Brushless DC Motor Controller
Custom high-power motor controller for three-phase brushless DC motors
Overview
I designed a custom brushless DC motor controller for controlling high-power three-phase motors. The project combines power electronics, embedded control, sensing, communication, and PCB design into a complete motor-control platform.
The controller uses a three-phase inverter driven by MOSFET gate drivers, with an STM32 microcontroller responsible for motor-control algorithms, PWM generation, current measurement, and system monitoring.
Power Stage
The power stage consists of a three-phase MOSFET inverter designed to drive a high-current BLDC motor from the battery supply.
Gate-driver circuitry provides independent control of the high-side and low-side MOSFETs while current-sensing circuitry provides feedback to the microcontroller for closed-loop motor control.
PCB Design
I designed the PCB around the requirements of the power stage, microcontroller, current sensing, voltage regulation, and communication interfaces.
Special attention was given to high-current paths, gate-drive routing, grounding, power distribution, and separation between the switching power stage and low-voltage control electronics.
Embedded Control
The STM32 firmware generates PWM signals for the inverter, acquires current and voltage measurements, and manages the controller's operating state.
The architecture was designed around eventually implementing closed-loop field-oriented control while providing interfaces for configuration, telemetry, and debugging.
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