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Wiki source code of Power controller

Version 35.5 by Mathias Larsen on 2026/09/23 17:35
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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 == Pinout ==
22
23 === Connector pinout ===
24
25 |=(% style="width: 281px;" %)Pin|=(% style="width: 135px;" %) |=(% style="width: 157px;" %)comment|=(% style="width: 132px;" %)
26 |(% style="width:281px" %)1|(% style="width:135px" %)CANH|(% style="width:157px" %) |(% style="width:132px" %)
27 |(% style="width:281px" %)2|(% style="width:135px" %)CANL|(% style="width:157px" %) |(% style="width:132px" %)
28 |(% style="width:281px" %)3|(% style="width:135px" %)FAN 1 PWM|(% style="width:157px" %) |(% style="width:132px" %)
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" %)Blob with tin|(% style="width:132px" %)
31 |(% style="width:281px" %)6|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
32 |(% style="width:281px" %)7|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
33 |(% style="width:281px" %)8|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
34 |(% style="width:281px" %)9|(% style="width:135px" %)Accumulator|(% style="width:157px" %) |(% style="width:132px" %)
35 |(% style="width:281px" %)10|(% style="width:135px" %)Front|(% style="width:157px" %) |(% style="width:132px" %)
36 |(% style="width:281px" %)11|(% style="width:135px" %)Power fan|(% style="width:157px" %) |(% style="width:132px" %)
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" %)
41 |(% style="width:281px" %)14|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
42 |(% style="width:281px" %)15|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
43 |(% style="width:281px" %)16|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
44 |(% style="width:281px" %)17|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
45 |(% style="width:281px" %)18|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
46 |(% style="width:281px" %)19|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
47 |(% style="width:281px" %)20|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
48 |(% style="width:281px" %)21|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
49 |(% style="width:281px" %)22|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
50 |(% style="width:281px" %)23|(% style="width:135px" %)GND|(% style="width:157px" %) |(% style="width:132px" %)
51 |(% style="width:281px" %)24|(% style="width:135px" %)12V|(% style="width:157px" %) |(% style="width:132px" %)
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" %)Blob with tin|(% style="width:132px" %)
56 |(% style="width:281px" %)29|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
57 |(% style="width:281px" %)30|(% style="width:135px" %)GND|(% style="width:157px" %)Blob with tin|(% style="width:132px" %)
58 |(% style="width:281px" %)31|(% style="width:135px" %)Buzzer|(% style="width:157px" %)Is brake light in wiring harnes|(% style="width:132px" %)
59 |(% style="width:281px" %)32|(% style="width:135px" %)Brake light|(% style="width:157px" %)Is buzzer in wiring harnes|(% style="width:132px" %)
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" %)
63
64 === Microcontroller Pinout ===
65
66 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
67
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
85 |18|PB2|Input: V-sense
86 |19|VSSA|Voltage source: Ground
87 |20|VREF|Voltage reference (Internal voltage refferance)
88 |21|VDDA|Voltage source: Power (+3V3)
89 |22|PB10|Digital output: LED 8
90 |23|VSS|Voltage source: Ground
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
102 |35|VSS|Voltage source: Ground
103 |36|VDD|Voltage source: Power (+3V3)
104 |37|PA13|SWDIO
105 |38|PA14|SWCLK
106 |40|PB3|Digital output: LED 3
107 |41|PB4|Digital output: LED 4
108 |42|PB5|Digital output: LED 5
109 |43|PB6|Digital output: Enable Pump 1
110 |44|PB7|Digital output: Enable Pump 2
111 |45|PB8|Digital output: LED 6
112 |46|PB9|LED 7
113 |47|VSS|Voltage source: Ground
114 |48|VDD|Voltage source: Power (+3V3)
115
116 == Distribution circuit ==
117
118 [[image:1790100104451-169.png]]
119
120 === Green LED ===
121
122 The green LED is used to see if the fuse is ok
123
124 [[image:1790098808447-123.png]]
125
126 === Current sense ===
127
128
129
130 ==== Shunt resistor ====
131
132 A resistor with 2mOhm is in series to measure the voltage drop over the resistance that gives a voltage of 0.002 ever Amp of current
133
134 [[image:1790100157872-786.png]]
135
136 Amplifier
137
138 the amplifier is a quad chanel amplifier with a gain of 200V/V. So when the measured voltage drop is passed trough the amplifier it will give 0.4V per 1A.
