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Wiki source code of Power controller

Version 31.2 by Mathias Larsen on 2026/09/23 14:57
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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 Supply voltage=12–24 V DC
5 Fused circuits=9 (5 × 24 V outputs, fan outputs, digital outputs, 12 V circuit, internal electronics)
6 24 V outputs=5
7 24 V fan outputs=2 (shared fuse)
8 12 V outputs=2
9 Digital outputs (shared fuse)=2 × 12 V switched (5 A), 2 × 24 V switched (330 mA), 2 × PWM
10 Communication interface=CAN FD
11 Maximum data rate=1 MbpsD
12 |Maximum data rate|1 Mbps
13 {{/wikibox}}
14
15 == Tables of contents ==
16
17 ----
18
19 {{toc/}}
20
21 == ==
22
23 == ==
24
25 == ==
26
27 == ==
28
29 == Pinout ==
30
31 === Connector pinout ===
32
33 |=(% style="width: 281px;" %)Pin|=(% style="width: 135px;" %) |=(% style="width: 157px;" %)comment|=(% style="width: 132px;" %)
34 |(% style="width:281px" %)1|(% style="width:135px" %)CANH|(% style="width:157px" %) |(% style="width:132px" %)
35 |(% style="width:281px" %)2|(% style="width:135px" %)CANL|(% style="width:157px" %) |(% style="width:132px" %)
36 |(% style="width:281px" %)3|(% style="width:135px" %)FAN 1 PWM|(% style="width:157px" %) |(% style="width:132px" %)
37 |(% style="width:281px" %)4|(% style="width:135px" %)FAN 2 PWM|(% style="width:157px" %) |(% style="width:132px" %)
38 |(% style="width:281px" %)5|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
39 |(% style="width:281px" %)6|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
40 |(% style="width:281px" %)7|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
41 |(% style="width:281px" %)8|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
42 |(% style="width:281px" %)9|(% style="width:135px" %)Accumulator|(% style="width:157px" %) |(% style="width:132px" %)
43 |(% style="width:281px" %)10|(% style="width:135px" %)Front|(% style="width:157px" %) |(% style="width:132px" %)
44 |(% style="width:281px" %)11|(% style="width:135px" %)Power fan|(% style="width:157px" %) |(% style="width:132px" %)
45 |(% style="width:281px" %)12|(% style="width:135px" %)Power fan|(% style="width:157px" %) |(% style="width:132px" %)
46 |(% style="width:281px" %)(((
47 13
48 )))|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
49 |(% style="width:281px" %)14|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
50 |(% style="width:281px" %)15|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
51 |(% style="width:281px" %)16|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
52 |(% style="width:281px" %)17|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
53 |(% style="width:281px" %)18|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
54 |(% style="width:281px" %)19|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
55 |(% style="width:281px" %)20|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
56 |(% style="width:281px" %)21|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
57 |(% style="width:281px" %)22|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
58 |(% style="width:281px" %)23|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
59 |(% style="width:281px" %)24|(% style="width:135px" %)12V|(% style="width:157px" %) |(% style="width:132px" %)
60 |(% style="width:281px" %)25|(% style="width:135px" %)12V|(% style="width:157px" %) |(% style="width:132px" %)
61 |(% style="width:281px" %)26|(% style="width:135px" %)12V power pump1|(% style="width:157px" %) |(% style="width:132px" %)
62 |(% style="width:281px" %)27|(% style="width:135px" %)12V Power pump2|(% style="width:157px" %) |(% style="width:132px" %)
