PCB MP Design Overview

PCB MP | What this does: This is a PCB for a router with a brushed DC Motor.
This PCB turns on a brushed DC motor with power MOFSETS. It also is the BMS for a 3s3p cylindrical cell li-ion battery pack, it accepts 5V through a
waterproof USB connector and steps it up to 12.6V, there are 2 normally open pushbuttons (one is for power-on and the other is a safety switch), there is a
thermistor on the PCB that only let’s it be used below 45°C, there are 2 LEDs (green and red) to indicate function and battery life

8.4V
12.6V

-
+ +

12.6V 30A
+
- -

Components:
1) 3s3P 18350 batteries
4.2V 2) PCB
3) Power Switch
0V 4) Poka Yoke Switch
5) 540 Brushed DC Motor
6) Screw holes

PCB MP | Current Schematic: 1 2 3 4 5 6 7 8

V OLTAGE REGULATOR LED INDICATORS COQ3

Q3 COQ5
Q5 BMS BATTERY CHARGUER CIRCUIT
AO D403 AO D403
Vbat TO 5V
3
PIQ303 2
PIQ302 2
PIQ502 3
PIQ503

A PIQ301 PIQ501 +BATT A

1
COC8 COQ4
Q4 COQ6
Q6
C8
COF1
F1 AO D403 AO D403
POVIN
VIN PIF102 PIF101 PIC801 PIC802 GND P+ 3 2 2 3
POP0
P+ PIQ403 PIQ402 PIQ602 PIQ603

P+ 0
COU1
U1 +5V 100uF
MIC5205
NLP0 PIQ401 PIQ601

1
P+ 1
IN O UT
5
PIU101 PIU105
PIR10 1 PIR1201 PIR1301 COR18
R18
3 4 COU3
PIU103 EN BP PIU104
R10 COR10 COR12
R12 COR13
R13 U3 COC12
C12 5 11.1V
1K
PIC401 PIC501 PIC601 1201
PIC0.1uF
GND
PIR1802 PIR1801 PITP901

5.1K 1M 5.1K S-8254AAFFT-TB-S COTP9

TP9
COC4 COC5 COC6
PIR201
COR2 PIU102
C4 C5 C6 PIR10 2 PIR1202 PIR1302
1 16 PIC1301 COR19
R19
R2
PIC402 470pF
PIC502 0.1uF
PIC602 47uF
COR7 VUSB
COD2
PIU301 COP VDD PIU3016
PIC120 COC13 PIC1601 6 7.4V
2

R7 D2 15 C13 PIR1902
1K PIR1901 PITP1001

COTP10
PIR202
47K
DL1 PIR702 PIR701 PID202 PID201
2
VC1 PIU3015
14 PIC1302
0.1uF COC16
C16
COR20
TP10

POVBAT
VBAT GND GND GND GND
470 ORANGE
PIU302
VMP VC2
VC3
PIU3014

PIU3013
13 PIC1602 0.1uF PIR2002
R20
1K PIR2001
4
PITP1101
3.7V
COR8
R8 COD3
D3 3 12 COTP11
TP11
PIR301 PIU303 D OP VC4 PIU3012
DL2 PIR802 PIR801 PID302 PID301
COR3
R3 COR21
R21
10K
C6 is a tantalum cap and is 0.9" away 470 PIR901 COR9
R9
GREEN 4
PIU304 VINI CTL
11
PIU3011 PIR2102 1K PIR2101

PIR302 from U1 output. 1K

5
PIU305 CDT
6 10
CCT SEL GND
PIR902 PIR1 01 PIC901 PIC10 1
PIU306 PIU3010

GND
B GND COR11
R11 COC9
C9 COC10
C10
98
PIR1401
COR14
R14
PIC1501 COC15
C15
B

GND PIR1 02
1K
PIC902 0.1uF
PIC10 2 0.1uF NC
VSS
PIU309
PIU308
7
PIU307
PIR1402
1K
PIC1502 2.2uF

COR22
R22
NLBAT0RTN PITP1201
BAT_RTN 3 0V
PIR2202
51 PIR2201
COTP12
TP12
PIR1701 0.01PIR1702
COR17
R17
PIR2301 0.01PIR2302
GND
COR23
R23

