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Power controller

Version 35.7 by Mathias Larsen on 2026/09/23 17:37
Power controller
3D model of the Power controller from Altium Designer
Supply voltage
12–24 V DC
Fused circuits
9 (5 × 24 V outputs, fan outputs, digital outputs, 12 V circuit, internal electronics)
24 V outputs
5
24 V fan outputs
2 (shared fuse)
12 V outputs
2
Digital outputs (shared fuse)
2 × 12 V switched (5 A), 2 × 24 V switched (330 mA), 2 × PWM
Communication interface
CAN FD
Maximum data rate
1 MbpsD
|Maximum data rate|1 Mbps

Tables of contents

Pinout

Connector pinout

Pin comment 
1CANH  
2CANL  
3FAN 1 PWM  
4FAN 2 PWM  
5GNDBlob with tin 
6GNDBlob with tin 
7GNDBlob with tin 
8GNDBlob with tin 
9Accumulator  
10Front  
11Power fan  
12Power fan  

13

GND  
14GND  
15GND  
16GND  
17GND  
18GND  
19GND  
20GND  
21GND  
22GND  
23GND  
2412V  
2512V  
2612V power pump1  
2712V Power pump2  
28GNDBlob with tin 
29GNDBlob with tin 
30GNDBlob with tin 
31BuzzerIs brake light in wiring harnes 
32Brake lightIs buzzer in wiring harnes 
3324Vreserve 
3424Vreserve 
3524Vsensor card 

Microcontroller Pinout

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 

Physical pinElectrical pin

Description

1VBATPower source from a backup battery if a RTC would be used (Connected to +3V3 in this case)
5OSC_INClock input (8MHz oscillator)
7NRSTNegative reset which can be connected to a button (Connected to +3V3)
8PA0Analog signal: Current 6 Supply 24V resserve
9PA1Analog signal: Current 7 Supply 24V resserve
10PA2Analog signal: Current 5 Supply sensor card
11PA3Analog signal: Current 4 Supply front 
12PA4Analog signal: Current 3 Supply accumulator
13PA5Analog signal: Current 2 Supply fans
14PA6Digital output LED 9
15PA7Digital output LED 2
16PB0Analog signal Current 8 Supply buzzer, brake light 
17PB1PWM: enable Fan 1
18PB2Input: V-sense
19VSSAVoltage source: Ground
20VREFVoltage reference (Internal voltage refferance)
21VDDAVoltage source: Power (+3V3)
22PB10Digital output: LED 8
23VSSVoltage source: Ground
24VDDVoltage source: Power (+3V3)
25PB11Current 1 Internal components 
26PB12Current 9 Supply 12 V Pumps inverter and datalogger  
29PB15PWM: enable fan 2
30PA8Digital output Enable buzzeer(On the car it is Brake light)
31PA9

Digital output Enable brake light(On the car it is the buzzer)

32PA10Input ASMS signal
33PA11CAN-BUS RXD
34PA12CAN-BUS TXD
35VSSVoltage source: Ground
36VDDVoltage source: Power (+3V3)
37PA13SWDIO
38PA14SWCLK
40PB3Digital output: LED 3
41PB4Digital output: LED 4
42PB5Digital output: LED 5
43PB6Digital output: Enable Pump 1
44PB7Digital output: Enable Pump 2
45PB8Digital output: LED 6
46PB9LED 7 
47VSSVoltage source: Ground
48VDDVoltage source: Power (+3V3)

Distribution circuit

1790100104451-169.png

Green LED

The green LED is used to see if the fuse is ok 

1790098808447-123.png

Current sense

Shunt resistor

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

1790100157872-786.png

Amplifier

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.

Filter

the filter is a low pass filter with a cutoff frequency of 1,6KHZ

Power Amplifier

1790101431805-672.png

Voltage measurement

A voltage divider with a ratio of 11 where 24V is equal to 2.182 on the microcontroller pin

1790101449150-901.png

12V supply(Did not work)

The buck converter overheated under load and made a whining sound

1790102044737-969.png

Mateksys PM20S-2 Power Module was used as a quick fix to ensure that it had 12V for the competion.

5V, 3V3 and Canbus

Used standard Align template 

Control logic

Source from micro controller

The programable red light is in the same RGB LED Diode

Direct sourcing of current from the microcontroller with a 350 ohm ressistor in series.

