PCB Design
4-layer motor controller PCB layout
FPGA Motor Controller
High-performance BLDC motor controller with FPGA-based FOC implementation.
Key Metrics
Overview
A high-performance motor controller designed for industrial spindle applications, featuring FPGA-based Field-Oriented Control for maximum efficiency and precision.
The Challenge
An industrial automation company needed a motor controller capable of precise field-oriented control (FOC) with minimal latency for high-speed spindle applications.
Our Solution
Developed an FPGA-based FOC controller using VHDL with custom PWM generation, ADC interfaces, and real-time current loop running at 100kHz. Designed compact 4-layer PCB.
The Result
Achieved 10µs control loop latency, enabling smooth operation at 60,000 RPM. Reduced motor heating by 25% through optimized commutation.
Deep Dive
FOC Implementation
The Field-Oriented Control algorithm was implemented entirely in VHDL, running on a Lattice ECP5 FPGA. This includes Clarke and Park transforms, PI controllers, and space vector PWM generation, all executing in parallel for minimal latency.
Hardware Design
The 4-layer PCB integrates the FPGA, gate drivers, current sensing, and power stage. Special attention was paid to EMI mitigation and thermal management. High-side current sensing provides accurate feedback for the control loop.
Firmware Integration
A RISC-V soft core handles high-level control tasks and communication, while the FPGA fabric manages real-time motor control. This hybrid approach provides flexibility without compromising performance.