MICRO C O NTROLLER M OTOR V OLTAGE REGULATOR - CHARGING CIRCUIT

+BATT

COL1
L1 D4 COD4
C COTP5
TP5 10uH SS34
C
PITP501 +12.6V
+5V +5V +5V 1 VUSB PIL101 PIL102 PID402 PID401 P+

COD1
D1
PID10 COC11
C11
PIC1 01 COC14
C14
PIC1401 PIR1602 U4 COU4 COR24
R24
PIR2402
COC20
C20
PIR2702
COU2
U2 COR16
R16 10 COR27
R27
COC1 PIC10 COC2 PIC201 PIU204 PIU2018 SS34
PID102 22uF
PIC1 02 22uF
PIC1402
FP6296 0.1uF
18

C1 C2 ATMEGA328P-AU 1.5 100K

4

COTP6
TP6 M_GND PIR1601 1 8
PIR2401 PIR2701
PIC2 01 COC22 PIC2301 COC23 PIC2401 COC24
0.1uF
PIC102 0.1uF
PIC20 PITP601 PIU401 LX HVDD PIU408 PIC2002 PIC2001 C22 C23 C24
VCC
AVCC

2
20
PIU2020 AREF PB0-D8
12
PIU2012 COC17
C17
PIC1701 2
PIU402 LX OC
7
PIU407 PIR2601 120K PIR2602
COR26
R26 PIR2802
PIC2 02 22uF
PIC2302 22uF
PIC2402 22uF
13 POM0GND
M_GND COR25
R25 COR28
R28
GND GND
PB1-D9 PIU2013
PIQ102 PIQ20 PIQ702 GND
1nF
PIC1702 3
VCC C O MP
6
8.2KPIR2502 PIC2102 10.5K

2
19 14 PIU403 PIU406 PIR2501 PIC2101
PIR2801
ADC6-A6 PB2-D10/SS C21 COC21 47nF
PIC301 PIC1801
PIU2019 PIU2014
22 15 1 1 1 4 5
COC3
C3 PIU2022 ADC7-A7 PB3-D11/M OSI PIU2015 M OSI SENSOR PIQ101 COQ1
Q1 SENSOR PIQ201 COQ2
Q2 SENSOR PIQ701 COQ7
Q7 PIU404 EN FB PIU405 PIC1902 PIC1901

GND
16 OSCILLATOR PIR601 COR6 COC19
C19 10pF
GND COC18
0.1uF
PIC302 PB4-D12/MISO PIU2016
17
MISO R6
PIQ103 AO D404
PIQ203 AO D404
PIQ703 AO D404
PIC1802 C18
PIU409
3

3
PB5-D13/SCK PIU2017 SCK PIY103 10K 1uF GND GND
3

9
VUSB
7
XTAL1/PB6-D20* PIU207
8
COY1Y1 2 PIR602 Isample
GND XTAL2/PB7-D21* PIU208 16MHz
PIY102
PIRs101 CORs1
Rs1 GND
PIY101 GND
0.002
1

23 GND
PC0-D14/ A0 VBAT GND 0.2W
RESET
PIU2023

24
PIRs102
PC1-D15/ A1 POIsample
Isample
PIU2024
25
+5V PC2-D16/ A2 POVUSB
VUSB
PIU2025
26
PC3-D17/A3 PIU2026 POTHRM
THRM GND
27
PC4-D18/ A4-SDA PIU2027
D PIR101 28 D
PC5-D19/ A5-SCL PIU2028

COR1
R1
RESET/PC6-D22*
29
PIU2029 RST
10K
PIR102 COR4
R4 COTP1
TP1
30
PD0-D0/RXD PIU2030 PIR402 100 PIR401 PITP101 RXD
31
PORST
RST PD1-D1/TXD PIU2031 PIR502 100 PIR501 PITP201 TXD
32
PD2-D2/INT0 PODS1
DS1 COR5
R5 COTP2
TP2
PIJ10 SWITCH USB PORT CHARGING
PIU2032

