I've been in the Nerf PCB game since at least 2016 developing the BritNerf MOSFET board as well as a board for the Stampede when I was with Blastersmiths. Back before the plague, I published a bunch of free to use board files but with real life and the pandemic, progress has stalled.
I've been working on them on and off again since April of this year on a range of boards. With the development of dual stage flywheel systems, I found wiring everything close in on the back of a printed cage and getting it all correct was a very frustrating exercise. To that end, I created a dual stage MOSFET flywheel board compatible with the Gryphon and Tempus when used with Daybreak flywheels.
This is the progress of the dual stage board from first concept through to the latest version at the time of writing (v0.5). It started originally as a single FET version but I quickly realised the utility of two MOSFETs, one for each pair of motors. I'm doing a lot of background work on different motor combinations for dual stage and some of the big 132 and 180 can motors draw a lot of current. By having multiple FETs, you're not stressing a single component past it's limit and it probably will work out cheaper to install. The latest version can be powered from either end after I discovered the need for that feature in the Tempus.
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v0.4 testing rig, note the lack of forward contacts in this version
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Testing these systems is fairly easy, you just chuck some motors into a printed cage and drop the board on the back back. Solder in a switch and an XT 60 plug and you're good to go. The obvious draw back here is the need for all the cans to be the same length. That certainly isn't the case in my current generation of Tempus build so there needs to be a solution for that.
Enter my MOSFET motor span board. The most recent version also has expansion connectors at the front to allow for daisy chaining boards forward. It is then possible to hook up a simple motor span board (see below) for dual stage motor systems with different can sizes. It might also be possible to link the trigger pins of two boards together and use the expansion slots at the front to link two MOSFET boards but I've not tried that yet.
The problem with extant motor MOSFET boards is they use smaller packages than really are ideal. Nerf motors draw a lot of current and even if the silicon in your MOSFET can handle theoretically high currents, the package it's in might not. For example, my go to N-channel FET is a IRLB3034 which, on paper, has a maximum current of 343A. The problem is that the TO-220 package it's mounted in is rated to 195A. That's still a lot of current but it can handle that because it has a giant heat sinking tab in addition to a much physically larger package for dumping heat out of. Smaller packages don't have that luxury and are prone to failure. Yes, it might look pretty to have a small SMT package with neat flashing LEDs but through hole technology means you get a durable, rugged board that won't fail. The BritNerf MOSFET board has been in circulation for years and is a reliable, dependable platform. I guess my HvZ heritage shows here: stuff cannot fail because the cost of a single failure is absolute. But that's a story for another discussion...
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Itty bitty FTW motor board
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And for all those FTW fans out there, these boards are a simpler way to install motors into an FTW build. I have a Grass snake powered by Krakens that are going to get one of these because it's a mess in there and it needs tidying!
Not everything goes to plan, however. There's an inconsistent bug in this one particular board and I need to properly hunt it down. Even though it uses the same library component as everything else, the Gerber files don't always produce a slot and often create a hole instead. This is the more traditional motor span board with an optional XT60 connector and input/output solder pads for daisy chaining multiple stages or just having powered supplied to one end of the board rather than the other. Oh and it has a diode mounting position because some folks have requested the ability to have an 'after-glow' effect that uses the back-EMF of the motors as they spin down. So that's neat...
I've run out of FETs and diodes so I'll have to wait for those to arrive before I can test those boards. In the mean time, I'll get the FTW board tested and probably strip out the front of the Tempus ahead of mounting those boards. In particular, I'm going to go back to the circuit diagram and see if I can daisy chain those single stage FET span boards.
Once all these files are ready, I will publish working Gerber files as well as the EAGLE files on my GitHub on a Creative Commons 0 or Public Domain license for folks to do whatever they want with them for free. I've already got a distributor ready to go for these and I think a few more are coming on board. However, if folks feel they want to order from JLC PCB or another fab house directly then they can just feed the Gerber files without need to pay a license fee to me to get their boards made and posted direct to them. Open source is best source.