added USB-C connector for power

2022-10-24 10:44:53 -07:00
parent 402c746636
commit a50acc5b61
45 changed files with 721539 additions and 1067434 deletions
--- a/.gitignore
+++ b/.gitignore
@@ -1,4 +1,5 @@
 nohup.out
+*.fcstd[0-9]*

 # For PCBs designed using KiCad: https://www.kicad.org/
 # Format documentation: https://kicad.org/help/file-formats/
--- a/1-click-bom.tsv
+++ b/1-click-bom.tsv
@@ -0,0 +1,15 @@
+References	Qty	DigiKey_SKU	LCSC SKU	Local Inv	MPN	Manufacturer	Notes	Other_Vendor	Other_Vendor_PN	Package
+BZ1	1	433-1028-ND	C252915		WT-1205	Soberton				
+C1, C3	2		C1591	2	CL10B104KB8NNNC	Samsung				
+C2	1		C69335		CL10A475KA8NQNC	Samsung				
+C4, C5	2		C1653	44	CL10C220JB8NNNC	Samsung				
+J1, J2, J3, J4	4	277-1263-ND	C480516		1715721	Phoenix Contact				
+J5	1						do not populate			
+Q1, Q2, Q3, Q4	4	785-1011-1-ND	C43307		AO3416	Alpha & Omega				SOT-23
+R1, R2, R11, R12, R21, R22, R23, R24, R25, R26, R27, R28, R29, R30, R31, R32, R33, R34, R35, R36, R37, R38, R39, R40, R41, R42, R43, R44, R45, R46, R47, R48, R49, R50, R51, R52, R53, R54, R55, R56, R58, R59, R60, R61, R62, R63, R64, R65, R66, R67, R68, R69, R70, R71, R72, R73, R74, R75, R76, R77, R78, R79, R80, R81, R82, R83, R84, R85, R86, R87, R88, R89, R90, R91, R92, R93, R94, R95, R96, R97	80	1206W4F953JT5E	C247167		C247167	Uniroyal				
+R3, R4, R5, R6, R7, R8, R9, R10, R13, R14, R15, R16, R17, R18, R19, R20	16	311-10.0KHRCT-ND	C98220	10	RC0603FR-0710KL	Yageo				0603
+R57	1	311-1.00KHRCT-ND	C22548	23	RC0603FR-071KL	Yageo				0603
+SW1	1	450-1649-ND	C266204		1825910-2	TE				
+U1	1				3-01-1234-B	HiLetgo	7-pin SPI/I2C convertible	Amazon	B01MQPQF24	
+U2	1		C132230		ATMEGA328PB-AU	Microchip				
+Y1	1		C389840		7325-1600A1010-00	XTY				
--- a/ArduinoNanoEquiv.kicad_sch
+++ b/ArduinoNanoEquiv.kicad_sch
--- a/BatteryTester.fcstd
+++ b/BatteryTester.fcstd
--- a/BatteryTester.kicad_pcb
+++ b/BatteryTester.kicad_pcb
--- a/BatteryTester.kicad_pro
+++ b/BatteryTester.kicad_pro
@@ -33,9 +33,9 @@
        "other_text_thickness": 0.15,
        "other_text_upright": false,
        "pads": {
-          "drill": 0.762,
-          "height": 1.524,
-          "width": 1.524
+          "drill": 3.2,
+          "height": 3.2,
+          "width": 3.2
        },
        "silk_line_width": 0.12,
        "silk_text_italic": false,
--- a/BatteryTester.kicad_sch
+++ b/BatteryTester.kicad_sch
--- a/BatteryTester.step
+++ b/BatteryTester.step
--- a/BatteryTester.stl
+++ b/BatteryTester.stl
--- a/R11_SMD.kicad_sch
+++ b/R11_SMD.kicad_sch
--- a/R12_SMD.kicad_sch
+++ b/R12_SMD.kicad_sch
--- a/R1_SMD.kicad_sch
+++ b/R1_SMD.kicad_sch
--- a/R2_SMD.kicad_sch
+++ b/R2_SMD.kicad_sch
--- a/README.md
+++ b/README.md
@@ -4,9 +4,10 @@
 This tester will discharge any combination of up to four NiMH and Li-Ion
 cells into a dummy load to determine capacity.  Cell type is determined
 automatically upon connection.  A pushbutton rotates through the four
-channels, selecting the results to view.  The display is a 1" OLED; an
-Arduino Nano is soldered to the board.  The Arduino's USB connector is used
-for power input and reprogramming.
