Changes for page Power controller
Last modified by Mathias Larsen on 2026/09/24 21:21
To version 38.1
edited by Mathias Larsen
on 2026/09/23 18:47
on 2026/09/23 18:47
Change comment:
There is no comment for this version
Summary
-
Page properties (1 modified, 0 added, 0 removed)
Details
- Page properties
-
- Content
-
... ... @@ -1,6 +1,4 @@ 1 1 {{wikibox title="Power controller" image="https://wiki.alignracing.no/bin/download/Electrical/Power%20controller/WebHome/Screenshot%202026-09-22%20211347.png?rev=1.1" caption="3D model of the Power controller from Altium Designer" width="30" labelWidth="50"}} 2 -Linjene må se nøyaktig slik ut i Content-feltet: 3 - 4 4 Supply voltage=12–24 V DC 5 5 Fused circuits=9 (5 × 24 V outputs, fan outputs, digital outputs, 12 V circuit, internal electronics) 6 6 24 V outputs=5 ... ... @@ -8,36 +8,35 @@ 8 8 12 V outputs=2 9 9 Digital outputs (shared fuse)=2 × 12 V switched (5 A), 2 × 24 V switched (330 mA), 2 × PWM 10 10 Communication interface=CAN FD 11 -Maximum data rate=1 MbpsD 12 -|Maximum data rate|1 Mbps 9 +Maximum data rate=1 Mbps 13 13 {{/wikibox}} 14 14 15 -== Table sof contents ==12 +== Table of contents == 16 16 17 17 ---- 18 18 19 19 {{toc/}} 20 20 18 + 19 + 21 21 == Pinout == 22 22 23 23 === Connector pinout === 24 24 25 -|=(% style="width: 281px;" %)Pin|=(% style="width: 135px;" %) comment|=(% style="width: 132px;" %)24 +|=(% style="width: 281px;" %)Pin|=(% style="width: 135px;" %)Signal|=(% style="width: 157px;" %)Comment|=(% style="width: 132px;" %) 26 26 |(% style="width:281px" %)1|(% style="width:135px" %)CANH|(% style="width:157px" %) |(% style="width:132px" %) 27 27 |(% style="width:281px" %)2|(% style="width:135px" %)CANL|(% style="width:157px" %) |(% style="width:132px" %) 28 28 |(% style="width:281px" %)3|(% style="width:135px" %)FAN 1 PWM|(% style="width:157px" %) |(% style="width:132px" %) 29 29 |(% style="width:281px" %)4|(% style="width:135px" %)FAN 2 PWM|(% style="width:157px" %) |(% style="width:132px" %) 30 -|(% style="width:281px" %)5|(% style="width:135px" %)GND|(% style="width:157px" %) Blobwith tin|(% style="width:132px" %)31 -|(% style="width:281px" %)6|(% style="width:135px" %)GND|(% style="width:157px" %) Blobwith tin|(% style="width:132px" %)32 -|(% style="width:281px" %)7|(% style="width:135px" %)GND|(% style="width:157px" %) Blobwith tin|(% style="width:132px" %)33 -|(% style="width:281px" %)8|(% style="width:135px" %)GND|(% style="width:157px" %) Blobwith tin|(% style="width:132px" %)29 +|(% style="width:281px" %)5|(% style="width:135px" %)GND|(% style="width:157px" %)Solder blob|(% style="width:132px" %) 30 +|(% style="width:281px" %)6|(% style="width:135px" %)GND|(% style="width:157px" %)Solder blob|(% style="width:132px" %) 31 +|(% style="width:281px" %)7|(% style="width:135px" %)GND|(% style="width:157px" %)Solder blob|(% style="width:132px" %) 32 +|(% style="width:281px" %)8|(% style="width:135px" %)GND|(% style="width:157px" %)Solder blob|(% style="width:132px" %) 34 34 |(% style="width:281px" %)9|(% style="width:135px" %)Accumulator|(% style="width:157px" %) |(% style="width:132px" %) 35 35 |(% style="width:281px" %)10|(% style="width:135px" %)Front|(% style="width:157px" %) |(% style="width:132px" %) 36 36 |(% style="width:281px" %)11|(% style="width:135px" %)Power fan|(% style="width:157px" %) |(% style="width:132px" %) 37 37 |(% style="width:281px" %)12|(% style="width:135px" %)Power fan|(% style="width:157px" %) |(% style="width:132px" %) 38 -|(% style="width:281px" %)((( 39 -13 40 -)))|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %) 37 +|(% style="width:281px" %)13|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %) 41 41 |(% style="width:281px" %)14|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %) 42 42 |(% style="width:281px" %)15|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %) 