I'm trying to sum up all the ingredients for motor control power electronics:
High Inrush current circuit – The short circuit and starting current rating of the DC motor is 7 times higher than the steady state operating state.
Current Sensing circuit - Active current control/feedback is needed as torque (~current) is the only right control parameter.
Current limiting circuit
Protection circuit from transient/spike from power supply
Overheating protection/Thermal shutdown
Overvoltage and undervoltage shutdown
Better heat dissipation IC & Board layout
Back EMF protection circuit
Reverse current protection – Charge builds up can cause damage back to the circuit by a reverse current surge when switch is closed. The electrical energy stored in the windings that have inductance in the DC motor. Flyback diode is a solution that dissipate the stored charge.
PWM Interface - Use a PWM, measure current, feedback the PWM with a PI controller from the current measurement
Did miss anything ? I'm doing a re-design from scratch.
load stall torque (650in-lb) and 30A peak current. Voltage 28Volts