One thing we learnt ages ago is that the control stage is relatively easy *in theory*, it's the power stage that's a headache especially when something goes wrong (as you say) and you pop 4 fet packs worth £40 each! Our friend Si Harrison (King B) is now using 400A IGBT half-bridge packs the size of a playing card- elegant but extremely expensive. Si is the real genius behind our controllers. He works for a company supplying and maintaining UPS systems and gets to rob secondhand silicon from old systems being taken off line.
Draven has two 1200W S2 motors running at 24v - at stall (which in RW happens all too often), they'll draw 250A. We've accidentally shorted the supply cables (120A nom copper braid) and it popped like a fuse in less than a second. Nasty.
BTW forgot to mention, our controllers weigh about 400g each - in RW, it's all about weight too!
That is true.
I program the PLC logic controllers that control large plant drives/ automation for industry/ chemical plant/ water works/ nuclear fuel etc. Now these 2000 Amp motors are really big to drive pumps that are twice as big as me to supply mega-litres per minute. Top heavy stuff. They need thier own cable 4 inch thick. I'd hate to touch one of these bare cables and fry myself. Mind you getting the code wrong makes it expensive to put right !
Makes the alternator on the delorean look even more puny !
Nick.