WE currently have a digital brushless motor where our control PCB is too large based upon the knowledge we possess, we need a partner , and or ideas list that can generate a reduction in size or a complete change in the design. If we can reduce our size 25% , with minimal cost increase and potentially increase heat management then we have success. Without it we suck.
Thus we need experienced PCB designers who know simple techniques to reduce size, reduce our heat problem and advance us without cost increase
If successful new projects in future potentially then become possible .
The PCB is currently surface mounted and has 5 Mosfets. Has a large aluminium plate as heat sink, ( changing to copper is not an option due to cost. Product has to deal with a high level of current from a 4AMP Hour Lithium Battery at 35 amps operational area. Our current issue is a / How can we reduce the size of the heat sink and reduce the size of the PCB in total, improve performance and provide alternative board layouts and constructions. We do currently have a fan installed to reduce teh heat , however size is an issue and industry doenst normally use a fan.
Also updated information for existing PCB size
Thanks for the messages. Its important to note that the overall size is still dictated by the heat sink as shown in the images . Thus cooling the board due to high current is priority one. Yes the PCB could reduce but the overall issue is heat first due to our flawed design.
Note 4 layers is not possible due to excessive wiring
we cannot relay the 2 layers are still required due to complexities
serious methods and real explanations of how and what are required
Yes correct we will select on quality of work not price alone
Yes over next 2 -3 years if we get this correct and product succeeds we will have around 40 projects
Suppliers of the PCB can be nominated and quotes can be reviewed yes current vendor isn't 100% contracted long term yet
Heat sink ideas should be listed please
copper is alternative but is expensive
Other materials we don't know cost
Existing Mosfets used in the design are now attached we currently use 6
Please see existing BOM of the PCB also interested in any type of cost reductions everyone
Hello everyone who has posted offers . We have some leading candidates. Those who will get this job and probably more are those that have demonstrated knowledge and commitment to finding another way . Thank you so much for the commitment. This has been very helpful, successful and will aid us get our product out successfully hopefully on cost on time and on budget. Any further data you wish to post please do it in next 12 hours . Thanks everyone again . And reminder just because you might not get this one make sure you communicate on the next one also which will happen.