1
1

PD3-D3/INT1 PIU201 PODS2

DS2
2
COJP1
JP1 PD4-D4 PIU202 PODL1
DL1
9
PD5-D5 PODL2
DL2
PIJ102 Arduino PinOut
PIU209
10
2

PD6-D6 PIU2010
11
PD7-D7 PIU2011
POSENSOR
SENSOR
GND

GND

PIU203 COJ2
J2
3

USB_B_Micro

+5V DS1 DS2 1

GND VBUS PIJ201 VIN

3
COTP3
TP3 COTP7
TP7 D+
PIC702
PIJ203
PITP301 PITP701
2
COC7
C7 7 X D- PIJ202

Shield
THERMISTOR 4

GND
E 0.1uF ID E
PIC701 COTP4
TP4 COTP8
TP8
PIJ204

PIJ206 PIJ205
PITP401 PITP801

+5V 8 Y

6
5
ICSP PORT +5V

COJ1
J1
PIR1501
1 2 GND GND GND
POMISO
MISO PIJ101 PIJ102 COR15
R15 GND
3 4
POSCK
SCK PIJ103 PIJ104 POMOSI
M OSI 10K
5 6 PIR1502
RST PIJ105 PIJ106
THRM
PITH101 2021
GND COTH1
TH1
10k DC Motor control
PITH102 3s3P BMS circuit
Router Master PCB
GND Dabass42
Sheet: /
File: RouterMaster.sch

