Tuesday, July 28, 2020

Soldering new BLDC controllers

Hi!

I recently got the PCB's of my new brushless motor controller. It is also my first 4-layer design, so I was quite excited about it. I also ordered a stencil, so that the soldering is faster and more reliable. When the PCB's finally came to me I was very happy with the result. Although after a closer look I noticed some via problems. I do not know what is the origin of this problem, but these vias seem to be really bad quality.



At the same time the soldermask is very thin and literally scrapes off when being touched by hot soldering iron. I guess this it what you get for 13$ (JLCPCB) :) Although for prototyping purposes this offer is a great deal as 13$ is super low price for a 4-layer design and I still haven't seen a similar offer anywhere else.

I found an issue with the MOSFETs after soldering them to the pads. One of these two pieces of drain connector sticking on both sides was shorting motor terminal to V+. I had to move each low side FET a bit further from the pad to get rid of this issue. It turned out that my FET library wasn't precise enough (missed these two insets), but fortunately it is an easy bug to fix in the next iteration.

Whoops
The board seems to work fine after all, although I'm still struggling with a noise problem described in more detail at: https://e2e.ti.com/support/motor-drivers/f/38/p/921831/3423441#3423441. I hope the TI guys will help me to solve it soon ;)

In the end a few photos of the assembly process and assembled board:






Next time I'm going to show the mechanical structure of the motor module, as well as some photos of machining the individual parts. A little teaser:



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