43 43 |(% style="width:281px" %)16|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %) ... ... @@ -50,55 +50,51 @@ 50 50 |(% style="width:281px" %)23|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %) 51 51 |(% style="width:281px" %)24|(% style="width:135px" %)12V|(% style="width:157px" %) |(% style="width:132px" %) 52 52 |(% style="width:281px" %)25|(% style="width:135px" %)12V|(% style="width:157px" %) |(% style="width:132px" %) 53 -|(% style="width:281px" %)26|(% style="width:135px" %)12V power pump1|(% style="width:157px" %) |(% style="width:132px" %) 54 -|(% style="width:281px" %)27|(% style="width:135px" %)12V Power pump2|(% style="width:157px" %) |(% style="width:132px" %)55 -|(% style="width:281px" %)28|(% style="width:135px" %)GND|(% style="width:157px" %) Blobwith tin|(% style="width:132px" %)56 -|(% style="width:281px" %)29|(% style="width:135px" %)GND|(% style="width:157px" %) Blobwith tin|(% style="width:132px" %)57 -|(% style="width:281px" %)30|(% style="width:135px" %)GND|(% style="width:157px" %) Blobwith tin|(% style="width:132px" %)58 -|(% style="width:281px" %)31|(% style="width:135px" %)Buzzer|(% style="width:157px" %)Is 59 -|(% style="width:281px" %)32|(% style="width:135px" %)Brake light|(% style="width:157px" %)Is buzzer 60 -|(% style="width:281px" %)33|(% style="width:135px" %)24V|(% style="width:157px" %) reserve|(% style="width:132px" %)61 -|(% style="width:281px" %)34|(% style="width:135px" %)24V|(% style="width:157px" %) reserve|(% style="width:132px" %)62 -|(% style="width:281px" %)35|(% style="width:135px" %)24V|(% style="width:157px" %) sensor card|(% style="width:132px" %)50 +|(% style="width:281px" %)26|(% style="width:135px" %)12V power pump 1|(% style="width:157px" %) |(% style="width:132px" %) 51 +|(% style="width:281px" %)27|(% style="width:135px" %)12V power pump 2|(% style="width:157px" %) |(% style="width:132px" %) 52 +|(% style="width:281px" %)28|(% style="width:135px" %)GND|(% style="width:157px" %)Solder blob|(% style="width:132px" %) 53 +|(% style="width:281px" %)29|(% style="width:135px" %)GND|(% style="width:157px" %)Solder blob|(% style="width:132px" %) 54 +|(% style="width:281px" %)30|(% style="width:135px" %)GND|(% style="width:157px" %)Solder blob|(% style="width:132px" %) 55 +|(% style="width:281px" %)31|(% style="width:135px" %)Buzzer|(% style="width:157px" %)Is brake light in wiring harness|(% style="width:132px" %) 56 +|(% style="width:281px" %)32|(% style="width:135px" %)Brake light|(% style="width:157px" %)Is buzzer in wiring harness|(% style="width:132px" %) 57 +|(% style="width:281px" %)33|(% style="width:135px" %)24V|(% style="width:157px" %)Reserve|(% style="width:132px" %) 58 +|(% style="width:281px" %)34|(% style="width:135px" %)24V|(% style="width:157px" %)Reserve|(% style="width:132px" %) 59 +|(% style="width:281px" %)35|(% style="width:135px" %)24V|(% style="width:157px" %)Sensor card|(% style="width:132px" %) 63 63 64 -=== Microcontroller Pinout ===61 +=== Microcontroller pinout === 65 65 66 -The power controller uses a microcontroller to control the pumps, fans, buzzer ,and brake light. It alsofeatures current monitoring and LED indicators. TheMicrocontroller used in this system is STM32G431CBT663 +The power controller uses a microcontroller to control the pumps, fans, buzzer and brake light. It also handles current monitoring and the LED indicators. The microcontroller used in this system is the STM32G431CBT6. 