Title: RouterMaster
Size: A4 Date: 2021-09-02 Rev:
KiCad E.D.A. kicad (5.1.4)-1 Id: 1/1
F F
1 2 3 4 5 6 7 8
 PCB MP | Current BOM:
Reference Value Footprint Datasheet Cost Mfg PN Vendor Link Vendor PN Qty Rev
C4 470pF C_0603_1608Metric h ps://datasheet.lcsc.com/lcsc/1810311135_Murata-Electronics-GRM188R72E471KW07D_C117800.pdf
0.08 GRM188R72E471KW07D h ps://lcsc.com/product-detail/Mul
C117800
layer-Ceramic-Capacitors-MLCC-SMD-SMT_Murata-Electronics-GRM
1 OK
C1-C3, C5, C7, C9, C10, C12, C13, C16, C20 0.1uF C_0603_1608Metric h ps://datasheet.lcsc.com/lcsc/1806111858_Vishay-Intertech-VJ0603Y104KXJAC_C165952.pdf
0.07 VJ0603Y104KXJAC h ps://lcsc.com/product-detail/Mul
C165952
layer-Ceramic-Capacitors-MLCC-SMD-SMT_Vishay-Intertech-VJ0603
11 OK
C6 47uF CP_EIA-3216-18_Kemet-A h ps://datasheet.lcsc.com/lcsc/2006190013_KEMET-T490A476M010ATE1K2_C561853.pdf
0.27 T490A476M010ATE1K2 h ps://lcsc.com/product-detail/Tantalum-Capacitors_KEMET-T490A476M010ATE1K2_C561853.html
C561853 1 OK
C8 100uF CP_EIA-3216-18_Kemet-A h ps://datasheet.lcsc.com/lcsc/1809291515_KEMET-T490A107M006ATE800_C122251.pdf
0.22 T490A107M006ATE800 h ps://lcsc.com/product-detail/span-style-background-color-
C122251 0-Tantalum-span-span-style-background-c
1 OK
C11, C14, C22-C24 22uF C_0603_1608Metric h ps://datasheet.lcsc.com/lcsc/1811082126_YAGEO-CC0603MRX5R6BB226_C109447.pdf
0.07 CC0603MRX5R6BB226 h ps://lcsc.com/product-detail/Mul
C109447
layer-Ceramic-Capacitors-MLCC-SMD-SMT_YAGEO-CC0603MRX5R6
5 OK
C15 2.2uF C_0603_1608Metric h ps://datasheet.lcsc.com/lcsc/1810311120_Murata-Electronics-GRT188R61H225ME13D_C126632.pdf
0.08 GRT188R61H225ME13D h ps://lcsc.com/product-detail/Mul
C126632
layer-Ceramic-Capacitors-MLCC-SMD-SMT_Murata-Electronics-GRT
1 OK
C17 1nF C_0603_1608Metric h ps://datasheet.lcsc.com/lcsc/1912111437_Murata-Electronics-GCJ188R71E102KA01D_C363952.pdf
0.04 GCJ188R71E102KA01D h ps://lcsc.com/product-detail/Mul
C363952
layer-Ceramic-Capacitors-MLCC-SMD-SMT_Murata-Electronics-GCJ
1 OK
C18 1uF C_0603_1608Metric h ps://datasheet.lcsc.com/lcsc/1912111437_TDK-C1608X5R1E105KT000E_C329944.pdf
0.04 C1608X5R1E105KT000E h ps://lcsc.com/product-detail/Mul
C329944
layer-Ceramic-Capacitors-MLCC-SMD-SMT_TDK-C1608X5R1E105KT
1 OK
C19 10pF C_0603_1608Metric h ps://www.mouser.com/datasheet/2/40/X7RDielectric-777024.pdf
0.22 0603YC100KAT2A h ps://www.mouser.com/ProductDetail/AVX/0603YC100KAT2A?qs=85rsz3mMAQl2%252Bgq3ovPgxA%3
581-0603YC100KAT2A 1 OK
C21 47nF C_0603_1608Metric h ps://www.mouser.com/datasheet/2/445/885012206093-1727689.pdf
0.10 885012206093 h ps://www.mouser.com/ProductDetail/Wurth-Elektronik/885012206093?qs=0KOYDY2FL288tq17Jsi3DA
710-885012206093 1 OK
D1, D4 SS34 D_SMC h ps://www.mouser.com/datasheet/2/308/SS39-D-1814961.pdf
0.68 SS34 h ps://www.mouser.com/ProductDetail/ON-Semiconductor-Fairchild/SS34/?qs=2ONuHmP%2FXzb3ub11
512-SS34 2 OK
D2 ORANGE LED_1206_3216Metric_Castellated h ps://www.mouser.com/datasheet/2/239/Lite-On-LTST-C150KFKT-1175232.pdf
0.32 LTST-C150KFKT h ps://www.mouser.com/ProductDetail/Lite-On/LTST-C150KFKT?qs=e82azXs4VXuJhUMTTSV2xQ%3D%3
859-LTST-C150KFKT 1 OK
D3 GREEN LED_1206_3216Metric_Castellated h ps://www.mouser.com/datasheet/2/445/150120VS75000-1714563.pdf
0.22 150120VS75000 h ps://www.mouser.com/ProductDetail/Wurth-Elektronik/150120VS75000/?qs=LlUlMxKIyB19Jz1m%2F
