At part of the autonomous combat robot project I design and built a custom brushed motor controller that was used in the locomotion system of the robot. The design is intended to have a continuous current handling of 200A with a wide input range of 9V to 72V. The design feature support for RS232, RS485, USB, PWM, and Analog control input in both open-loop and close-loop operating.
This design has been proven to work very well. During the duration of the competition, this controller operated without failure and even exceeded expectations. During the third round of the competition, one of the locomotion motors was over-worked and destroyed while the motor controller was still fully functional even after this motor failure. This stands out because the motors used were Amplfow A28-150s which feature a stall current of 285 Amps. This implies that the motor controller was able to sustain current at or above this motor rating long enough to destroy the motor while not destroying the controller itself.
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