I was wondering if I could upgrade my current bldc motor controller (three phase motor)(*) to a higher wattage/output power by doing the following modifications:
- Replace mosfets with higher power rates ones (higher amps, lower Rds(on), equal or higher voltage rating )
- replace shunt with much thicker one (and recalibrate)
- Improve cooling of mosfets (bigger heatsink, perhaps some activate cooling with eg a fan)
- use thicker wires/leads on the pcb to account for the higher amperage
Would these mods enable me to increase the power output of the controller by for example 3 times (if I choose mosfets that can handle the required amount of amps/ can handle the voltage and potential voltage spikes(Note: I will keep the battery voltage the exact same as before the mod, I am currently using 84volt (20s)))?
Would I need to make any other mods in order for this to work (other than the ones I've mentioned above in the list? For example would there be other components I would need to replace because the original components will likely not be able to handle the increased amps?
Would there theoretically be a limit to how much I can increase the power output using these modifications (for example would it be doable to increase the power output 10 fold if I choose the right components? I know this won't be very practical since I'll need much more cooling and much thicker wires but it's more of a theoretical question) and what would be the issue causing this limit ? (ignoring possible issues like not being able to fit enough mosfets in the controller, the controller becoming too heavy etc.)
*info about the controller/setup: It's a 72v-84v 1000-1200w (three phase) BLDC motor controller (rotor position determined using 3 hall sensors). The motor is an outrunner with permanent magnets in the rotor. Currently has a shunt mod increasing the power to perhaps 1400watt. The battery is 10p20s.
If anything is unclear/incomplete about my explanation please let me know and I'll try to clarify.
Thank you very much!