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I'm making a new board that's going to be primarily surface mount. I found out that there are places that will populate it for like $100 per board in quantity 10 down to $17 per board in quantity 500. And surface mount parts are cheaper.
The new board is going to have 8 pwm channels. 4 high and 4 low. You can run the controller as 3 phase controller with a boost stage on the front end, a DC controller that's rated for like 1600-2000 amps??? (if I can get all 4 IGBTs to current share well), or a regular old 3 phase controller without the boost stage, or a high powered solar MPPT tracker/charger, or a grid tie inverter, or non-grid-tie inverter for a house (3 phase or single phase). Some of those need either 1 or 3 inductors though. I want to figure out how to wind my own very high current inductors. The inductor I have is made of laminated steel sheets, and I think a roll of copper sheet wrapped around it. That's rated for 200amp. I would need a 400amp inductor though. That way a 72v or 144v car could be boosted up to 288v or whatever, and you could run the millions of cheap 20HP 230VAC motors on ebay. The dimensions will probably be around 14" x 10" x 5".
I'm also going to try doing a water cooled version. I had never heard of those ball nose mill bits, but eclipse told me about them, and so I'm going to get a base plate later (in the future someday when I save up enough money) and mill those round channels, and epoxy some 1/2" tubing inside the channels under the 4 600v (or 1200v) 600amp IGBTs.
The microcontroller is the dsPIC33ep512MU810 which is good to 70MHz, and can do 12 pwms, and 8 simultaneous A/D conversions. It has 100 pins, so I'm going to include some optional future use inputs and outputs.
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