Any suggestions on this would be greatly appreciated. I have been using the MC33035 BLDC controller which drives an HIP4086. The motor has 3 hall sensors. Output current less than 2 amps peak typical, rare cases of 3.
The voltages are 27VDC. My board has a .1 sense resistor on the low side which allows current sensing back into the MC33035 through a trim pot for limiting. I have followed very closely the circuit provided with the MC33035 and HIP 4086, and the combination was done on the driver module that the supplier for my motor provides as an option. I needed a few more options on the driver so I could not use their off the shelf module. The input to the board is 0 - 3v3 PWM from the Propeller into an H11F1SM-ND whereas the output of the H11F1 controls a dividing circuit so that the output becomes 0 - 6.35VDC into the MC33035 for speed control.
My version has a failure rate, where a mosfet( IRF540) will short on some amount of boards. Maybe 20 - 25 in 250 boards. It is a real pain sending out replacement boards and having end users have to replace the board. I want to keep the same functionality with the output of the Prop controlling speed using the same PWM output. The techs at both companies have looked at the schematics and we can't find a reason for the failures. I really need to start over on the motor driver.