63 |(% style="width:281px" %)28|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
64 |(% style="width:281px" %)29|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
65 |(% style="width:281px" %)30|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
66 |(% style="width:281px" %)31|(% style="width:135px" %)Buzzer|(% style="width:157px" %)Is brake light in wiring harnes|(% style="width:132px" %)
67 |(% style="width:281px" %)32|(% style="width:135px" %)Brake light|(% style="width:157px" %)Is buzzer in wiring harnes|(% style="width:132px" %)
68 |(% style="width:281px" %)33|(% style="width:135px" %)24V|(% style="width:157px" %)reserve|(% style="width:132px" %)
69 |(% style="width:281px" %)34|(% style="width:135px" %)24V|(% style="width:157px" %)reserve|(% style="width:132px" %)
70 |(% style="width:281px" %)35|(% style="width:135px" %)24V|(% style="width:157px" %)sensor card|(% style="width:132px" %)
71
72
73
74 === Microcontroller Pinout ===
75
76 The power controller uses a microcontroller to control the pumps, fans, buzzer, and brake light. It also features current monitoring and LED indicators. The Microcontroller used in this system is STM32G431CBT6
77
78
79 |=Physical pin|=Electrical pin|=(((
80 Description
81 )))
82 |1|VBAT|Power source from a backup battery if a RTC would be used (Connected to +3V3 in this case)
83 |5|OSC_IN|Clock input (8MHz oscillator)
84 |7|NRST|Negative reset which can be connected to a button (Connected to +3V3)
85 |8|PA0|Analog signal: Current 6 Supply 24V resserve
86 |9|PA1|Analog signal: Current 7 Supply 24V resserve
87 |10|PA2|Analog signal: Current 5 Supply sensor card
88 |11|PA3|Analog signal: Current 4 Supply front
89 |12|PA4|Analog signal: Current 3 Supply accumulator
90 |13|PA5|Analog signal: Current 2 Supply fans
91 |14|PA6|Digital output LED 9
92 |15|PA7|Digital output LED 2
93 |16|PB0|Analog signal Current 8 Supply buzzer, brake light
94 |17|PB1|PWM: enable Fan 1
95 |18|PB2|Input: V-sense
96 |19|VSSA|Voltage source: Ground
97 |20|VREF|Voltage reference (Internal voltage refferance)
98 |21|VDDA|Voltage source: Power (+3V3)
99 |22|PB10|Digital output: LED 8
100 |23|VSS|Voltage source: Ground
101 |24|VDD|Voltage source: Power (+3V3)
102 |25|PB11|Current 1 Internal components
103 |26|PB12|Current 9 Supply 12 V Pumps inverter and datalogger 
104 |29|PB15|PWM: enable fan 2
105 |30|PA8|Digital output Enable buzzeer(On the car it is Brake light)
106 |31|PA9|(((
107 Digital output Enable brake light(On the car it is the buzzer)
108 )))
109 |32|PA10|Input ASMS signal
110 |33|PA11|CAN-BUS RXD
111 |34|PA12|CAN-BUS TXD
112 |35|VSS|Voltage source: Ground
113 |36|VDD|Voltage source: Power (+3V3)
114 |37|PA13|SWDIO
115 |38|PA14|SWCLK
116 |40|PB3|Digital output: LED 3
117 |41|PB4|Digital output: LED 4
118 |42|PB5|Digital output: LED 5
119 |43|PB6|Digital output: Enable Pump 1
120 |44|PB7|Digital output: Enable Pump 2
121 |45|PB8|Digital output: LED 6
122 |46|PB9|LED 7
123 |47|VSS|Voltage source: Ground
124 |48|VDD|Voltage source: Power (+3V3)
125
126 == Distribution circuit ==
127
128 [[image:1790100104451-169.png]]
129
130 === Green LED ===
131
132 The green LED is used to see if the fuse is ok
133
134 [[image:1790098808447-123.png]]
135
136 === Current sense ===
137
138 [[image:1790100157872-786.png]]
139
140 === Power Amplifier ===
141
142 [[image:1790101431805-672.png]]
143
144 === Voltage measurement ===
145
146 [[image:1790101449150-901.png]]
147
148 === 12V supply(Did not work) ===
149
150 The buck converter overheated under
151
152 [[image:1790102044737-969.png||height="368" width="925"]]