67 67 68 68 69 -|=Physical pin|=Electrical pin|=((( 70 -Description 71 -))) 72 -|1|VBAT|Power source from a backup battery if a RTC would be used (Connected to +3V3 in this case) 73 -|5|OSC_IN|Clock input (8MHz oscillator) 74 -|7|NRST|Negative reset which can be connected to a button (Connected to +3V3) 75 -|8|PA0|Analog signal: Current 6 Supply 24V resserve 76 -|9|PA1|Analog signal: Current 7 Supply 24V resserve 77 -|10|PA2|Analog signal: Current 5 Supply sensor card 78 -|11|PA3|Analog signal: Current 4 Supply front 79 -|12|PA4|Analog signal: Current 3 Supply accumulator 80 -|13|PA5|Analog signal: Current 2 Supply fans 81 -|14|PA6|Digital output LED 9 82 -|15|PA7|Digital output LED 2 83 -|16|PB0|Analog signal Current 8 Supply buzzer, brake light 84 -|17|PB1|PWM: enable Fan 1 66 +|=Physical pin|=Electrical pin|=Description 67 +|1|VBAT|Backup battery supply, used if an RTC is needed (connected to +3V3 in this design) 68 +|5|OSC_IN|Clock input (8 MHz oscillator) 69 +|7|NRST|Active-low reset, can be connected to a button (connected to +3V3) 70 +|8|PA0|Analog signal: Current 6, supply 24 V reserve 71 +|9|PA1|Analog signal: Current 7, supply 24 V reserve 72 +|10|PA2|Analog signal: Current 5, supply sensor card 73 +|11|PA3|Analog signal: Current 4, supply front 74 +|12|PA4|Analog signal: Current 3, supply accumulator 75 +|13|PA5|Analog signal: Current 2, supply fans 76 +|14|PA6|Digital output: LED 9 77 +|15|PA7|Digital output: LED 2 78 +|16|PB0|Analog signal: Current 8, supply buzzer and brake light 79 +|17|PB1|PWM: Enable fan 1 85 85 |18|PB2|Input: V-sense 86 86 |19|VSSA|Voltage source: Ground 87 -|20|VREF|Voltage reference ( Internal voltage refferance)82 +|20|VREF|Voltage reference (internal voltage reference) 88 88 |21|VDDA|Voltage source: Power (+3V3) 89 89 |22|PB10|Digital output: LED 8 90 90 |23|VSS|Voltage source: Ground 91 91 |24|VDD|Voltage source: Power (+3V3) 92 -|25|PB11|Current 1 Internal components 93 -|26|PB12|Current 9 Supply 12 V Pumps inverter and datalogger 94 -|29|PB15|PWM: enable fan 2 95 -|30|PA8|Digital output Enable buzzeer(On the car it is Brake light) 96 -|31|PA9|((( 97 -Digital output Enable brake light(On the car it is the buzzer) 98 -))) 99 -|32|PA10|Input ASMS signal 100 -|33|PA11|CAN-BUS RXD 101 -|34|PA12|CAN-BUS TXD 87 +|25|PB11|Analog signal: Current 1, internal components 88 +|26|PB12|Analog signal: Current 9, supply 12 V pumps, inverter and data logger 89 +|29|PB15|PWM: Enable fan 2 90 +|30|PA8|Digital output: Enable buzzer (on the car it is the brake light) 91 +|31|PA9|Digital output: Enable brake light (on the car it is the buzzer) 92 +|32|PA10|Input: ASMS signal 93 +|33|PA11|CAN bus RXD 94 +|34|PA12|CAN bus TXD 102 102 |35|VSS|Voltage source: Ground 103 103 |36|VDD|Voltage source: Power (+3V3) 104 104 |37|PA13|SWDIO ... ... @@ -106,112 +106,192 @@ 106 106 |40|PB3|Digital output: LED 3 107 107 |41|PB4|Digital output: LED 4 108 108 |42|PB5|Digital output: LED 5 109 -|43|PB6|Digital output: Enable Pump 1110 -|44|PB7|Digital output: Enable Pump 2102 +|43|PB6|Digital output: Enable pump 1 103 +|44|PB7|Digital output: Enable pump 2 111 111 |45|PB8|Digital output: LED 6 112 -|46|PB9|LED 7 105 +|46|PB9|Digital output: LED 7 113 113 |47|VSS|Voltage source: Ground 114 114 |48|VDD|Voltage source: Power (+3V3) 115 115 116 116 == Distribution circuit == 117 117 111 +The board has 9 distribution circuits, one for each fused output group. All 9 circuits use the same design, and the component reference designators follow the circuit number (circuit 1 uses R101–R104, C101, D101 and F101, circuit 2 uses R201–R204, and so on). Each circuit consists of: 112 + 113 +* A fuse in a Littelfuse nano fuse holder, so the fuse can be replaced without soldering 114 +* A 2 mΩ shunt resistor for current measurement 115 +* A current sense amplifier channel and a low-pass filter to the microcontroller ADC 116 +* An RGB LED, where the green channel shows that the fuse is intact and the red channel is controlled by the microcontroller 117 + 118 118 [[image:1790100104451-169.png]] 119 119 120 +|=Component|=Value|=Ref Des (circuit 1) 121 +|Fuse holder|Littelfuse nano|F101 122 +|Shunt resistor|2 mΩ, 1 %, 5 W, 2512|R101 123 +|Filter resistor|10 kΩ|R102 124 +|Filter capacitor|10 nF|C101 125 +|Green LED resistor|4.7 kΩ, 0805|R103 126 +|Red LED resistor|350 Ω|R104 127 +|RGB LED|Würth 150282M167310|D101 128 + 120 120 === Green LED === 121 121 122 -The green LED is used to see if the fuse is ok 131 +The green LED indicates whether the fuse is intact. It is connected from the output side of the fuse to ground through a 4.7 kΩ resistor. When the fuse is intact, the LED lights up. If the fuse blows, the LED loses its supply and turns off. This makes it easy to find a blown fuse by looking at the board. 