139
140 ==== Filter ====
141
142 the filter is a low pass filter with a cutoff frequency of 1,6KHZ
143
144
145
146 === Power Amplifier ===
147
148 [[image:1790101431805-672.png]]
149
150 === Voltage measurement ===
151
152 A voltage divider with a ratio of 11 where 24V is equal to 2.182 on the microcontroller pin
153
154 [[image:1790101449150-901.png]]
155
156 === 12V supply(Did not work) ===
157
158 The buck converter overheated under load and made a whining sound
159
160 [[image:1790102044737-969.png||height="368" width="925"]]
161
162 Mateksys PM20S-2 Power Module was used as a quick fix to ensure that it had 12V for the competion.
163
164 === 5V, 3V3 and Canbus ===
165
166 Used standard Align template
167
168 == Control logic ==
169
170 === Source from micro controller ===
171
172 The programable red light is in the same RGB LED Diode
173
174 Direct sourcing of current from the microcontroller with a 350 ohm ressistor in series.
175
176 [[image:1790098512666-432.png]]
177
178 = Highside  switching =
179
180 to switch the
181
182 [[image:1790181075885-591.png||height="343" width="367"]]
183
184 Pump
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
187
188 [[image:1790181054296-268.png||height="306" width="371"]]
189
190 == ==
191
192 == ==
193
194 == Known issues ==
195
196 12 V did not work
197
198 Current measurement not tested
199
200
201 == Features to add ==
202
203 Add mosfets to cut power if the Lv battery is to low to save power
204
205 Add a power distrobution for Autonomus system
206
207
208 == BOM(bill of materials) ==
209
210 |=Part Number|=Description|=Ref Des|=Qty|=Manufacturer|=MPN
211 |CC0603KRX5R6BB475|Chip Capacitor, 4.7µF +/-20%, 10V, 0603|C1|1|Yageo Group|CC0603KRX5R6BB475
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 |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|(( fatal error – no data ))| |
215 |885012206020|MLCC, General Purpose, 0603, 100nF, 10V|C11|1|Wurth Elektronik|885012206020
216 |885012006051|MLCC, General Purpose, 0603, 10pF, 50V|C12, C13|2|Wurth Elektronik|885012006051
217 |885012208124|MLCC, General Purpose, 1206, 2.2µF, 100V|C17, C19|2|Wurth Elektronik|885012208124
218 |885012108022|MLCC, General Purpose, 1206, 10µF, 50V|C18|1|Wurth Elektronik|885012108022
219 |885012206071R|MLCC, General Purpose, 0603, 100nF, 25V|C20|1|Wurth Elektronik|885012206071R
220 |885012107014|MLCC, General Purpose, 0805, 10µF, 16V|C21, C22|2|Wurth Elektronik|885012107014
221 |MBASU105SB5104KFNA01|MLCC, 50V, 10%, X5R, 0.1uF, 0402|C23, C24|2|TAIYO YUDEN|MBASU105SB5104KFNA01
222 |GRM32ER71H475KA88L|MLCC, 1210, 4.7uF, 50V, ±10%, X7R|C902, C903|2|Murata|GRM32ER71H475KA88L
223 |GRM188R71A225KE15D|MLCC, 0603, 2.2uF, X7R, 10V|C904|1|Murata|GRM188R71A225KE15D
224 |CC0402KRX7R6BB104|Chip Capacitor, 100nF +/-20%, 10V, 0402|C905, C908|2|Yageo Group|CC0402KRX7R6BB104
225 |GRM1555C1H102JA01J|MLCC, 0402, 1nF, 50V, ±5%, C0G|C906|1|Murata|GRM1555C1H102JA01J
226 |GRM1555C1H4R3CA01D|MLCC, 0402, 4.3pF, 50V, C0G, ±0.25pF|C907|1|Murata|GRM1555C1H4R3CA01D
227 |GRM32ER61E226KE15L|MLCC, 1210, 22uF, 25V, X5R|C909, C910, C911, C912|4|Murata|GRM32ER61E226KE15L
228 |824094024|WE-TVS TVS Diode, SOT23-3L, 2 Channel, 24V, 38pF|D1|1|Wurth Elektronik|824094024
229 |824500261|WE-TVSP SMT Power TVS Diode, DO-214AC, 400W, 26VDC|D2|1|Wurth Elektronik|824500261
230 |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
231 |01550900DR|Fuseholder - Acs Nano|F101, F201, F301, F401, F501, F601, F701, F801, F901, F902, F903, F904|12|Littelfuse|01550900DR
232 |0466.125NR|Electric Fuse, Very Fast Blow, 0.125A, 125VAC/VDC, 1206|F102|1|Littelfuse|0466.125NR
233 |776231-1|Conn Shrouded Header, HDR 35 POS, 4mm, Thru-Hole|J1|1|TE Connectivity|776231-1