153
154 Mateksys PM20S-2 Power Module was used as a quick fix to ensure that it had 12V for the competion.
155
156
157 === 5V and 3V3 supply ===
158
159 Is
160
161 == Controll logic ==
162
163 === LED light ===
164
165 The programable red light is in the same RGB LED Diode
166
167 Direct sourcing of current from the microcontroller with a 350 ohm ressistor in series.
168
169 [[image:1790098512666-432.png]]
170
171 === Buzzer/Brake light ===
172
173 PUMPS
174
175
176 == ==
177
178 == ==
179
180 == Known issues ==
181
182 12 V did not work
183
184 Current measurement not tested
185
186
187 == Features to add ==
188
189 Add mosfets to cut power if the Lv battery is to low to save power
190
191 Add a power distrobution for Autonomus system
192
193
194 == BOM(bill of materials) ==
195
196 |=Part Number|=Description|=Ref Des|=Qty|=Manufacturer|=MPN
197 |CC0603KRX5R6BB475|Chip Capacitor, 4.7µF +/-20%, 10V, 0603|C1|1|Yageo Group|CC0603KRX5R6BB475
198 |CL10B104KA8NNNC|MLCC, 0.1 uF, 25V, ±10%, X7R, 0603|C2, C3, C4, C8, C9, C10, C14, C15, C16|9|Samsung Electro-Mechanics|CL10B104KA8NNNC
199 |CL10B105KA8NFNC|MLCC, 1uF, 25V, 10%, X7R, 0603|C5, C7|2|Samsung Electro-Mechanics|CL10B105KA8NFNC
200 |CL10B103KB8NNNC|MLCC, 10nF, 50V, +125C, X7R, ±10%, 0603|C6, C101, C201, C301, C401, C501, C601, C701, C801, C901|10|(( fatal error – no data ))| |
201 |885012206020|MLCC, General Purpose, 0603, 100nF, 10V|C11|1|Wurth Elektronik|885012206020
202 |885012006051|MLCC, General Purpose, 0603, 10pF, 50V|C12, C13|2|Wurth Elektronik|885012006051
203 |885012208124|MLCC, General Purpose, 1206, 2.2µF, 100V|C17, C19|2|Wurth Elektronik|885012208124
204 |885012108022|MLCC, General Purpose, 1206, 10µF, 50V|C18|1|Wurth Elektronik|885012108022
205 |885012206071R|MLCC, General Purpose, 0603, 100nF, 25V|C20|1|Wurth Elektronik|885012206071R
206 |885012107014|MLCC, General Purpose, 0805, 10µF, 16V|C21, C22|2|Wurth Elektronik|885012107014
207 |MBASU105SB5104KFNA01|MLCC, 50V, 10%, X5R, 0.1uF, 0402|C23, C24|2|TAIYO YUDEN|MBASU105SB5104KFNA01
208 |GRM32ER71H475KA88L|MLCC, 1210, 4.7uF, 50V, ±10%, X7R|C902, C903|2|Murata|GRM32ER71H475KA88L
209 |GRM188R71A225KE15D|MLCC, 0603, 2.2uF, X7R, 10V|C904|1|Murata|GRM188R71A225KE15D
210 |CC0402KRX7R6BB104|Chip Capacitor, 100nF +/-20%, 10V, 0402|C905, C908|2|Yageo Group|CC0402KRX7R6BB104
211 |GRM1555C1H102JA01J|MLCC, 0402, 1nF, 50V, ±5%, C0G|C906|1|Murata|GRM1555C1H102JA01J
212 |GRM1555C1H4R3CA01D|MLCC, 0402, 4.3pF, 50V, C0G, ±0.25pF|C907|1|Murata|GRM1555C1H4R3CA01D
213 |GRM32ER61E226KE15L|MLCC, 1210, 22uF, 25V, X5R|C909, C910, C911, C912|4|Murata|GRM32ER61E226KE15L
214 |824094024|WE-TVS TVS Diode, SOT23-3L, 2 Channel, 24V, 38pF|D1|1|Wurth Elektronik|824094024
215 |824500261|WE-TVSP SMT Power TVS Diode, DO-214AC, 400W, 26VDC|D2|1|Wurth Elektronik|824500261
216 |150282M167310|WL-SFTD Full-color Top LED, 2828, R/G/B, 70°|D101, D201, D301, D402, D501, D601, D701, D801, D901|9|Wurth Elektronik|150282M167310
217 |01550900DR|Fuseholder - Acs Nano|F101, F201, F301, F401, F501, F601, F701, F801, F901, F902, F903, F904|12|Littelfuse|01550900DR
218 |0466.125NR|Electric Fuse, Very Fast Blow, 0.125A, 125VAC/VDC, 1206|F102|1|Littelfuse|0466.125NR
219 |776231-1|Conn Shrouded Header, HDR 35 POS, 4mm, Thru-Hole|J1|1|TE Connectivity|776231-1
220 |76829-0002|Mega-Fit Straight Male Header, 2x2, 5.7mm Pitch|J2|1|Molex|76829-0002
221 |(4 pin header)|2.54mm pitch 1x4 vertical header|J3|1|(( fatal error – no data ))| |
