SpeedUp turned a 36 V direct-drive sim-racing wheel brief into an electronics architecture covering power entry, motor drive, rotor sensing, USB control, and a hardware safety path, then carried that structure into six schematic sheets and an editable KiCad project for engineering review.
The result is a concrete starting point for a DIY direct-drive steering wheel controller: an STM32G474 motor-control MCU, a DRV8353RS three-phase gate driver, an AS5047P absolute magnetic encoder interface, current sensing, a brake chopper, USB-C, and a downloadable source package. It is a first engineering draft for review, not a production-ready motor drive or a verified 15 N·m wheel base.
Project Summary
| Field | Details |
|---|---|
| Project | 36 V BLDC controller for a DIY direct-drive sim-racing steering wheel |
| Input | Natural-language prompt with motor, encoder, torque, voltage, and current targets |
| Output | Editable hierarchical KiCad schematic project |
| Key modules | POWER_ENTRY, AUX_POWER, INVERTER, CONTROL_USB, ROTOR_ENCODER, SAFETY |
| Main components | STM32G474RET6, DRV8353RSRGZR, AS5047P-ATSM, LM74502-Q1, discrete 80 V MOSFET power stage |
| Included files | KiCad project and schematic sheets, local symbol and footprint libraries, 71-line CSV BOM, design notes, README, downloadable ZIP |
| Status | First engineering draft for review; no routed PCB or firmware included |
The Prompt
The project began with a compact but unusually specific motor-control request:
Design a BLDC motor control board for a direct-drive sim racing steering wheel.encoder:Absolute magnetic encoder,pole-pair count:14,target torque:15Nm,continuous current:25-30A,peak phase current:47-50A,motor voltage:36V,encoder MPN:AS5047P
This is the kind of prompt that makes a generated project more reviewable. It gives the architecture a real load class, a position-sensing method, and measurable electrical targets instead of asking only for a generic motor controller.
What SpeedUp Generated
SpeedUp generated a structured schematic-stage project with:
- A system architecture showing six functional modules and their power, motor, USB, encoder, fault, and emergency-stop connections.
- A top-level KiCad project plus six hierarchical schematic sheets.
- A protected 36 V input, brake-resistor output, bus-voltage sensing, and staged overvoltage response.
- A three-phase inverter based on the DRV8353RS and twelve 80 V MOSFETs, with two devices in parallel for each switch position.
- An STM32G474 control and USB sheet with complementary PWM signals, phase-current inputs, bus-voltage sensing, temperature sensing, SWD, and USB-C.
- An AS5047P absolute magnetic encoder sheet with 3.3 V/5 V level translation.
- A separate hardware safety sheet for stop-loop monitoring, watchdog behavior, fault combination, and drive enable.
- A 71-line BOM representing 175 placed component quantities, plus local symbol and footprint libraries.
- A downloadable schematic-only KiCad review package.
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Project Architecture
The featured architecture image maps the controller into six reviewable blocks:
POWER_ENTRYaccepts the raw 36 V input, protects the bus, senses bus voltage, drives the external brake resistor, and reports power faults.AUX_POWERconverts the high-voltage bus into 12 V gate-drive power, 3.3 V logic power, and a 5 V encoder rail.INVERTERcontains the three half bridges, phase-current shunts, gate driver, DC-link capacitors, motor terminal, and power-stage temperature sensing.CONTROL_USBcenters on the STM32G474RET6 and connects PWM, current feedback, encoder SPI, protection commands, status signals, USB, and SWD.ROTOR_ENCODERinterfaces the AS5047P absolute magnetic encoder to the 3.3 V controller domain.SAFETYimplements a separate hardware permission path so software alone does not directly define whether the gate driver can run.
This separation matters in a high-torque wheel base. It lets an engineer review the energy path, control loop inputs, position feedback, user connection, and disable behavior as distinct engineering problems before PCB layout begins.
KiCad Schematic Output
The downloadable package contains BLDC_Steering_Wheel_Controller.kicad_pro, a top-level .kicad_sch, six module schematics, project-local symbols and footprints, a CSV BOM, a README, and design notes. The old PCB file was intentionally excluded because it did not contain the updated bypass capacitor and protection-component choices.
That boundary is important: this is an editable BLDC motor controller schematic, not a finished wheel-base PCB. Engineers can open the source in KiCad 10, trace named signals between sheets, replace parts, change thresholds, and use the hierarchy as the basis for a formal design review.
