Another month. Wow.
So how do you build a truly competition grade high current speed controller? Answer: Carefully :-). I've got what I believe is the final layout of my speed controller and its off to the PCB house for a prototype run. Things that I've learned are: 2 oz copper means holes get smaller. 4 layer boards have weird layout requirements The strangest was theiving.
Theiving is a technique where small squares of copper are added to a layer (away from other features) to create a better copper/substrate ratio so that plating is more even. Strange! The PCB house guys added it for me so I didn't have to worry about it but it was news to me.
The second thing I've learned is that FETs are cheaper than copper. My original design used 16 FETs (4 per leg) and that meant dissipating 240 watts of heat when fully loaded. Not impossible, but it was a challenge. So taking a cue from Victor and others, I ran the thermal analysis with 32 FETs, dissipation drops to 60 watts. A whole lot better. Now I need only a fan and my water cooling system is surplus. (not that I looked forward to having a radiator hose blow in my battlebot!)
Building them up next Friday, and then its off to melt steel (crowbars make a great dummy load for a 200Amp speed controller :-)