MOSFET Controllers
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Advanced Wargame Systems
Professional modifications and leading-edge electronics for AEGs. Recognized for designing the very first AEG active braking circuit to the renowned Scorpion "hi-realism" MOSFET controllers, the apex of AEG control circuit innovation!
Announcement:
[5/1/10] After being away for over half a year, we are finally back in business as of May 2010! Tons of projects to get under way!
[6/8/10] The Sentry/Pulse/Scorpion are completely SOLD OUT! New batch expected to arrive between June 20-30.
[6/19/10] Parts for the new X500 have been shipped to the assembly factory, estimate 12 business days until completion.
[6/20/10] Amperage-meter project finalized and uploaded, production pending. Now moving on to the ammo counter add-on project.
[7/13/10] Apologies for the lack of updates! The boards DID arrive on time, we just have been testing and coding it over the past few days.
COMING SOON: Sentry / Pulse / Scorpion X500
 X500 series controller PCB layout |
 X500 series controller schematic (click to enlarge) |
Max voltage up to 22V
We have managed to successfully increase the voltage rating from the previous standard of 16V to a new higher rating of 22V! This is made possible by the new 5-watt voltage regulator and a redesign of the MOSFET gate control system on the new controller. This is the highest attainable "AEG-safe" voltage rating for computerized MOSFET controllers.
Idle current down to 40uA NEW RECORD
Although the 70uA sleep current of the X445 controller was already extremely low, we've managed to do it again by lowering the sleep current even futher to just 40uA! Newer energy-saving components and a more efficient power handling code on the microcontroller means your battery can remain connected for several MORE years (although the battery likely would've self-discharged by then). Was and now still is the lowest idle current of any computerized MOSFET controller.
Length & height decreased by ~20% NEW RECORD
 Size comparison, X500 vs X440 vs AA-battery |
With technology always improving, we can start to make things much smaller without trading off any crucial ratings, which is exactly what we did with the new X500 controller. Some of the parts are nearly as small as a grain of sand so assembly by human hands becomes impossible at this point. Everything is assembled by precision chip-shooter machines so you never have to worry about human error during assembly. And of course every component is carefully selected to be well within the required wattage rating, therefore any larger higher-wattage variant would simply be a waste of precious PCB real estate. Below are the changes that played the biggest role in decreasing the controller's overall size.
Four SUPER-SO8 power MOSFETs
 New SUPER-SO8 casing vs old D2PAK casing |
While attempting to reduce the board size, we realized something: the D2PAK casing actually consists of 80% useless ceramic! Surely there must be a more efficient design that does away with most of the unnecessary portions. After researching, we found the perfect one: the SUPER-SO8 casing. The catch is a single SUPER-SO8 can only handle 100A whereas a single D2PAK can handle 195A (limited by the casing), but this is compensated by simply replacing each D2PAK with 2 SUPER-SO8s. Now we get a higher current rating of 200A while using less space! There is also less resistance since the casing completely "hugs" the PCB instead of using leads like the D2PAK.
 Casing size comparison, SUPER-SO8 (left) vs D2PAK (right) and D2PAK internals (center) Only the conductive cross-section in the D2PAK matters, which happens to have the same area as 2 SUPER-SO8s |
The power rating of the 2 SUPER-SO8 combined is 250W, a decrease from the 375W of the D2PAK, but wait! Remember what we said about wasted space when using components rated higher than needed? The same applies here, we simply do not need 375W. To get an idea of just how massive 250W already is:
Power equation: P = R*(I^2)
Given values: R = 0.001 ohm, P = 250W
Current: I = sqrt(250W/0.001ohm) = 500 AMPS!
There will NEVER be an AEG that draws even close to that much current under normal operation, let alone the rated 200A which will already melt your wires (unless using giant 1AWG wires)! Other MOSFET controllers may use ultra high current and watt ratings as a selling point, but we're drawing the line at 200A for the sake of size reduction, which is actually something that WILL come in handy and thus truly innovative.
And just to be sure (since we DID have doubts about the tiny size too), we tested the MOSFETs on a high-power setup with an M150 spring, Magnum motor, and 11.1V lipoly, yet the MOSFETs remained cool to the touch! We'll probably never get over how something so tiny can carry so much current!
