135V / 200A ESC Krakatoa

As the title says.

Completely untested. Pure paper exercise for another larger project.

This is for educational purposes only.

I will release the schematics later.

Cheers,
Valentine

PS Schematics link below

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You are spitting out designs in an incredible frequency and they all look nice as well, despite their functionality!

Impressive! looks great

That’s a beast! I take it the name implies how much magic smoke is stored inside? :laughing:
At that power level, what would be the pros and cons of soldering thick wires along the board for the conducting paths, versus using the super wide PCB traces?

The bare pcb 5mm ground copper trace is for extra solder or wire to carry the current. There is another VIN bare copper on the back. Then you need screw terminals for the wires. And yes, if you smoke this, it will look like a volcano. :boom: :boom: :boom:

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Posted the project link above in the original post. The BOM is all in stock.

Five board batch costs 115, or about $23 per board before shipping / taxes / import duties

Old Tom Bombadil is a merry fellow,
Bright blue his jacket is, and his boots are yellow.
None has ever caught him yet, for Tom, he is the master:
His songs are stronger songs, and his feet are faster.

I see people cloning the project, thank you! Hope it works out for you.

Three things.

This is a table-top exercise. It works in your head only, may not work IRL.

Secondly, I keep adjusting the design based on whatever my needs are, and tomorrow the design may be slightly different.

Lastly, this is a REALLY high powered board. At the high end (if the design really works), manufactured with correct cooling and 3oz copper and bar traces it could produce 27kW continuous output. As a comparison, a medium sized golf cart motor is 5kW and a high end golf cart motor is 10kW. You will most probably injure yourself, or worse, trying to test this at home.

Don’t do this in your garage with bare hands and no serious protective gear and equipment. Really.

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I’m back from vacation. And coming back with a bang!

Fabbed the Krakatoa board, ready to test. 4 layers of 2oz copper. Banana for comparison. Also put the Mosquito board next to it.

Reminds me a little bit of the Giant suit of armor in the Tower of London exhibit:

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Wow that’s some high power!

I can only imagine what kind of power supply / battery configuration would be needed to stress test such a board. My fingers tingle just thinking about it…

I have high current lead acid batteries and high load power resistors.

Well, this is the setup. Good news that it works. Bad news is that it blew up my power supply. Next step is to test with a 1000A lead acid battery. Pencil for the wire thickness comparison. In a few hours, if you hear a loud cataclysmic explosion, that’s the Krakatoa board blowing up.

Oh yeah and buy a new PS…

The test was successful. I discovered a number of small problems and had to rework the design to make it user friendly. The Infineon driver is not exactly what you call user friendly so I had to add some friendliness. Downside is it made it more expensive and complex.

Modified driver is in the link above on that thread. Below is just a screengrab of the 3d render.

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For those of you who noticed I changed the design again. At very high drain voltage and current the IR cannot deliver the gate current required to open the gates and overheats. The mosfets I chose are made of very cheap chinesium and have extremely high gate charge. Plus I proved the IR works and moving on to improve my designs. This is not a real production pcb, this board is a test and experimentation setup for me. Who knows, tomorrow I may reject the dgd drivers, too, and rework it again with yet another driver.

Omnia mutantur, nos et mutamur in illis;
Illa vices quasdam res habet, illa vices;
Quo modo? Fit semper tempore melior homo.

Cheers,
Valentine