36V Power Entry, Braking, and Overvoltage Staging
Regenerative braking is a defining problem for a direct-drive steering wheel. When the driver forces the wheel against commanded torque, the motor can return energy to the DC bus. The schematic therefore includes three nominal response levels rather than asking one protection device to absorb every event:
| Function | Nominal design point | Purpose |
|---|---|---|
| Brake chopper rising threshold | Approximately 43.3 V | Sends regenerated energy into the external braking resistor before the bus climbs further |
| LM74502 input overvoltage disconnect | Approximately 45.7 V typical | Disconnects the protected bus from an excessive input condition |
| P6KE51CA minimum breakdown | 48.5 V | Clamps the remaining fast transient above normal operation |
| DC-link capacitor rating | 80 V | Keeps the capacitor voltage rating above the TVS maximum clamp specification |
These are calculated schematic targets based on nominal resistor values and data-sheet thresholds; they are not measured trip points. Comparator tolerance, TVS dynamic behavior, cable inductance, brake-resistor energy, supply behavior, and switching overshoot still need simulation and bench validation.
The external braking resistor also needs its own pulse-energy calculation. At this power level, resistance alone is not enough: the review must cover peak current, pulse duration, repetitive energy, temperature rise, wiring, connector current, and safe failure behavior.
STM32G4, DRV8353RS, and the Three-Phase Inverter
The STM32G474 is a useful architectural choice for this kind of controller because it combines complementary motor-control PWM timers, fast ADC resources, USB full-speed capability, and enough processing headroom for field-oriented control. In the generated project it receives three phase-current signals, DC-bus voltage, and power-stage temperature while driving six PWM inputs on the gate driver.
The DRV8353RS provides the three-phase gate-drive stage and three current-shunt amplifier channels. The design uses twelve 80 V N-channel MOSFETs: two devices in parallel for each high-side and low-side switch position. Three 2 mΩ shunts provide phase-current measurement paths, while four 470 µF, 80 V electrolytic capacitors support the DC link.
One small connection is especially important. DRV8353RS pin 44, VCC, is the internal regulator output for the device's integrated buck section. In this project it is bypassed to ground through IV_C17, a 470 nF capacitor; it is not tied directly to ground. RT/SD remains low so the unused buck stays disabled.
For the next hardware pass, the inverter needs more than component ratings on paper. The PCB must minimize gate loops and commutation loops, use symmetric copper for paralleled MOSFETs, provide Kelvin sensing around the shunts, control switching-node coupling, and keep worst-case drain overshoot below the 80 V MOSFET rating.
AS5047P Rotor Position and USB Force-Feedback Path
The ROTOR_ENCODER sheet uses the specified AS5047P absolute magnetic encoder. It runs from the 5 V encoder rail, with a TXU0304 translating SPI signals between the 3.3 V STM32 domain and the 5 V sensor domain. This gives the controller absolute mechanical angle data at startup rather than relying only on incremental commutation feedback.
The prompt's 14 pole-pair count belongs in firmware and motor configuration. Electrical angle is derived from mechanical angle and pole-pair count, so the control stack must verify direction, zero offset, wrap behavior, encoder latency, magnetic field strength, and angle alignment before closed-loop torque is enabled.
USB-C is present on the CONTROL_USB sheet as a USB 2.0 device connection with ESD protection. The intended product path is USB HID force feedback, but that firmware is not included in the package. A working wheel base still needs the USB descriptors, force-feedback effect handling, calibration, torque limits, fault reporting, and real-time FOC implementation.
BOM Preview
The CSV BOM contains 71 line items and 175 total placed quantities. Representative parts include:
| Part | Role in the controller |
|---|---|
| STM32G474RET6 | Motor-control MCU, ADC sampling, PWM generation, USB, safety/status coordination |
| DRV8353RSRGZR | Three-phase smart gate driver with SPI and current-shunt amplifiers |
| AS5047P-ATSM | 14-bit absolute magnetic rotor-position encoder |
| LM74502QDDFRQ1 | Reverse-polarity and overvoltage controller for the 36 V input path |
| DMTH84M1SPSQ-13 | 80 V MOSFET used in the input switch, brake chopper, and three-phase bridge |
| EEUFS1K471L | 470 µF, 80 V DC-link capacitor |
| LM5164DDAR | High-voltage buck stage for the 12 V gate-drive rail |
| AP63203WU-7 | 3.3 V synchronous buck regulator for control electronics |
The BOM is a review surface, not a purchasing release. Availability, genuine part sourcing, voltage/current derating, package identity, footprint dimensions, thermal models, and approved alternates still need to be checked.