+channels, selecting the results to view.  The display is a 1" OLED.  A USB-C
+connector is used for power; the AVRISP header pads are used to program the
+onboard ATMega328PB microcontroller (and could optionally be used instead of
+USB-C for power).

 While the default configuration offers testing of NiMH and Li-Ion cells, the
 voltage range constants in the software can be adjusted to enable testing of
@@ -19,13 +20,12 @@ expanding from one channel to four, I also made these changes:

 1) The IRFZ44N is a far larger MOSFET than needed.  The AO3416 should be
   more than sufficient, with power dissipation in this application of only
-   a few milliwatts.
-2) Replacing the 10Ω load resistors with 4.7Ω resistors provides a
-   reasonable discharge current (around 200-250 mA) for NiMH, while not
-   being excessively high for Li-Ion (closer to 700-800 mA).  Mount them
-   with a gap between the board to improve cooling.  They will get hot to
-   the touch when discharging Li-Ion cells; 800 mA into 4.7Ω works out to
-   3 W.
+   a few milliwatts.  My experience with the previous version has borne out
+   this decision; the AO3416 doesn't even break a sweat. :)
+2) This version replaces the 4.7Ω 5W through-hole load resistors with sets of 
+   20 95.1Ω ¼W SMD resistors that pencil out to 4.755Ω and the same power. 
+   This should facilitate automated manufacturing, and the PCB should be
+   better able to absorb and disspiate the heat.
 3) The software was cleaned up a bit to better manage transitions between
   different states: idle (no battery), discharging, discharged, and error 
   (voltage too low or high)
--- a/fabrication/BatteryTester-B_Cu.gbl
+++ b/fabrication/BatteryTester-B_Cu.gbl
--- a/fabrication/BatteryTester-B_Mask.gbs
+++ b/fabrication/BatteryTester-B_Mask.gbs
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--- a/fabrication/BatteryTester-B_Paste.gbp
+++ b/fabrication/BatteryTester-B_Paste.gbp
@@ -0,0 +1,15 @@
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--- a/fabrication/BatteryTester-B_Silkscreen.gbo
+++ b/fabrication/BatteryTester-B_Silkscreen.gbo
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--- a/fabrication/BatteryTester-Edge_Cuts.gm1
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--- a/fabrication/BatteryTester-F_Cu.gtl
+++ b/fabrication/BatteryTester-F_Cu.gtl
--- a/fabrication/BatteryTester-F_Mask.gts
+++ b/fabrication/BatteryTester-F_Mask.gts
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--- a/fabrication/BatteryTester-F_Paste.gtp
+++ b/fabrication/BatteryTester-F_Paste.gtp
@@ -0,0 +1,323 @@
+%TF.GenerationSoftware,KiCad,Pcbnew,(6.0.6)*%
+%TF.CreationDate,2022-10-24T10:13:03-07:00*%
+%TF.ProjectId,BatteryTester,42617474-6572-4795-9465-737465722e6b,rev?*%
+%TF.SameCoordinates,PX6350ce0PY83c6600*%
+%TF.FileFunction,Paste,Top*%
+%TF.FilePolarity,Positive*%
+%FSLAX46Y46*%
+G04 Gerber Fmt 4.6, Leading zero omitted, Abs format (unit mm)*
+G04 Created by KiCad (PCBNEW (6.0.6)) date 2022-10-24 10:13:03*
+%MOMM*%
+%LPD*%
+G01*
+G04 APERTURE LIST*
+G04 Aperture macros list*
+%AMRoundRect*
+0 Rectangle with rounded corners*
+0 $1 Rounding radius*
+0 $2 $3 $4 $5 $6 $7 $8 $9 X,Y pos of 4 corners*
+0 Add a 4 corners polygon primitive as box body*
+4,1,4,$2,$3,$4,$5,$6,$7,$8,$9,$2,$3,0*
+0 Add four circle primitives for the rounded corners*
+1,1,$1+$1,$2,$3*
+1,1,$1+$1,$4,$5*
+1,1,$1+$1,$6,$7*