1790098512666-432.png

Highside   switching

to switch the 

1790181075885-591.png

Pump

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 

1790181054296-268.png

Known issues

12 V did not work

Current measurement not tested 

Features to add

Add mosfets to cut power if the Lv battery is to low to save power

Add a power distrobution for Autonomus system

BOM(bill of materials)

Part NumberDescriptionRef DesQtyManufacturerMPN
CC0603KRX5R6BB475Chip Capacitor, 4.7µF +/-20%, 10V, 0603C11Yageo GroupCC0603KRX5R6BB475
CL10B104KA8NNNCMLCC, 0.1 uF, 25V, ±10%, X7R, 0603C2, C3, C4, C8, C9, C10, C14, C15, C169Samsung Electro-MechanicsCL10B104KA8NNNC
CL10B105KA8NFNCMLCC, 1uF, 25V, 10%, X7R, 0603C5, C72Samsung Electro-MechanicsCL10B105KA8NFNC
CL10B103KB8NNNCMLCC, 10nF, 50V, +125C, X7R, ±10%, 0603C6, C101, C201, C301, C401, C501, C601, C701, C801, C90110(( fatal error – no data ))  
885012206020MLCC, General Purpose, 0603, 100nF, 10VC111Wurth Elektronik885012206020
885012006051MLCC, General Purpose, 0603, 10pF, 50VC12, C132Wurth Elektronik885012006051
885012208124MLCC, General Purpose, 1206, 2.2µF, 100VC17, C192Wurth Elektronik885012208124
885012108022MLCC, General Purpose, 1206, 10µF, 50VC181Wurth Elektronik885012108022
885012206071RMLCC, General Purpose, 0603, 100nF, 25VC201Wurth Elektronik885012206071R
885012107014MLCC, General Purpose, 0805, 10µF, 16VC21, C222Wurth Elektronik885012107014
MBASU105SB5104KFNA01MLCC, 50V, 10%, X5R, 0.1uF, 0402C23, C242TAIYO YUDENMBASU105SB5104KFNA01
GRM32ER71H475KA88LMLCC, 1210, 4.7uF, 50V, ±10%, X7RC902, C9032MurataGRM32ER71H475KA88L
GRM188R71A225KE15DMLCC, 0603, 2.2uF, X7R, 10VC9041MurataGRM188R71A225KE15D
CC0402KRX7R6BB104Chip Capacitor, 100nF +/-20%, 10V, 0402C905, C9082Yageo GroupCC0402KRX7R6BB104
GRM1555C1H102JA01JMLCC, 0402, 1nF, 50V, ±5%, C0GC9061MurataGRM1555C1H102JA01J
GRM1555C1H4R3CA01DMLCC, 0402, 4.3pF, 50V, C0G, ±0.25pFC9071MurataGRM1555C1H4R3CA01D
GRM32ER61E226KE15LMLCC, 1210, 22uF, 25V, X5RC909, C910, C911, C9124MurataGRM32ER61E226KE15L
824094024WE-TVS TVS Diode, SOT23-3L, 2 Channel, 24V, 38pFD11Wurth Elektronik824094024
824500261WE-TVSP SMT Power TVS Diode, DO-214AC, 400W, 26VDCD21Wurth Elektronik824500261
150282M167310WL-SFTD Full-color Top LED, 2828, R/G/B, 70°D101, D201, D301, D402, D501, D601, D701, D801, D9019Wurth Elektronik150282M167310
01550900DRFuseholder - Acs NanoF101, F201, F301, F401, F501, F601, F701, F801, F901, F902, F903, F90412Littelfuse01550900DR
0466.125NRElectric Fuse, Very Fast Blow, 0.125A, 125VAC/VDC, 1206F1021Littelfuse0466.125NR
776231-1Conn Shrouded Header, HDR 35 POS, 4mm, Thru-HoleJ11TE Connectivity776231-1
76829-0002Mega-Fit Straight Male Header, 2x2, 5.7mm PitchJ21Molex76829-0002
(4 pin header)2.54mm pitch 1x4 vertical headerJ31(( fatal error – no data ))  
44914-0401Conn Header Vert 4POS 3mmJ41Molex44914-0401
1461247-3Relay, Gen Purpose, SPST, 8A, 24VK11TE ConnectivityOJ-SH-124LMH,000
784234510WE-CNSA Common Mode Line Filter, 1210, 7850Ω, 200mAL11(( fatal error – no data ))  
74438323100WE-MAPI SMT Power Inductor, 2510, 10µH, 0.9A, 733mΩL2, L32Wurth Elektronik74438323100
XAL7070-651MEBGeneral Purpose Inductor, 0.65uH, 20%, 3028L9011CoilcraftXAL7070-651MEB 
