Very interesting what you did with the chits with Black Powder. We did something similar wth our "What if...?" War of 1812 games we just played (see the thread in this section of LAF). We assigned playing cards to each Brigade (Ace, king, Queen, etc.), and the turn sequence went like this:
A. Attach Army Commanders to a brigade, if desired.
B. Draw cards for each Brigade's orders/movement sequence.
C. Move Army commanders who didn't move in step A.
D. Reshuffle, and draw cards for each Brigade's firing sequence.
E. Remove "disorder" makers, save those in HtH combat.
F. Fight HtH combats.
We like it, as it appears you liked using your chits. It did add some more "Fog of war" elements into the game, and I think we'll be using it in our future Black Powder games...