+1,1,$1+$1,$8,$9*
+0 Add four rect primitives between the rounded corners*
+20,1,$1+$1,$2,$3,$4,$5,0*
+20,1,$1+$1,$4,$5,$6,$7,0*
+20,1,$1+$1,$6,$7,$8,$9,0*
+20,1,$1+$1,$8,$9,$2,$3,0*%
+G04 Aperture macros list end*
+%ADD10RoundRect,0.250000X-0.312500X-0.625000X0.312500X-0.625000X0.312500X0.625000X-0.312500X0.625000X0*%
+%ADD11RoundRect,0.200000X0.200000X0.275000X-0.200000X0.275000X-0.200000X-0.275000X0.200000X-0.275000X0*%
+%ADD12RoundRect,0.150000X-0.150000X0.587500X-0.150000X-0.587500X0.150000X-0.587500X0.150000X0.587500X0*%
+%ADD13RoundRect,0.225000X-0.225000X-0.250000X0.225000X-0.250000X0.225000X0.250000X-0.225000X0.250000X0*%
+%ADD14RoundRect,0.225000X0.225000X0.250000X-0.225000X0.250000X-0.225000X-0.250000X0.225000X-0.250000X0*%
+%ADD15RoundRect,0.225000X0.250000X-0.225000X0.250000X0.225000X-0.250000X0.225000X-0.250000X-0.225000X0*%
+%ADD16RoundRect,0.200000X-0.275000X0.200000X-0.275000X-0.200000X0.275000X-0.200000X0.275000X0.200000X0*%
+%ADD17R,1.600000X0.550000*%
+%ADD18R,0.550000X1.600000*%
+%ADD19R,1.400000X1.200000*%
+G04 APERTURE END LIST*
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+M02*
--- a/fabrication/BatteryTester-F_Silkscreen.dxf
+++ b/fabrication/BatteryTester-F_Silkscreen.dxf
--- a/fabrication/BatteryTester-F_Silkscreen.gto
+++ b/fabrication/BatteryTester-F_Silkscreen.gto
--- a/fabrication/BatteryTester-NPTH-drl_map.gbr
+++ b/fabrication/BatteryTester-NPTH-drl_map.gbr
@@ -0,0 +1,981 @@
+%FSLAX45Y45*%
+G04 Gerber Fmt 4.5, Leading zero omitted, Abs format (unit mm)*
+G04 Created by KiCad (PCBNEW (6.0.6)) date 2022-10-24 10:13:07*
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--- a/fabrication/BatteryTester-NPTH.drl
+++ b/fabrication/BatteryTester-NPTH.drl
@@ -0,0 +1,27 @@
+M48
+; DRILL file {KiCad (6.0.6)} date Mon Oct 24 10:13:06 2022
+; FORMAT={-:-/ absolute / metric / decimal}
+; #@! TF.CreationDate,2022-10-24T10:13:06-07:00
+; #@! TF.GenerationSoftware,Kicad,Pcbnew,(6.0.6)
+; #@! TF.FileFunction,NonPlated,1,2,NPTH
+FMAT,2
+METRIC
+; #@! TA.AperFunction,NonPlated,NPTH,ComponentDrill
+T1C2.100
+; #@! TA.AperFunction,NonPlated,NPTH,ComponentDrill
+T2C3.200
+%
+G90
+G05
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+T0
+M30
--- a/fabrication/BatteryTester-PTH-drl_map.gbr
+++ b/fabrication/BatteryTester-PTH-drl_map.gbr
--- a/fabrication/BatteryTester-PTH.drl
+++ b/fabrication/BatteryTester-PTH.drl
@@ -0,0 +1,101 @@
+M48
+; DRILL file {KiCad (6.0.6)} date Mon Oct 24 10:13:06 2022
+; FORMAT={-:-/ absolute / metric / decimal}
+; #@! TF.CreationDate,2022-10-24T10:13:06-07:00
+; #@! TF.GenerationSoftware,Kicad,Pcbnew,(6.0.6)
+; #@! TF.FileFunction,Plated,1,2,PTH
+FMAT,2
+METRIC
+; #@! TA.AperFunction,Plated,PTH,ViaDrill
+T1C0.400
+; #@! TA.AperFunction,Plated,PTH,ComponentDrill
+T2C1.000
+; #@! TA.AperFunction,Plated,PTH,ComponentDrill
+T3C1.001
+; #@! TA.AperFunction,Plated,PTH,ComponentDrill
+T4C1.300
+%
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--- a/fabrication/BatteryTester-job.gbrjob
+++ b/fabrication/BatteryTester-job.gbrjob
@@ -0,0 +1,127 @@
+{
+  "Header": {
+    "GenerationSoftware": {
+      "Vendor": "KiCad",
+      "Application": "Pcbnew",
+      "Version": "(6.0.6)"
+    },
+    "CreationDate": "2022-10-24T10:13:04-07:00"
+  },
+  "GeneralSpecs": {
+    "ProjectId": {
+      "Name": "BatteryTester",
+      "GUID": "42617474-6572-4795-9465-737465722e6b",
+      "Revision": "rev?"