222 |44914-0401|Conn Header Vert 4POS 3mm|J4|1|Molex|44914-0401
223 |1461247-3|Relay, Gen Purpose, SPST, 8A, 24V|K1|1|TE Connectivity|OJ-SH-124LMH,000
224 |784234510|WE-CNSA Common Mode Line Filter, 1210, 7850Ω, 200mA|L1|1|(( fatal error – no data ))| |
225 |74438323100|WE-MAPI SMT Power Inductor, 2510, 10µH, 0.9A, 733mΩ|L2, L3|2|Wurth Elektronik|74438323100
226 |XAL7070-651MEB|General Purpose Inductor, 0.65uH, 20%, 3028|L901|1|Coilcraft|XAL7070-651MEB|
227 |BSS123NH6327XTSA1|MOSFET N-CH 100V 0.19A SOT-23|Q201, Q202, Q803, Q804, Q905, Q906|6|Infineon|BSS123NH6327XTSA1
228 |BSS83PH6327XTSA1|SIPMOS Small-Signal Transistor, -0.33A, -60V, SOT-23|Q801, Q802|2|Infineon|BSS83PH6327XTSA1
229 |IAUCN04S7L028ATMA1|Mosfet, N-ch, 40V, 100A|Q901, Q902|2|Infineon|IAUCN04S7L028ATMA1
230 |BSC084P03NS3GATMA1|P-Channel OptiMOS P3, -30V VDS, -78.6A ID, PG-TDSON-8-1|Q903, Q904|2|Infineon|BSC084P03NS3GATMA1
231 |(( TBD ))|Generic Resistor, 350Ω, 0603|R104, R204, R304, R404, R504, R606, R704, R804, R904|9|(( TBD ))| |
232 |(( TBD ))|Generic Resistor, 1KΩ, 0603|R205, R206, R807, R808, R913, R914|6|(( TBD ))| |
233 |(( TBD ))|Generic Resistor, 10KΩ, 0603|R1, R207, R208, R805, R806, R809, R810, R811, R812, R911, R912, R915, R916|13|(( TBD ))| |
234 |(( TBD ))|Generic Resistor, 1.6KΩ, 0603|R2|1|(( TBD ))| |
235 |(( TBD ))|Generic Resistor, 2.2Ω, 0603|R3|1|(( TBD ))| |
236 |(( TBD ))|Generic Resistor, 27KΩ, 0603|R4|1|(( TBD ))| |
237 |(( TBD ))|Generic Resistor, 5.1KΩ, 0603|R5|1|(( TBD ))| |
238 |WSLF25122L000FEA|Res Metal Strip 2512, 0.002Ω, 1%, 5W|R101, R201, R301, R401, R501, R601, R701, R801, R901|9|Vishay|WSLF25122L000FEA
239 |CR0603-FX-1002ELF|SMD Resistor, 10kΩ, ±1%, 100mW, 0603|R102, R105, R202, R302, R402, R502, R602, R702, R802, R902|10|Bourns|CR0603-FX-1002ELF
240 |CR0805-JW-472ELF|SMD Resistor, 4.7kΩ, ±5%, 125mW, 0805|R103, R203, R303, R403, R503, R603, R703, R803, R903|9|Bourns|CR0805-JW-472ELF
241 |CR0603-FX-1001ELF|RES SMD 1K Ohm, 1%, 1/10W, 0603|R106|1|Bourns|CR0603-FX-1001ELF
242 |CRCW060347K5FKEA|Res Thick Film 0603, 47.5KΩ, 1%, 1/10W|R905|1|Vishay|CRCW060347K5FKEA
243 |RC0603FR-13100KL|Chip Resistor, 100KΩ, ±1%, 0.1W, 0603|R906|1|Yageo Group|RC0603FR-13100KL
244 |AC0402FR-0712K1L|Res Thick Film 0402, 12.1KΩ, 1%, 1/16W|R907|1|Yageo Group|AC0402FR-0712K1L
245 |CRCW060340K2FKEA|Res Thick Film 0603, 40.2KΩ, 1%, 1/10W|R908|1|Vishay|CRCW060340K2FKEA
246 |CRCW06039K53FKEA|Res Thick Film 0603, 9.53KΩ, 1%, 1/10W|R909|1|Vishay|CRCW06039K53FKEA
247 |WSR33L000FEA|Res Metal Strip 4527, 0.003Ω, 1%, 3W|R910|1|Vishay|WSR33L000FEA
248 |STM32G431CBT6|MCU 32-bit ARM Cortex M4, 128KB Flash, 48-Pin LQFP|U1|1|STMicroelectronics|STM32G431CBT6
249 |NCV7344D13R2G|CAN FD Transceiver, ISO 11898-2, 5Mbps, SOIC-8|U2|1|onsemi|NCV7344D13R2G
250 |INA4180A4IPWR|26V Quad Channel Current Sense Amplifier, 14-TSSOP|U3, U4, U5|3|Texas Instruments|INA4180A4IPWR
251 |AP64060WU-7|DC-DC Synchronous Step Down, 4.5-40V to 0.8-26V, 0.6A, TSOT-26|U6|1|Diodes Inc.|AP64060WU-7
252 |AP2112K-3.3TRG1|Fixed Positive LDO, 3.3V, 0.4V Dropout, PDSO5|U7|1|Diodes Inc.|AP2112K-3.3TRG1
253 |LM5148RGYR|3.5-80V Current Mode Synchronous Buck Controller, 24-VQFN|U801|1|Texas Instruments|LM5148RGYR
254 |ASE-8.000MHz-E-T|Crystal Oscillator, 8MHz, 3.3V, 15pF, 4-Pin SMD|Y1|1|Abracon|ASE-8.000MHZ-E-T
255
256
257
258 = AR27 plan =
259
260 Here is the documentaion for AR27
261
262 == Changes ==
263
264 === More ci ===
265
266 == Supply circuit plan ==
267
268 === ===
269
270