123 123 133 +The LED is powered directly from the output voltage, so the current depends on the supply. At 24 V the current is roughly 4–5 mA, and at 12 V it is about 2 mA. This turned out to be brighter than necessary. 134 + 124 124 [[image:1790098808447-123.png]] 125 125 126 126 === Current sense === 127 127 139 +The current in each circuit is measured by passing it through a shunt resistor with a very low resistance and measuring the voltage drop across it. This small voltage is amplified, filtered and read by the microcontroller's ADC. 128 128 129 - 130 130 ==== Shunt resistor ==== 131 131 132 -A resistor with2mOhmis in series tomeasurethe voltage dropoverthe resistancethatgivesa voltage of 0.002 everAmp of current143 +A 2 mΩ shunt resistor is placed in series with the load. The voltage drop across it is 2 mV per ampere of current (0.002 V/A). 133 133 145 +The shunt is a Vishay WSLF2512 metal strip resistor with 1 % tolerance and a 5 W rating. The low resistance keeps the losses small: at 8 A the voltage drop is only 16 mV and the power loss is about 0.13 W. 146 + 134 134 [[image:1790100157872-786.png]] 135 135 136 -Amplifier 149 +==== Amplifier ==== 137 137 138 - the amplifier is a quadSo when the measured voltage dropispassedtrough the amplifieritwillgive 0.4V per1A.151 +The amplifier is a quad-channel current sense amplifier with a gain of 200 V/V. When the measured voltage drop passes through the amplifier, the output is therefore 0.4 V per ampere. 139 139 140 - ====Filter====153 +The board uses three INA4180A4 amplifiers (U3, U4, U5) from Texas Instruments. This gives 12 channels, of which 9 are used. The INA4180 measures on the high side and accepts a common-mode voltage of up to 26 V, so it can measure directly on the 24 V outputs. 141 141 142 -th efilterisalowpassfilterwith acutofffrequencyof1,6KHZ155 +With the 3.3 V ADC on the microcontroller, the maximum measurable current is about 8 A (3.3 V / 0.4 V/A ≈ 8.25 A). Above this, the amplifier output saturates. 143 143 157 +|=Current|=Shunt voltage|=Amplifier output 158 +|1 A|2 mV|0.4 V 159 +|2.5 A|5 mV|1.0 V 160 +|5 A|10 mV|2.0 V 161 +|8 A|16 mV|3.2 V 144 144 163 +==== Filter ==== 145 145 146 - ===PowerAmplifier===165 +The filter is a low-pass filter with a cutoff frequency of 1.6 kHz. 147 147 167 +It is an RC filter made of a 10 kΩ resistor and a 10 nF capacitor between the amplifier output and the ADC pin: f,,c,, = 1 / (2π × 10 kΩ × 10 nF) ≈ 1.6 kHz. The filter removes high-frequency noise, for example from PWM-controlled fans and switching loads, before the signal is sampled. The capacitor also acts as a charge reservoir for the ADC's sampling capacitor. 168 + 169 +=== Power amplifier === 170 + 148 148 [[image:1790101431805-672.png]] 149 149 150 150 === Voltage measurement === 151 151 152 - Avoltagedividerwitharatio of11 where24Vis equalto2.182onthemicrocontroller pin175 +The supply voltage is measured so the microcontroller can monitor the LV battery voltage. The signal is read on pin PB2 (V-sense). 153 153 177 +A voltage divider with a ratio of 1:11 is used, so 24 V corresponds to 2.182 V on the microcontroller pin. 178 + 179 +The input voltage is calculated in firmware as V,,in,, = V,,pin,, × 11. With a 3.3 V ADC, the highest voltage that can be measured is about 36 V, which gives good margin above the 24 V supply. 