+    },
+    "Size": {
+      "X": 73.71,
+      "Y": 76.25
+    },
+    "LayerNumber": 2,
+    "BoardThickness": 1.6,
+    "Finish": "None"
+  },
+  "DesignRules": [
+    {
+      "Layers": "Outer",
+      "PadToPad": 0.0,
+      "PadToTrack": 0.0,
+      "TrackToTrack": 0.2,
+      "MinLineWidth": 0.25,
+      "TrackToRegion": 0.508,
+      "RegionToRegion": 0.508
+    }
+  ],
+  "FilesAttributes": [
+    {
+      "Path": "BatteryTester-F_Cu.gtl",
+      "FileFunction": "Copper,L1,Top",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "BatteryTester-B_Cu.gbl",
+      "FileFunction": "Copper,L2,Bot",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "BatteryTester-F_Paste.gtp",
+      "FileFunction": "SolderPaste,Top",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "BatteryTester-B_Paste.gbp",
+      "FileFunction": "SolderPaste,Bot",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "BatteryTester-F_Silkscreen.gto",
+      "FileFunction": "Legend,Top",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "BatteryTester-B_Silkscreen.gbo",
+      "FileFunction": "Legend,Bot",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "BatteryTester-F_Mask.gts",
+      "FileFunction": "SolderMask,Top",
+      "FilePolarity": "Negative"
+    },
+    {
+      "Path": "BatteryTester-B_Mask.gbs",
+      "FileFunction": "SolderMask,Bot",
+      "FilePolarity": "Negative"
+    },
+    {
+      "Path": "BatteryTester-Edge_Cuts.gm1",
+      "FileFunction": "Profile",
+      "FilePolarity": "Positive"
+    }
+  ],
+  "MaterialStackup": [
+    {
+      "Type": "Legend",
+      "Name": "Top Silk Screen"
+    },
+    {
+      "Type": "SolderPaste",
+      "Name": "Top Solder Paste"
+    },
+    {
+      "Type": "SolderMask",
+      "Thickness": 0.01,
+      "Name": "Top Solder Mask"
+    },
+    {
+      "Type": "Copper",
+      "Thickness": 0.035,
+      "Name": "F.Cu"
+    },
+    {
+      "Type": "Dielectric",
+      "Thickness": 1.51,
+      "Material": "FR4",
+      "Name": "F.Cu/B.Cu",
+      "Notes": "Type: dielectric layer 1 (from F.Cu to B.Cu)"
+    },
+    {
+      "Type": "Copper",
+      "Thickness": 0.035,
+      "Name": "B.Cu"
+    },
+    {
+      "Type": "SolderMask",
+      "Thickness": 0.01,
+      "Name": "Bottom Solder Mask"
+    },
+    {
+      "Type": "SolderPaste",
+      "Name": "Bottom Solder Paste"
+    },
+    {
+      "Type": "Legend",
+      "Name": "Bottom Silk Screen"
+    }
+  ]
+}
--- a/85934
+++ b/85934
--- a/gerbers-1.0.zip
+++ b/gerbers-1.0.zip
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+++ b/gerbers/BatteryTester-B_CrtYd.gbr
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--- a/gerbers/BatteryTester-B_Cu.gbl
+++ b/gerbers/BatteryTester-B_Cu.gbl
--- a/gerbers/BatteryTester-B_Mask.gbs
+++ b/gerbers/BatteryTester-B_Mask.gbs
--- a/gerbers/BatteryTester-B_Paste.gbp
+++ b/gerbers/BatteryTester-B_Paste.gbp
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--- a/gerbers/BatteryTester-B_SilkS.gbo
+++ b/gerbers/BatteryTester-B_SilkS.gbo
@@ -1,14 +0,0 @@
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--- a/gerbers/BatteryTester-Edge_Cuts.gm1
+++ b/gerbers/BatteryTester-Edge_Cuts.gm1
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--- a/gerbers/BatteryTester-F_Cu.gtl
+++ b/gerbers/BatteryTester-F_Cu.gtl
--- a/gerbers/BatteryTester-F_Mask.gts
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