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|(( fatal error – no data ))| |
236 |44914-0401|Conn Header Vert 4POS 3mm|J4|1|Molex|44914-0401
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|(( fatal error – no data ))| |
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|
241 |BSS123NH6327XTSA1|MOSFET N-CH 100V 0.19A SOT-23|Q201, Q202, Q803, Q804, Q905, Q906|6|Infineon|BSS123NH6327XTSA1
242 |BSS83PH6327XTSA1|SIPMOS Small-Signal Transistor, -0.33A, -60V, SOT-23|Q801, Q802|2|Infineon|BSS83PH6327XTSA1
243 |IAUCN04S7L028ATMA1|Mosfet, N-ch, 40V, 100A|Q901, Q902|2|Infineon|IAUCN04S7L028ATMA1
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 ))| |
252 |WSLF25122L000FEA|Res Metal Strip 2512, 0.002Ω, 1%, 5W|R101, R201, R301, R401, R501, R601, R701, R801, R901|9|Vishay|WSLF25122L000FEA
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 |CR0805-JW-472ELF|SMD Resistor, 4.7kΩ, ±5%, 125mW, 0805|R103, R203, R303, R403, R503, R603, R703, R803, R903|9|Bourns|CR0805-JW-472ELF
255 |CR0603-FX-1001ELF|RES SMD 1K Ohm, 1%, 1/10W, 0603|R106|1|Bourns|CR0603-FX-1001ELF
256 |CRCW060347K5FKEA|Res Thick Film 0603, 47.5KΩ, 1%, 1/10W|R905|1|Vishay|CRCW060347K5FKEA
257 |RC0603FR-13100KL|Chip Resistor, 100KΩ, ±1%, 0.1W, 0603|R906|1|Yageo Group|RC0603FR-13100KL
258 |AC0402FR-0712K1L|Res Thick Film 0402, 12.1KΩ, 1%, 1/16W|R907|1|Yageo Group|AC0402FR-0712K1L
259 |CRCW060340K2FKEA|Res Thick Film 0603, 40.2KΩ, 1%, 1/10W|R908|1|Vishay|CRCW060340K2FKEA
260 |CRCW06039K53FKEA|Res Thick Film 0603, 9.53KΩ, 1%, 1/10W|R909|1|Vishay|CRCW06039K53FKEA
261 |WSR33L000FEA|Res Metal Strip 4527, 0.003Ω, 1%, 3W|R910|1|Vishay|WSR33L000FEA
262 |STM32G431CBT6|MCU 32-bit ARM Cortex M4, 128KB Flash, 48-Pin LQFP|U1|1|STMicroelectronics|STM32G431CBT6
263 |NCV7344D13R2G|CAN FD Transceiver, ISO 11898-2, 5Mbps, SOIC-8|U2|1|onsemi|NCV7344D13R2G
264 |INA4180A4IPWR|26V Quad Channel Current Sense Amplifier, 14-TSSOP|U3, U4, U5|3|Texas Instruments|INA4180A4IPWR
265 |AP64060WU-7|DC-DC Synchronous Step Down, 4.5-40V to 0.8-26V, 0.6A, TSOT-26|U6|1|Diodes Inc.|AP64060WU-7
266 |AP2112K-3.3TRG1|Fixed Positive LDO, 3.3V, 0.4V Dropout, PDSO5|U7|1|Diodes Inc.|AP2112K-3.3TRG1
267 |LM5148RGYR|3.5-80V Current Mode Synchronous Buck Controller, 24-VQFN|U801|1|Texas Instruments|LM5148RGYR
268 |ASE-8.000MHz-E-T|Crystal Oscillator, 8MHz, 3.3V, 15pF, 4-Pin SMD|Y1|1|Abracon|ASE-8.000MHZ-E-T
269
270 = AR27 Concept =
271
272 Here is the for AR27
273
274 == Changes ==
275
276 * Circuits
277 ** more dedicate supply circuits
278 ** Keep the same current
279 ** Adjust the signal led resistor on the PCB
280 * Digital signals
281 ** Adjust the signal led resistor on the PCB
282 * 12V supply
283 ** 3 seprate 12 V supply
284 *** Pump1
285 *** Pump2
286 *** Inverter/ other 12Vsupply
287 * Autonomous
288 ** Supplied by ASMS
289 ** Potentially control ASSI
290 ** ASMS state detection
291
292 == Supply table ==
293
294 === Standard supply table ===
295
296 |= |= |=
297 | | |
298 | | |
299
300 === Autonomous supply table ===
301
302 |= |=amount|=Current
303 |Steering motor |1|?
304 |(((
305 ASB/ESB
306 )))| |
307 |ASSI| |
308 | | |
309
310 == Relevant rules ==
311
312 |=(% style="width: 472px;" %)Rule number|=(% style="width: 650px;" %)Rule
313 |(% style="width:472px" %) |(% style="width:650px" %)
314 |(% style="width:472px" %) |(% style="width:650px" %)
315 |(% style="width:472px" %) |(% style="width:650px" %)
316 |(% style="width:472px" %) |(% style="width:650px" %)
317 |(% style="width:472px" %) |(% style="width:650px" %)
318 |(% style="width:472px" %) |(% style="width:650px" %)
319 |(% style="width:472px" %) |(% style="width:650px" %)
320
321
322
323
324 === ===
325
326