4S→6S Series-Injection Drone Power Module — 150 A Burst

Overview

A bidirectional battery power-boost module that series-injects a 2S booster pack onto a 4S main pack for burst propulsion — sixteen paralleled power FETs, hardware-latched protection and full analytical verification.

Challenge

Design a 150A burst bidirectional power module with 16 paralleled FETs, hardware over-current latching, floating-pack cell sensing, and precharge circuit — all verified analytically before layout.

Our Approach

• 8+8 NCE60P50K FET banks: bypass + inject topology
• ACS758 current sensing into LM393 hardware SR-latch OCP
• INA149 difference amplifiers with ADS1115 ADC for floating cells
• Precharge circuit for ESC bulk-capacitor inrush limiting
• Design Verification Report gating schematic capture

Technical Highlights

• 16 paralleled TO-252 FETs on 2 oz thermal planes
• Firmware-independent hardware OCP with SR-latch
• Floating-pack instrumentation riding 16.8–25.2V above ground
• DVR-gated design flow — verification before layout

Deliverables

• ✓Design Verification Report
• ✓LCSC-sourced BOM
• ✓KiCad schematic and layout
• ✓Proof-board test plan