What Still Needs Human Review
Before anyone fabricates or tests this controller, engineers should complete at least the following work:
- Confirm that the selected motor's torque constant can reach 15 N·m within the intended current limit and thermal envelope.
- Calculate continuous and transient losses for every MOSFET, shunt, connector, fuse, bus capacitor, and brake component.
- Design the PCB stack-up, high-current copper, gate loops, phase paths, DC-link loop, grounding, sensing returns, thermal vias, and heatsinking.
- Verify current-sense amplifier range, ADC timing, PWM dead time, gate resistance, switching frequency, and short-circuit response.
- Validate the 43.3 V brake, 45.7 V disconnect, and TVS behavior across tolerances and real regenerative events.
- Specify and test the external brake resistor, wiring, enclosure, touch temperature, and fault containment.
- Review the AS5047P magnet, air gap, alignment, shielding, field-strength diagnostics, angle offset, and mechanical mounting.
- Implement and tune FOC, torque limiting, encoder calibration, USB HID force feedback, watchdog handling, and safe startup/shutdown firmware.
- Verify emergency-stop behavior and define which faults require a power cycle, a manual reset, or an automatic recovery.
- Recheck all custom symbols, footprints, connector ratings, isolation assumptions, component availability, and manufacturing constraints.
- Prototype at reduced voltage and current before progressing to full 36 V bus energy or a 15 N·m mechanical load.
Related SpeedUp Projects and Guides
- Portable High-Speed Hair Dryer Circuit Design Generated from a Prompt – another three-phase motor-inverter project with power, sensing, and safety boundaries.
- AI Schematic Generator for KiCad Circuit Projects – the broader workflow for turning product requirements into structured schematic sheets and an editable KiCad handoff.
FAQ
Is this DIY direct-drive steering wheel controller production ready?
No. It is a first engineering draft for review. The package provides an architecture, editable KiCad schematics, component context, and concrete protection assumptions, but it still needs PCB design, firmware, mechanical integration, simulation, prototype testing, and full-power validation.
Does the design prove that the wheel base can deliver 15 N·m?
No. The schematic is sized around the prompt's voltage and current targets, but actual torque depends on the selected motor's torque constant, winding, current control, cooling, mechanical construction, and control tuning. The 15 N·m target must be demonstrated on the complete motor-and-controller system.
Why use an STM32G4 for a BLDC steering-wheel controller?
The STM32G4 family provides motor-control timers, fast ADC resources, USB, and processing capacity suitable for a FOC-based controller architecture. Those peripherals make it a reasonable starting point, but firmware architecture, sampling synchronization, control-loop timing, and fault handling still determine the final result.
What does the AS5047P do in this project?
The AS5047P provides absolute mechanical rotor angle over SPI. Firmware combines that measurement with the 14 pole-pair count and a calibrated electrical offset to calculate the electrical angle required by field-oriented control.
What files are included in the download?
The ZIP includes the KiCad project and top-level schematic, six hierarchical module sheets, local symbol and footprint libraries, a 71-line CSV BOM, design notes, and a README. It intentionally does not include the unsynchronized PCB file, firmware, enclosure CAD, manufacturing outputs, or test data.
Can I generate a similar motor controller from my own prompt?
Yes. Include the nominal and maximum bus voltage, motor pole pairs, torque constant or motor model, continuous and peak phase current, encoder model and supply, brake-resistor strategy, USB/CAN requirements, connector limits, cooling assumptions, safety behavior, and required output format. More explicit constraints make the first schematic draft easier to review.
Download the 36V Direct-Drive Steering Wheel KiCad Project
Use this ZIP as a schematic-stage review starting point. It includes the editable project, six subsystem sheets, local libraries, BOM, design notes, and README; add the PCB layout, FOC and USB HID firmware, motor and brake-resistor selection, enclosure/mechanical files, prototype measurements, safety testing, and manufacturing documentation before treating it as a complete engineering handoff.
Ready to turn your own motor-control requirements into reviewable engineering artifacts?
Create a free account and start a new SpeedUp project with your voltage, current, motor, encoder, interface, and safety constraints.























