180 + 181 +|=Supply voltage|=Voltage on pin 182 +|12 V|1.09 V 183 +|20 V|1.82 V 184 +|24 V|2.18 V 185 +|30 V|2.73 V 186 + 154 154 [[image:1790101449150-901.png]] 155 155 156 -=== 12V supply( Did not work) ===189 +=== 12 V supply (did not work) === 157 157 158 -The buck converter over heatedunderload andmade a whiningsound191 +The 12 V supply is a synchronous buck converter that steps the 24 V supply down to 12 V for the pumps, inverter and data logger. It is built around an LM5148 buck controller (U801) from Texas Instruments, which drives two external N-channel power MOSFETs (IAUCN04S7L028, Q901 and Q902) as the high-side and low-side switches. The output inductor is a 0.65 µH Coilcraft XAL7070 (L901), and a 3 mΩ resistor (R910) is used for current sensing in the controller. 159 159 193 +|=Component|=Part|=Ref Des 194 +|Buck controller|LM5148RGYR|U801 195 +|Power MOSFETs|IAUCN04S7L028ATMA1|Q901, Q902 196 +|Inductor|XAL7070-651MEB, 0.65 µH|L901 197 +|Current sense resistor|3 mΩ, 3 W|R910 198 +|Output capacitors|22 µF, 25 V|C909–C912 199 + 200 +The buck converter overheated under load and made a whining sound. 201 + 160 160 [[image:1790102044737-969.png||height="368" width="925"]] 161 161 162 -Mateksys PM20S-2 PowerModule was used as a quick fix toensure thatit had 12V for the competion.204 +A Mateksys PM20S-2 power module was used as a quick fix to provide 12 V for the competition. 163 163 164 -=== 5V, 3 V3 and Canbus ===206 +=== 5 V, 3.3 V and CAN bus === 165 165 166 -Use dstandard Align template208 +Uses the standard Align template. 167 167 210 +* **5 V:** An AP64060 synchronous buck converter (U6) steps the input voltage down to 5 V. It accepts 4.5–40 V in and delivers up to 0.6 A. 211 +* **3.3 V:** An AP2112K-3.3 LDO regulator (U7) generates 3.3 V for the microcontroller and the current sense amplifiers. 212 +* **CAN bus:** An NCV7344 CAN FD transceiver (U2) connects the microcontroller to the CAN bus. The transceiver supports up to 5 Mbps, and the bus runs at 1 Mbps. A common-mode choke (L1) reduces noise on the bus lines, and a TVS diode (D1) protects them against ESD and voltage spikes. 213 + 214 +The whole board is protected by a 400 W power TVS diode (D2) on the input, which clamps voltage spikes on the supply. 215 + 168 168 == Control logic == 169 169 170 -=== Source from micro 218 +=== Sourced from the microcontroller === 171 171 172 -The programable red light is inthe same RGB LEDDiode220 +The programmable red light is part of the same RGB LED as the green fuse indicator. It is controlled by the firmware and can be used to show the status of each circuit, for example an overcurrent or an output that is switched off. 173 173 174 - Direct sourcingof current from the microcontrollerwith a 350 ohmressistor in series.222 +Current is sourced directly from the microcontroller through a 350 Ω series resistor. When the pin is driven high (3.3 V), current flows through the resistor and the red LED to ground. The STM32 pins can supply up to about 20 mA each, so no transistor is needed. This gives an LED current of roughly 3–4 mA, which made the LEDs too bright. The resistor value should be increased on the next version. 175 175 176 176 [[image:1790098512666-432.png]] 177 177 178 -= Highside 226 +=== High-side switching === 179 179 180 -to switch the 228 +The buzzer, brake light and pumps are switched on the high side. The load's negative side is permanently connected to ground, and the controller switches the positive supply. This means a short from the output wire to chassis cannot turn the load on, and the load is completely unpowered when it is off. 181 181 182 - [[image:1790181075885-591.png||height="343"width="367"]]230 +Each output uses a P-channel MOSFET as the main switch between the supply and the load. A P-channel MOSFET is used because it can switch the high side without a charge pump or gate driver. It turns on when its gate is pulled below its source (the supply voltage). 