Advanced 4 layer PCB design
 The way MOSFET controllers should be designed for maximum reliability |
Once again for the purpose of size reduction, we have decided to start using a single 4-layer PCB, something no MOSFET controller has attempted before. Layer 2 is a dedicated ground plane that completely shields the control circuit from any noise or EMI (electromagnetic interference) from the power layer, providing maximum circuit stability during high current flow. Layer 3 is a duplicate of the bottom layer, but with 4oz copper thickness to carry the majority of the motor current with ease. Combined with the bottom layer, the total thickness is 5.5oz, allowing the PCB to handle more of the current the MOSFET is rated for. This is the largest copper thickness attempted on any MOSFET controller and we're planning to go with 7.5oz in the future! (Most 2 layer PCBs are limited to just 1.5oz due to trace size restrictions)
Comm port now accepts inputs
On the previous X445, the communication port only outputted signals to notify add-on circuits of various events. But starting with the X500, the communication port will also output and read inputs all on a single wire! It will continue its job of sending output signals as usual, but between signals it will frequently switch to input mode and check to see if a signal is being sent to it. The first input signal to be added will be "stop firing", which will allow add-on circuits to remotely turn off the MOSFETs.
Also added output signals for when the trigger is pressed and released. Have no idea why we forgot to add that for the X445..
Sentry X500 will have burst fire!
Yes you read that correctly, our lowest-tier Sentry controller will have burst fire like the Pulse and Scorpion controllers! BUT the Sentry will be using the less reliable form of TIME-based burst fire, which is currently used on every other burst MOSFET controller out there. Time-based "guessing" of the gear cycles will never be as perfect as the sensor-based burst fire of the Pulse and Scorpion, but at least you won't need to install any switches into the gearbox!
You simply install the MOSFET, fire 2 shots on semi, turn on burst mode using the control panel, and the controller will use the recorded time of the previous shot cycle as the basis for burst fire. And yes 2-burst and DMR will also be available on the Sentry's control panel, via a simple flick of the switch.
This timer-based burst fire will also be hidden on the Pulse and Scorpion. If you somehow break the wiring to the gear switch needed by the Pulse and Scorpion, you can set them to "Sentry Emulation" mode via the control panel, forcing the sensor-based burst to downgrade to timer-based so you can continue using burst fire without the gear switch.
This will probably be the world's most affordable burst fire controller at just $50, which is what many stores are charging for just a basic non-braking MOSFET unit!
Minor design improvements
- The DIP control panel will have each switch pair labeled for easier identification.
- The controller-side wire connector will have each socket pair labeled for easier indentification.
- All wire pairs will be completely heatshrinked to reduce wire clutter.
- June 19th, 2010
Updated: Pulse / Scorpion X445
Adaptive RoF Control
The Pulse & Scorpion have been updated with "adaptive" RoF control which allows reducing an AEG's RoF to exactly 10, 15, or 20 rnd/sec regardless of the internal setup!
Unlike the previous version that uses PWM to reduce the speed of the entire cycle, adaptive RoF control runs every cycle at maximum speed and pauses between each cycle. Compared to PWM, this method produces no switching loss, does not subject the gears to prolonged stress, and maintains first-shot trigger response time. Basically, adaptive RoF control experiences none of the side-effects normally associated with PWM speed control!
It also has the added benefit of making an AEG sound very realistic when enabling adaptive RoF control on a hi-speed setup. The higher the AEG's base RoF, the shorter the duration of the gear noise per shot before pausing (whereas PWM prolongs the gear noise). An ideal realism AEG should have NO gear noise at all, so less gear noise is always better!
This is currently the most advanced, efficient, and realistic form of AEG RoF control, available only on the Pulse & Scorpion X445 controllers!
Easier Installation!
Starting with the Pulse / Scorpion X445, all switches will come PRE-SOLDERED to their respective wiring, reducing the installation steps by nearly 50%! The Pulse will simply require soldering the trigger wires and epoxying a tiny switch to the gearbox, and you're done! The Scorpion is nearly as easy, having just one more switch to epoxy then the Pulse (unless ordering without pre-modded hopup).