710-150120VS75000 1 OK
F1 0 Fuse_1812_4532Metric_Castellated h ps://datasheet.lcsc.com/lcsc/1912111437_Li
0.47 1812L200/12DR
elfuse-1812L200-12DR_C315901.pdf
h ps://lcsc.com/product-detail/Rese
C315901
able-Fuses_Li elfuse-1812L200-12DR_C315901.html
1 OK
J1 Conn_02x03_Odd_Even PinHeader_2x03_P2.54mm_Ver cal DNP 1 OK
h ps://datasheet.lcsc.com/szlcsc/
1912111437_XKB-Connec vity-U-
J2 USB_B_Micro U-E-M7SS-Y-0 E-M7SS-Y-0_C381141.pdf 1.06 U-E-M7SS-Y-0 h ps://lcsc.com/product-detail/New-Arrivals_XKB-Enterprise-U-E-M7SS-Y-0_C381141.html
C381141 1 OK
JP1 Jumper_2_Open SolderJumper-2_P1.3mmOpen_RoundedPad1.0x1.5mm DNP 1 OK
L1 10uH L_Bourns-SRN8040_8x8.15mm h ps://www.mouser.com/datasheet/2/54/srn8040ta-1391519.pdf
0.83 SRN8040TA-100M h ps://www.mouser.com/ProductDetail/Bourns/SRN8040TA-100M?qs=Vt59ZOdFuWZHXKgwFo0tyA%3D
652-SRN8040TA-100M 1 OK
Q1, Q2, Q7 AOD404 TO-252-2 h p://aosmd.com/pdfs/datasheet/AOD404.pdf
0.00 AOD404 h ps://www.aliexpress.com/item/1005002971721999.html?spm=a2g0o.productlist.0.0.78461a197Gow
AOD404 3 OK
Q3-Q6 AOD403 TO-252-2 h p://www.aosmd.com/pdfs/datasheet/AOI403.pdf
0.00 AOD403 h ps://www.aliexpress.com/item/1005002971721999.html?spm=a2g0o.productlist.0.0.78461a197Gow
AOD403 4 OK
R2 47K R_0603_1608Metric h ps://www.mouser.com/datasheet/2/54/crxxxxx-1858361.pdf
0.10 CR0603-JW-473ELF h ps://www.mouser.com/ProductDetail/Bourns/CR0603-JW-473ELF/?qs=4wQOTo1SlKkxv8Dz9mkwPw%
652-CR0603-JW-473ELF 1 OK
R1, R3, R6, R15 10K R_0603_1608Metric h ps://www.mouser.com/datasheet/2/348/sfr-e-1507454.pdf
0.10 SFR03EZPF1002 h ps://www.mouser.com/ProductDetail/ROHM-Semiconductor/SFR03EZPF1002/?qs=byeeYqUIh0P65uw
755-SFR03EZPF1002 4 OK
R4, R5 100 R_0603_1608Metric h ps://www.mouser.com/datasheet/2/427/crcwce3-1762584.pdf
0.10 CRCW0603100RJNEAC h ps://www.mouser.com/ProductDetail/Vishay-Dale/CRCW0603100RJNEAC/?qs=E3Y5ESvWgWN6yxvHw
71-CRCW0603100RJNEAC 2 OK
R7, R8 470 R_0603_1608Metric h ps://www.mouser.com/datasheet/2/315/AOA0000C334-1314047.pdf
0.17 ERJ-S03J471V h ps://www.mouser.com/ProductDetail/Panasonic/ERJ-S03J471V?qs=Zyl8A9hlmJqf2TYg%252BmLyfQ%3
667-ERJ-S03J471V 2 OK
R9, R11, R14, R18-R21 1K R_0603_1608Metric h ps://datasheet.lcsc.com/lcsc/1912111437_PANASONIC-ERJP03J102V_C427272.pdf
0.04 ERJP03J102V h ps://lcsc.com/product-detail/Chip-span-style-background-color-
C427272 0-Resistor-span-Surface-Mount_PAN
7 OK
R10, R13 5.1K R_0603_1608Metric h ps://www.mouser.com/datasheet/2/447/PYu_AC_51_RoHS_L_7-1714230.pdf
0.10 AC0603FR-135K1L h ps://www.mouser.com/ProductDetail/YAGEO/AC0603FR-135K1L?qs=r5DSvlrkXmJb%252BQMH4MIw%
603-AC0603FR-135K1L 2 OK
R12 1M R_0603_1608Metric h ps://www.vishay.com/doc?20066 0.12 RCC06031M00FKEA h ps://www.mouser.com/ProductDetail/Vishay-Dale/RCC06031M00FKEA?qs=GedFDFLaBXHlMNeJInwoZ
71-RCC06031M00FKEA 1 OK
R16 1.5 R_0603_1608Metric h ps://www.mouser.com/datasheet/2/447/PYu_RT_1_to_0_01_RoHS_L_11-1669912.pdf
0.15 RT0603DRE071R5L h ps://www.mouser.com/ProductDetail/YAGEO/RT0603DRE071R5L?qs=UG%2F8xqv%2F6WcIkObVBGihp
603-RT0603DRE071R5L 1 OK
R22 51 R_0805_2012Metric h ps://www.mouser.com/datasheet/2/315/AOA0000C301-1488782.pdf
0.10 ERJ-6GEYJ510V h ps://www.mouser.com/ProductDetail/Panasonic/ERJ-6GEYJ510V?qs=YMBIwoNQYdVuEOSMRjWbGA%
667-ERJ-6GEYJ510V 1 OK