183 183 184 -Pum p232 +The microcontroller runs on 3.3 V and cannot pull the gate of the P-channel MOSFET far enough on its own. A small N-channel MOSFET is therefore used as a level shifter: 185 185 186 -The nchannel mosfet(BSS123NH6327XTSA1) is th same as the buzzer/brake light but the pchannle mosfet(BSS123NH6327XTSA1) is a pchannel mosfet with a higher rated current the 234 +* **Output off:** The microcontroller pin is low, so the N-channel MOSFET is off. A pull-up resistor holds the P-channel gate at the supply voltage, so V,,GS,, = 0 V and the P-channel MOSFET is off. 235 +* **Output on:** The microcontroller pin goes high (3.3 V) and turns on the N-channel MOSFET. This pulls the P-channel gate towards ground, V,,GS,, becomes negative and the P-channel MOSFET turns on. 187 187 188 - [[image:1790181054296-268.png||height="306"width="371"]]237 +A 1 kΩ series resistor on the N-channel gate limits the current from the microcontroller pin, and a 10 kΩ pull-down keeps the output off while the microcontroller is starting up or in reset. 189 189 190 -== == 239 +==== Buzzer and brake light ==== 191 191 192 - ====241 +The buzzer and brake light are switched on the high side using an N-channel MOSFET (BSS123NH6327XTSA1) that drives a P-channel MOSFET (BSS83PH6327XTSA1). 193 193 194 - ==Known issues==243 +These outputs run on 24 V. The BSS83P is rated for -60 V and -0.33 A, which limits each output to 330 mA. This is enough for the buzzer and an LED brake light. The maximum gate-source voltage of the BSS83P is ±20 V, so the gate must not be pulled all the way to ground from 24 V. The two 10 kΩ resistors on the P-channel gate form a voltage divider that limits V,,GS,, to about half the supply (≈ -12 V). 195 195 196 - 12 V didnot work245 +[[image:1790181075885-591.png||height="343" width="367"]] 197 197 198 -Current measurement not tested 247 +|=Function|=Buzzer / brake light 248 +|Supply|24 V 249 +|N-channel MOSFET|BSS123NH6327XTSA1 (Q803, Q804) 250 +|P-channel MOSFET|BSS83PH6327XTSA1 (Q801, Q802) 251 +|Gate resistor|1 kΩ (R807, R808) 252 +|Pull-down / pull-up / divider|10 kΩ (R805, R806, R809–R812) 253 +|Maximum output current|330 mA 199 199 255 +==== Pump ==== 200 200 201 - ==Featurestoadd==257 +The N-channel MOSFET (BSS123NH6327XTSA1) is the same as for the buzzer and brake light, but the P-channel MOSFET (BSC084P03NS3GATMA1) has a much higher current rating. 202 202 203 - Addmosfetsto cut powerif theLv battery is tolowtosavepower259 +The pumps run on 12 V and draw considerably more current. The BSC084P03 is a power MOSFET rated for -30 V and -78.6 A, with an on-resistance of about 8.4 mΩ. At 5 A this gives a loss of only about 0.2 W, so no heatsink is needed. Since the supply is 12 V, the gate can be pulled fully to ground without exceeding the ±20 V gate-source rating. 204 204 205 - Addaower distrobutionfor Autonomus system261 +[[image:1790181054296-268.png||height="306" width="371"]] 206 206 263 +|=Function|=Pump 1 / Pump 2 264 +|Supply|12 V 265 +|N-channel MOSFET|BSS123NH6327XTSA1 (Q905, Q906) 266 +|P-channel MOSFET|BSC084P03NS3GATMA1 (Q903, Q904) 267 +|Gate resistor|1 kΩ (R913, R914) 268 +|Pull-down / pull-up|10 kΩ (R911, R912, R915, R916) 269 +|Maximum output current|5 A 207 207 208 -== BOM(billofmaterials)==271 +== Known issues == 209 209 273 +* The 12 V supply did not work. 274 +* The current measurement has not been tested. 275 + 276 +== Features to add == 277 + 278 +* Add MOSFETs to cut power if the LV battery voltage is too low, to save power. 279 +* Add power distribution for the autonomous system. 