Design implementation of high performance DC motor drive

DC Motors are quite common in large number of applications ranging from small tools to large industrial machines. Efficiency of such machines depends on proper operation of these motors to a much larger extent. Moreover, heavy duty applications require high current demanding motors. High current also leads to addition of other noise issues. Here we put forward a high performance motor drive circuit tested for heavy duty applications demanding DC currents up to 200 A where switching of motors was done at 32KHz to remove the switching noise. The usage of dynamic switching frequency is represented here which enables us to achieve higher duty cycles up to 99.6% which is not possible with static switching frequencies in absence of charge pump. The drive circuit having dimensions 5cm×5cm has been tested for extreme load and noise conditions and several protection measures implemented in this circuit are described here.