R17, R23 0.01 R_2512_6332Metric h ps://datasheet.lcsc.com/lcsc/2003061603_Shenzhen-Yezhan-Elec--YLR12-3-10F-W_C489549.pdf
0.19 YLR12-3-10F-W h ps://lcsc.com/product-detail/Current-Sense-Resistors-Shunt-Resistors_Shenzhen-Yezhan-Elec-YLR12-3
C489549 2 OK
R24 10 R_0603_1608Metric
h ps://4donline.ihs.com/images/VipMasterIC/IC/ROHM/ROHM-S-A0011096274/ROHM-S-A0011096274-1.pdf?hkey=CECEF36DEECDED6468708AAF2E19C0C6
0.10 SDR03EZPJ100 h ps://www.mouser.com/ProductDetail/ROHM-Semiconductor/SDR03EZPJ100?qs=byeeYqUIh0ONFiBKd
755-SDR03EZPJ100 1 OK
R25 8.2K R_0603_1608Metric h ps://www.mouser.com/datasheet/2/315/AOA0000C301-1488782.pdf
0.10 ERJ-3GEYJ822V h ps://www.mouser.com/ProductDetail/Panasonic/ERJ-3GEYJ822V?qs=cjWVw0OZ8%2FaZVQevwfCOYg%
667-ERJ-3GEYJ822V 1 OK
R26 120K R_0603_1608Metric h ps://www.mouser.com/datasheet/2/54/crxxxxx-1858361.pdf
0.10 CR0603-FX-1203ELF h ps://www.mouser.com/ProductDetail/Bourns/CR0603-FX-1203ELF?qs=e7cxVwPieuqUag3kwHXPtg%3
652-CR0603FX-1203ELF 1 OK
R27 100K R_0603_1608Metric h ps://4donline.ihs.com/images/VipMasterIC/IC/VISH/VISH-S-A0003599164/VISH-S-A0003599164-1.pdf?hkey=CECEF36DEECDED6468708AAF2E19C0C6
0.10 CRCW0603100KFKEAC h ps://www.mouser.com/ProductDetail/Vishay-Dale/CRCW0603100KFKEAC?qs=E3Y5ESvWgWPxzfNYyM
71-CRCW0603100KFKEAC 1 OK
R28 10.5K R_0603_1608Metric h ps://www.mouser.com/datasheet/2/392/susumu_RR_Data_Sheet-1206438.pdf
0.10 RR0816P-1052-D-03C h ps://www.mouser.com/ProductDetail/Susumu/RR0816P-1052-D-03C?qs=nCAm%252BcMdy9y%2FTa8
754-RR0816P-1052D03C 1 OK
Rs1 0.002 R_2512_6332Metric h ps://datasheet.lcsc.com/lcsc/2009261536_YAGEO-PA2512FKE7W0R002E_C728306.pdf
0.13 PA2512FKE7W0R002E h ps://lcsc.com/product-detail/Chip-Resistor-Surface-Mount_YAGEO-PA2512FKE7W0R002E_C728306.ht
C728306 1 OK
TH1 10k R_0603_1608Metric h ps://datasheet.lcsc.com/lcsc/1810170335_PANASONIC-ERTJ1VG103FA_C153011.pdf
0.10 ERTJ1VG103FA h ps://lcsc.com/product-detail/span-style-background-color-
C153011 0-NTC-span-Thermistors_PANASONIC-ERT
1 OK
U1 MIC5205 SOT-23-5 h p://ww1.microchip.com/downloads/en/DeviceDoc/20005785A.pdf
0.38 MIC5205-5.0YM5-TR h ps://lcsc.com/product-detail/Dropout-Regulators-LDO_Microchip-Tech-MIC5205-5-0YM5-TR_C70431.
C70431 1 OK
U2 ATMEGA328P-AU TQFP-32_7x7mm_P0.8mm h ps://datasheet.lcsc.com/lcsc/1809101618_Microchip-Tech-ATMEGA328P-AU_C14877.pdf
4.02 ATMEGA328P-AU h ps://lcsc.com/product-detail/ATMEL-AVR_ATMEL_ATMEGA328P-AU_ATMEGA328P-AU_C14877.html
C14877 1 OK
U3 S-8254AAFFT-TB-S SOP65P640X110-16N-S8254A h ps://datasheet.lcsc.com/lcsc/1912211133_ABLIC-S-8254AAFFT-TB-S_C468227.pdf
0.94 S-8254AAFFT-TB-S h ps://lcsc.com/product-detail/BaC468227
ery-Management-ICs_ABLIC-S-8254AAFFT-TB-S_C468227.html
1 OK
U4 FP6296 SOIC-8-1EP_3.9x4.9mm_P1.27mm_EP2.29x3mm h ps://datasheet.lcsc.com/lcsc/1810182103_Feeling-Tech-FP6296XR-G1_C133888.pdf
0.85 FP6296XR-G1 h ps://lcsc.com/product-detail/DC-DC-Converters_Feeling-Tech-FP6296XR-G1_C133888.html
C133888 1 OK
Y1 16MHz CSTNE16M0V530000R0 h ps://www.mouser.com/datasheet/2/281/murata_04192018_CSTN_CeramResonCERAL-1323383.pdf
0.28 CSTNE16M0V530000R0 h ps://www.mouser.com/ProductDetail/Murata-Electronics/CSTNE16M0V530000R0?qs=y6ZabgHbY%25
81-CSTNE16M0V530000R 1 OK
TOTAL 75
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History, Feedback, and Constraints
PCB MP | History:

Step History

Two friends decided to make a handheld router as a side project to their corporate tech
1 jobs. We have strong mechanical engineering knowledge but no experience with power
electronics.
Our rst PCB is designed by a Chinese electronics rm. It has a lot of issues and doesn’t
2
work well.
We payed an EE rm in Columbia to redesign the PCB using an ATMEGA328. The PCB
3 worked most of the time but there were layout problems and traces would burn up when
the motor was under high load.

We payed a US EE to re-layout the board with the same BOM, samples of this design
4
have been kicked o but not arrived yet.

5 We payed another EE to review the design for errors which we’d like addressed

6 Today: We want a design we can mass produce (10,000-20,000 units)

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PCB MP | Constraints:
Constraints

Chinese-made components are preferred because they are not short in supply. Because our design was
IC supply / Chinese originally done by a chinese rm all of our components are available
components
Any new components must be available like our current ones. A good rule of thumb is that if you can buy it
on aliexpress then you’re probably good to go

Chinese-made ICs are not a problem for us, but bad design is a problem. See attached PDF from previous
EE for his review
Design Errors and Fault
Tolerance One example of this are the power MOFSETS. The columbian rm initially used some TI fancy mofsets but
they’re no longer available. So we’re using AOD404s (seem to be chinese copies because originals are no
longer manufactured) but rather than using 1 we’re using 3 in parallel to make the design fault tolerant.

We used an Arduino chip so we could understand and write the rmware ourselves but never planned on
using it in high volume. Anyways now the atmega328pb is no longer in stock. We’d like to switch to a
Microcontroller
smaller IC at some point but now the main constraint is nding an IC that will be consistently available.
Looks like ESP32s are generally available but please see if there’s a better option with shortish lead times