280 + 281 +== BOM (bill of materials) == 282 + 210 210 |=Part Number|=Description|=Ref Des|=Qty|=Manufacturer|=MPN 211 211 |CC0603KRX5R6BB475|Chip Capacitor, 4.7µF +/-20%, 10V, 0603|C1|1|Yageo Group|CC0603KRX5R6BB475 212 212 |CL10B104KA8NNNC|MLCC, 0.1 uF, 25V, ±10%, X7R, 0603|C2, C3, C4, C8, C9, C10, C14, C15, C16|9|Samsung Electro-Mechanics|CL10B104KA8NNNC 213 213 |CL10B105KA8NFNC|MLCC, 1uF, 25V, 10%, X7R, 0603|C5, C7|2|Samsung Electro-Mechanics|CL10B105KA8NFNC 214 -|CL10B103KB8NNNC|MLCC, 10nF, 50V, +125C, X7R, ±10%, 0603|C6, C101, C201, C301, C401, C501, C601, C701, C801, C901|10| (( fatalerror – no data ))||287 +|CL10B103KB8NNNC|MLCC, 10nF, 50V, +125C, X7R, ±10%, 0603|C6, C101, C201, C301, C401, C501, C601, C701, C801, C901|10|Samsung Electro-Mechanics|CL10B103KB8NNNC 215 215 |885012206020|MLCC, General Purpose, 0603, 100nF, 10V|C11|1|Wurth Elektronik|885012206020 216 216 |885012006051|MLCC, General Purpose, 0603, 10pF, 50V|C12, C13|2|Wurth Elektronik|885012006051 217 217 |885012208124|MLCC, General Purpose, 1206, 2.2µF, 100V|C17, C19|2|Wurth Elektronik|885012208124 ... ... @@ -232,23 +232,23 @@ 232 232 |0466.125NR|Electric Fuse, Very Fast Blow, 0.125A, 125VAC/VDC, 1206|F102|1|Littelfuse|0466.125NR 233 233 |776231-1|Conn Shrouded Header, HDR 35 POS, 4mm, Thru-Hole|J1|1|TE Connectivity|776231-1 234 234 |76829-0002|Mega-Fit Straight Male Header, 2x2, 5.7mm Pitch|J2|1|Molex|76829-0002 235 -|(4 pin header)|2.54mm pitch 1x4 vertical header|J3|1| (( fatalerror –no data ))||308 +|(4 pin header)|2.54mm pitch 1x4 vertical header|J3|1|Generic| 236 236 |44914-0401|Conn Header Vert 4POS 3mm|J4|1|Molex|44914-0401 237 237 |1461247-3|Relay, Gen Purpose, SPST, 8A, 24V|K1|1|TE Connectivity|OJ-SH-124LMH,000 238 -|784234510|WE-CNSA Common Mode Line Filter, 1210, 7850Ω, 200mA|L1|1| (( fatalerror –no data ))||311 +|784234510|WE-CNSA Common Mode Line Filter, 1210, 7850Ω, 200mA|L1|1|Wurth Elektronik|784234510 239 239 |74438323100|WE-MAPI SMT Power Inductor, 2510, 10µH, 0.9A, 733mΩ|L2, L3|2|Wurth Elektronik|74438323100 240 -|XAL7070-651MEB|General Purpose Inductor, 0.65uH, 20%, 3028|L901|1|Coilcraft|XAL7070-651MEB |313 +|XAL7070-651MEB|General Purpose Inductor, 0.65uH, 20%, 3028|L901|1|Coilcraft|XAL7070-651MEB 241 241 |BSS123NH6327XTSA1|MOSFET N-CH 100V 0.19A SOT-23|Q201, Q202, Q803, Q804, Q905, Q906|6|Infineon|BSS123NH6327XTSA1 242 242 |BSS83PH6327XTSA1|SIPMOS Small-Signal Transistor, -0.33A, -60V, SOT-23|Q801, Q802|2|Infineon|BSS83PH6327XTSA1 243 243 |IAUCN04S7L028ATMA1|Mosfet, N-ch, 40V, 100A|Q901, Q902|2|Infineon|IAUCN04S7L028ATMA1 244 244 |BSC084P03NS3GATMA1|P-Channel OptiMOS P3, -30V VDS, -78.6A ID, PG-TDSON-8-1|Q903, Q904|2|Infineon|BSC084P03NS3GATMA1 245 -|(( TBD ))|Generic Resistor, 350Ω, 0603|R104, R204, R304, R404, R504, R606, R704, R804, R904|9|(( TBD ))| |246 -|(( TBD ))|Generic Resistor, 1KΩ, 0603|R205, R206, R807, R808, R913, R914|6|(( TBD ))| |247 -|(( TBD ))|Generic Resistor, 10KΩ, 0603|R1, R207, R208, R805, R806, R809, R810, R811, R812, R911, R912, R915, R916|13|(( TBD ))| |248 -|(( TBD ))|Generic Resistor, 1.6KΩ, 0603|R2|1|(( TBD ))| |249 -|(( TBD ))|Generic Resistor, 2.2Ω, 0603|R3|1|(( TBD ))| |250 -|(( TBD ))|Generic Resistor, 27KΩ, 0603|R4|1|(( TBD ))| |251 -|(( TBD ))|Generic Resistor, 5.1KΩ, 0603|R5|1|(( TBD ))| |318 +|(( TBD ))|Generic Resistor, 350Ω, 0603|R104, R204, R304, R404, R504, R606, R704, R804, R904|9|(( TBD ))| 319 +|(( TBD ))|Generic Resistor, 1KΩ, 0603|R205, R206, R807, R808, R913, R914|6|(( TBD ))| 320 +|(( TBD ))|Generic Resistor, 10KΩ, 0603|R1, R207, R208, R805, R806, R809, R810, R811, R812, R911, R912, R915, R916|13|(( TBD ))| 321 +|(( TBD ))|Generic Resistor, 1.6KΩ, 0603|R2|1|(( TBD ))| 322 +|(( TBD ))|Generic Resistor, 2.2Ω, 0603|R3|1|(( TBD ))| 323 +|(( TBD ))|Generic Resistor, 27KΩ, 0603|R4|1|(( TBD ))| 324 +|(( TBD ))|Generic Resistor, 5.1KΩ, 0603|R5|1|(( TBD ))| 252 252 |WSLF25122L000FEA|Res Metal Strip 2512, 0.002Ω, 1%, 5W|R101, R201, R301, R401, R501, R601, R701, R801, R901|9|Vishay|WSLF25122L000FEA 253 253 |CR0603-FX-1002ELF|SMD Resistor, 10kΩ, ±1%, 100mW, 0603|R102, R105, R202, R302, R402, R502, R602, R702, R802, R902|10|Bourns|CR0603-FX-1002ELF 254 254 |CR0805-JW-472ELF|SMD Resistor, 4.7kΩ, ±5%, 125mW, 0805|R103, R203, R303, R403, R503, R603, R703, R803, R903|9|Bourns|CR0805-JW-472ELF ... ... @@ -269,21 +269,25 @@ 269 269 270 270 = AR27 Concept = 271 271 272 - Hereis the for AR27345 +This section describes the concept for AR27. 