire
Schematic diagram (PDF and editable format, e.g., KiCad or Eagle).
PCB layout (Gerber files, drill files, and 3D render if possible).
Bill of Materials (BOM) with part numbers from DigiKey, Mouser, or similar, including costs.
Brief assembly guide (e.g., soldering tips or pin assignments for Arduino code).
Preferences:
- Use widely available, cost-effective components.
- If possible, suggest a single dual-motor driver IC to reduce complexity (e.g., DRV8302 or similar).
- Add optional status LEDs (power, motor activity) if budget allows.
Additional Notes:
I’ll provide photos or a wiring diagram of my prototype if needed—just let me know.
Budget: TBD depending on expereince, delievery time and number of revisions. Timeline: 2–4 weeks preferred.
Questions for You:
Do you have experience with BLDC motor control and Arduino integration?
Can you recommend motor drivers based on my 24V motors?
What motor specs do you need from me (e.g., current, Hall voltage)?
Functional Requirements:
Motor Control:
- Control two independent BLDC hub motors with Hall sensors (3-phase, 24V, current rating TBD—assume 5–10A per motor for now).
- Replace the two RioRand motor drivers (model TBD, likely 30A ESCs) with integrated drivers on the PCB.
- Support Hall sensor feedback for precise speed and position control.
Microcontroller:
- Use an Arduino Nano (or equivalent ATmega328P-based design) as the processor.
- Must process input from the RC receiver and generate PWM signals for the motor drivers.
- Include a programming header (e.g., ISP or USB) for uploading firmware.
RC Interface:
- Interface with my existing RC receiver (brand will be provided upon hiring)
- Receiver takes input from an RC remote with a single thumb transducer (e.g., joystick or throttle) and outputs a PWM/PPM signal.
Power Management:
- Powered by a 24V battery LiPo
- Include a 24V to 5V step-down converter (e.g., buck converter, 3A output) to power the Arduino Nano and RC receiver.
- Add basic protection: a 5–10A fuse on the 24V input and decoupling capacitors.
Connectors:
- Power input: Screw terminal or XT60 connector for the 24V battery.
- Motor outputs: Two 6-pin headers (3 phases + 3 Hall signals) per motor.
- RC receiver: 3-pin header.
- Programming: 6-pin ISP header or USB port.
Design Constraints:
Size: Compact design, ideally no larger than 100mm x 100mm (adjust based on your recommendation, but I need it to fit in a small enclosure)
Mounting: Include 4 mounting holes for securing the board.
Environment: Indoor/outdoor use (e.g., scooter or robot), so consider durability and heat dissipation.
Current Prototype Details:
-Details will be provided upon hire
Schematic diagram (PDF and editable format, e.g., KiCad or Eagle).
PCB layout (Gerber files, drill files, and 3D render if possible).
Bill of Materials (BOM) with part numbers from DigiKey, Mouser, or similar, including costs.
Brief assembly guide (e.g., soldering tips or pin assignments for Arduino code).
Preferences:
- Use widely available, cost-effective components.
- If possible, suggest a single dual-motor driver IC to reduce complexity (e.g., DRV8302 or similar).
- Add optional status LEDs (power, motor activity) if budget allows.
Additional Notes:
I’ll provide photos or a wiring diagram of my prototype if needed—just let me know.
Budget: TBD depending on expereince, delievery time and number of revisions. Timeline: 2–4 weeks preferred.
Questions for You:
Do you have experience with BLDC motor control and Arduino integration?
Can you recommend motor drivers based on my 24V motors?
What motor specs do you need from me (e.g., current, Hall voltage)?