BSS123NH6327XTSA1MOSFET N-CH 100V 0.19A SOT-23Q201, Q202, Q803, Q804, Q905, Q9066InfineonBSS123NH6327XTSA1
BSS83PH6327XTSA1SIPMOS Small-Signal Transistor, -0.33A, -60V, SOT-23Q801, Q8022InfineonBSS83PH6327XTSA1
IAUCN04S7L028ATMA1Mosfet, N-ch, 40V, 100AQ901, Q9022InfineonIAUCN04S7L028ATMA1
BSC084P03NS3GATMA1P-Channel OptiMOS P3, -30V VDS, -78.6A ID, PG-TDSON-8-1Q903, Q9042InfineonBSC084P03NS3GATMA1
(( TBD ))Generic Resistor, 350Ω, 0603R104, R204, R304, R404, R504, R606, R704, R804, R9049(( TBD ))  
(( TBD ))Generic Resistor, 1KΩ, 0603R205, R206, R807, R808, R913, R9146(( TBD ))  
(( TBD ))Generic Resistor, 10KΩ, 0603R1, R207, R208, R805, R806, R809, R810, R811, R812, R911, R912, R915, R91613(( TBD ))  
(( TBD ))Generic Resistor, 1.6KΩ, 0603R21(( TBD ))  
(( TBD ))Generic Resistor, 2.2Ω, 0603R31(( TBD ))  
(( TBD ))Generic Resistor, 27KΩ, 0603R41(( TBD ))  
(( TBD ))Generic Resistor, 5.1KΩ, 0603R51(( TBD ))  
WSLF25122L000FEARes Metal Strip 2512, 0.002Ω, 1%, 5WR101, R201, R301, R401, R501, R601, R701, R801, R9019VishayWSLF25122L000FEA
CR0603-FX-1002ELFSMD Resistor, 10kΩ, ±1%, 100mW, 0603R102, R105, R202, R302, R402, R502, R602, R702, R802, R90210BournsCR0603-FX-1002ELF
CR0805-JW-472ELFSMD Resistor, 4.7kΩ, ±5%, 125mW, 0805R103, R203, R303, R403, R503, R603, R703, R803, R9039BournsCR0805-JW-472ELF
CR0603-FX-1001ELFRES SMD 1K Ohm, 1%, 1/10W, 0603R1061BournsCR0603-FX-1001ELF
CRCW060347K5FKEARes Thick Film 0603, 47.5KΩ, 1%, 1/10WR9051VishayCRCW060347K5FKEA
RC0603FR-13100KLChip Resistor, 100KΩ, ±1%, 0.1W, 0603R9061Yageo GroupRC0603FR-13100KL
AC0402FR-0712K1LRes Thick Film 0402, 12.1KΩ, 1%, 1/16WR9071Yageo GroupAC0402FR-0712K1L
CRCW060340K2FKEARes Thick Film 0603, 40.2KΩ, 1%, 1/10WR9081VishayCRCW060340K2FKEA
CRCW06039K53FKEARes Thick Film 0603, 9.53KΩ, 1%, 1/10WR9091VishayCRCW06039K53FKEA
WSR33L000FEARes Metal Strip 4527, 0.003Ω, 1%, 3WR9101VishayWSR33L000FEA
STM32G431CBT6MCU 32-bit ARM Cortex M4, 128KB Flash, 48-Pin LQFPU11STMicroelectronicsSTM32G431CBT6
NCV7344D13R2GCAN FD Transceiver, ISO 11898-2, 5Mbps, SOIC-8U21onsemiNCV7344D13R2G
INA4180A4IPWR26V Quad Channel Current Sense Amplifier, 14-TSSOPU3, U4, U53Texas InstrumentsINA4180A4IPWR
AP64060WU-7DC-DC Synchronous Step Down, 4.5-40V to 0.8-26V, 0.6A, TSOT-26U61Diodes Inc.AP64060WU-7
AP2112K-3.3TRG1Fixed Positive LDO, 3.3V, 0.4V Dropout, PDSO5U71Diodes Inc.AP2112K-3.3TRG1
LM5148RGYR3.5-80V Current Mode Synchronous Buck Controller, 24-VQFNU8011Texas InstrumentsLM5148RGYR
ASE-8.000MHz-E-TCrystal Oscillator, 8MHz, 3.3V, 15pF, 4-Pin SMDY11AbraconASE-8.000MHZ-E-T

AR27 Concept

Here is the for AR27

Changes

  • Circuits
    • more dedicate supply circuits
    • Keep the same current
    • Adjust the signal led resistor on the PCB
  • Digital signals
    • Adjust the signal led resistor on the PCB
  • 12V supply
    • 3 seprate 12 V supply
      • Pump1
      • Pump2
      • Inverter/ other 12Vsupply
  • Autonomous
    • Supplied by ASMS
    • Potentially control ASSI
    • ASMS state detection

Supply table

Standard supply table

 Voltage 
IPC24 
Pumps12 
Fans24 
HVbox12 
Energy meter  
Inverter  
Accumulator  
Brake light  
   
   

Autonomous supply table

 amountCurrent
Steering motor 1?

ASB/ESB

 ?
ASSI2?
RES1?

Relevant rules

Rule numberRule