273 273 274 274 == Changes == 275 275 349 +* Connector 350 +** Change main connector 276 276 * Circuits 277 -** more dedicate supply circuits 278 -** Keep the same current 279 -** Adjust the signal led resistor on the PCB 352 +** More dedicated supply circuits 353 +** Keep the same current sensing 354 +** Increase the signal LED resistor on the PCB (the LEDs were too bright) 355 +* Microcontroller 356 +** Needs more inputs 280 280 * Digital signals 281 -** Adjustthe signalledresistor on the PCB282 -* 12V supply 283 -** 3seprate 12 V supply284 -*** Pump1 285 -*** Pump2 286 -*** Inverter/ other 12V supply358 +** Increase the green signal LED resistor on the PCB (the LEDs were too bright) 359 +* 12 V supply 360 +** Three separate 12 V supplies: 361 +*** Pump 1 362 +*** Pump 2 363 +*** Inverter / other 12 V loads 287 287 * Autonomous 288 288 ** Supplied by ASMS 289 289 ** Potentially control ASSI ... ... @@ -293,42 +293,37 @@ 293 293 294 294 === Standard supply table === 295 295 296 -|= |=Voltage|= Commonpower|=NR297 -|IPC|24V| standalone|1298 -|Pumps|12V| standalone|2299 -|Fans|24V| standalone|300 -|HVbox|24V| standalone|301 -|Energy meter|12V| inverter,Energy meter302 -|Inverter x|12Vinverter,Energy meter373 +|= |=Voltage|=Shared supply|=Qty 374 +|IPC|24V|Standalone|1 375 +|Pumps|12V|Standalone|2 376 +|Fans|24V|Standalone| 377 +|HV box|24V|Standalone| 378 +|Energy meter|12V|Inverter, energy meter| 379 +|Inverter|12V|Inverter, energy meter| 303 303 |Accumulator|24V|Standalone| 304 -|Brake light|24V|Buzzer brake light| 305 -|buzzer|24V|Buzzer brake light| 306 -|Sensor module R|24V|Sensor modules, telemetry| 307 -|Sensor moduleF|24V|Sensor modules, telemetry| 308 -|Tire temp|12V|telemetri tire temp| 309 -|Telemetrie|12V|telemetri tire temp| 310 -|telemetri|24V|Sensor modules, telemetry| 311 -|((( 312 -Dashboard 313 -)))|24V|Standalone | 381 +|Brake light|24V|Buzzer, brake light| 382 +|Buzzer|24V|Buzzer, brake light| 383 +|Sensor module (rear)|24V|Sensor modules, telemetry| 384 +|Sensor module (front)|24V|Sensor modules, telemetry| 385 +|Tire temperature|12V|Telemetry, tire temperature| 386 +|Telemetry|12V|Telemetry, tire temperature| 387 +|Telemetry|24V|Sensor modules, telemetry| 388 +|Dashboard|24V|Standalone| 314 314 |SDC|24V|Standalone| 315 -|SDC monitor |24V|Dashboard telemetrie SDC monitor| 316 -|internal circuitry |24V|Standalone| 317 -| | | | 390 +|SDC monitor|24V|Dashboard, telemetry, SDC monitor| 391 +|Internal circuitry|24V|Standalone| 318 318 319 319 === Autonomous supply table === 320 320 321 -|= |=amount|=Current 322 -|Steering motor |1|? 323 -|((( 324 -ASB/ESB 325 -)))| |? 395 +|= |=Qty|=Current 396 +|Steering motor|1|? 397 +|ASB/ESB| |? 326 326 |ASSI|2|? 327 327 |RES|1|? 328 328 329 329 == Relevant rules == 330 330 331 -|=(% style="width: 472px;" %)Rule number|=(% style="width: 650px;" %)Rule 403 +|=(% style="width: 472px;" %)Rule number|=(% style="width: 650px;" %)Rule 332 332 |(% style="width:472px" %) |(% style="width:650px" %) 333 333 |(% style="width:472px" %) |(% style="width:650px" %) 334 334 |(% style="width:472px" %) |(% style="width:650px" %) ... ... @@ -336,10 +336,3 @@ 336 336 |(% style="width:472px" %) |(% style="width:650px" %) 337 337 |(% style="width:472px" %) |(% style="width:650px" %) 338 338 |(% style="width:472px" %) |(% style="width:650px" %) 339 - 340 - 341 - 342 - 343 -=== === 344 - 345 -