Size Same footprint

Firmware Firmware needs to be compact (no oating point math) and rock solid for shipping to consumers
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PCB MP | Review from last EE: Got to x a lot of this stu but still keep available parts
Schema c
1. Voltage regulator (MIC5205)
a. Maximum input voltage speci ed at 16V. Although it’s not cri cally low, I would go with a higher input voltage (20 to 24) to avoid induc ve kickback from the motor damaging it. Alterna vely, you could add a TVS diode on the ba ery
pack. This would also protect against ESD during assembly.
b. The quiescent current is pre y high (es mated 120 ~ 150uA at a load current of less than 30mA). Parts with lower quiescent current may be available.
c. C6 – tantalum capacitors have shorter life and are easily damaged by heat. These days ceramic capacitor technology advanced enough so 22uF ceramics or higher are very a ordable. I would replace C6 with 2x 22uF ceramics, 10V at
least. I would place one right at the output of the regulator (next top the pin) and the other one close to the microcontroller.C5 won’t be required anymore.
d. Based on “a” and “b” I would replace the MIC5205 part.
e. The R2/R3 divider will only allow the microcontroller to read a voltage up to 6.27V (if the internal reference of 1.1V is used). If VCC is used as reference, it will allow reading a voltage up to 28.5V which is way too high. Either way, it has
to be recalculated. Also it needs a decoupling capacitor (ceramic 100nF would be ne) – see ADC sec on of the microcontroller
2. BMS charger circuit
a. AOD403 is obsolete. You should pick another one. I did some searching on Digikey and the other ones that would be good replacements (Same package) are obsolete as well (also AOD… devices). I would suggest replacing the package
to a LFPAK56, PowerSO8 or similar. Those are much be er packages for this transistor and they exist with RdsON much smaller than 6mOhm
b. I assume the purpose of R13 is to slow down the turning ON of the MOSFET. The chip already seems to have a pre y small current (min 10uA) so it may not be needed.
c. My experience with Chinese manufactured semiconductors had not been great.
d. I would change R17 and R23 with a single 5 milliohms resistor – easier to do PCB rou ng and be er to pick up the voltage drop.
3. MOTOR
a. If PWM is used o drive the motor then the MOSFETs need a gate driver
b. The current measuring circuit needs a current sense ampli er. The ISample voltage is way too small (70mV at the max current of 35A). That is only 65LSB of the ADC if used with the 1.1V reference. If used with the VCC reference would
be completely unusable.
c. R6 can be smaller: 51kOhm or so
4. VOLTAGE REGULATOR – CRITICAL
a. This is not a Li-Ion charger but a simple voltage regulator. Based on R27 / R28 the output voltage is set at 12.6V which is 4.2V / cell. This is the charge termina on voltage. A er the current drops under a speci ed threshold the charger
should stop charging. This regulator will never stop charging the ba ery. It will hold the voltage at 4.2V per cell, causing metallic Li electropla ng of the electrodes leading to internal short circuits = explosion and/or re. This is a very
dangerous circuit for charging a Li-Ion ba ery.
b. It seems like the current limit is set to about 4A (switch current) which leads to over 2A of input current. The power supply should be able to provide that. Plugging it into a computer USB port would probably trigger it to go into over-
current protec on or simply reboot the computer (some do not have over-current protec ons). In other words, it does not seem like there is a func onal current limit.
5. MICROCONTROLLER
a. Missing a larger decoupling capacitor (see VOLTAGE REGULATOR secC on)
b. Missing decoupling capacitors on the ADC inputs
c. Missing decoupling caps on the bu on inputs
d. Pre y expensive part for what it does ($2.15 in volume). It’s an old 8 bit microcontroller. There are many alterna ves today based on Cortex CPUs (32 bit) and much cheaper. One op on would be: ST STM32G030F6P6TR $0.93 AT
Digikey (in volume)
6. USB PORT CHARGING
a. I would add a ferrite bead or inductor to reduce EMI on the cable
7. LED INDICATORS
a. I would drive the LED with an IO going low. Flip the circuit so the LED is placed in between VCC and an IO. This way the LED current does not have to go through the microcontroller internal supply rail.
b. You could probably safely reduce the 470 ohm to 330 or 270.
c. C8 seems a bit too big. The USB standard limits the maximum capacitance to 10uF. If you have anything bigger (144uF here) you would need a so start circuit. Of course this applies if you are planning from charging the router from a
computer port.

PCB Layout
1. Smaller connectors are available for ISP programming of the microcontroller. Loog at TAG connect. This connector would also cost 0 on the PCB side.
2. Decoupling capacitors on the microcontroller power lines have only one via to the ground. At least two are recommended. Same applied to the ground / power connec ons of the micro. Same applies to the USB connector. Only 3 vias to
take all the charging current.
3. The drill legend is not required. More useful would be to place the layer stack-up (which should include the copper weight on each layer). Due to the 35A max current I advise to manufacture using 2oz of copper on all layers
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