To see just how much [less] work is involved, take a look at the updated manual. Don't worry, its only 4 pages! Even though most of the work will already be done for you, there is NO price increase!
Metal Hopup Modding
Metal/steel hopups are now accepted for the Scorpion hopup sensor mod and at no additional cost! Just send yours in and we'll the drilling for you!
- June 1st, 2010
Released: Sentry / Pulse / Scorpion X440
The long awaited X440 series AEG MOSFET controllers are now available for ordering!
 X440 series controller PCB layout |
Ultra-low Voltage Requirement w/ Supercapacitor "backup"
Fried MOSFET units have long been a common occurance which tends to happen sooner or later, being most prevalent when used with the new generation Magnum/Turbo motors. Most people are quick to point out overcurrent as the main cause, but that is usually not the case! The true cause lies within the in-line voltage drop when the motor operates under heavy load. The heavier the load, the greater the in-line voltage drop (eg: house lights flickering when AC powers up). Once the load is removed, the line voltage jumps back up to the true remaining voltage level.
 Line voltage during motor operation |
Here we see the line voltage levels before, during, and after a lengthy auto fire. Notice the high power AEG causes a greater voltage dip with a more rapid voltage decline compared to the stock AEG, mainly due to the heavier load the motor has to push.
Since all logic-level power MOSFETs require a minimum gate drive voltage of 4V, too large of a voltage drop will underdrive the MOSFET, causing it to become resistive and rapidly overheat. In the graph, the point where the high power AEG's line voltage drops below the MOSFET required 4V threshold is the point where basic MOSFET units burnout/fry. The same eventually happens to the stock AEG if fired long enough for the same condition to occur.
In order to prevent underdriving the MOSFET, our previous X3-- series controllers had a cutoff threshold at 5V (minimum voltage for the microcontroller). Although this prevents MOSFET burnouts, it still posed a problem with high-power AEGs easily activating the 5V cutoff due to the larger in-line voltage drop. But at least it was better option than risking a MOSFET burnout.
 New innovative voltage regulation design |
But this changes with the new X440 series controllers! We have created a unique regulation design that uses a linear regulator to convert any battery voltage from 2-18V to 2.5V, just the right voltage to store a large supply of energy in a 220,000uF supercapacitor. The stored energy in the supercapacitor is then sent to a boost regulator which steps-up the 2.5V to 5V. The supercap, by itself, can supply the boost regulator for several seconds, allowing a perfectly steady 5V supply to the microcontroller, even if the in-line voltage spikes BELOW 2.5V! This design is basically the first "uninterruptible power supply" for AEG MOSFETs and may be the end of all future MOSFET burnouts!
Improved 8-DIP Control Panel
The "control panel" that was present on the previous X3-- series controllers consisted of a 3-DIP switch and a side-adjusted potentiometer. The 3-DIP limited the controller's on/off options to just three: burst fire, lipoly protection, and realism mode, whereas the potentiometer controlled the motor speed. At the time of design, it seemed a 3-DIP switch was the biggest that be could fit on the v3 controller without having to increase the width.
But we've now stumbled across an even better solution: the CHP-081TA. A half-pitch 8-DIP switch, so small that all 8 switches managed to fit on the controller AND is half the height of the previous 3-DIP switch. Below is the older X3-- controller's 3-DIP setup compared with the new X440 controller's 8-DIP setup:
| Previous X3-- controller | |
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Switches 1 & 2 - Realism Mode
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Switches 3 & 4 - Burst Fire
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Switches 5 & 6 - Lipoly Mode
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Switches 7 & 8 - Speed Control
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Massive Current Rating
The new controller version will utilize a powerful new MOSFET: the IRLS3034. This is IRF's newest high-power logic-level MOSFET, with a current rating of 195A (at just 5V gate voltage) with a peak current of 1375A!
Simpler Error Indication
The error indication LED is now a duo-color LED (red & green). Combining the red and green gives yellow, giving a total of 3 colors to use. Green indicates startup success (when battery is connected), yellow indicates wiring-error or overtemperature, and red for low voltage cutoff or short-circuit. The LED is located just below the microcontroller near the center of the PCB.
- November 19th, 2009