Leopoldo Rodríguez
2c3dffa232
Electrical/PCB: - LTC4040 Block B sized to the 12 Ah 1S4P pack (RPROG 825R -> 2.42 A ~ C/5, RS 8 mR -> 3.1 A input limit, PFI 4.60 V, backup 4.79 V, charge 4.00 V Li-ion via VSYS-referenced straps) + Block E cutoff (P11) + Block F PA4->VEH5V re-tap + Block H fail-safe Modo-B bypass (K1 normally-closed relay) + Block I NTC->PB1. - CARRIER-BOARD conversion: simpleRTK2B Pro on UNO-pattern female headers (MOD1; D0/D1=UART1, D2=RX2, D8=TX2, IOREF=3V3, 5V=SW_5V) + 4G NTRIP Master on on-board XBee socket (J7/J8; VCC=3V3_MODEM via new Block K MP1584 buck off SW_5V - the HP XBee socket is 3.3 V not 5 V). Board 120x100, placement + GND pour + DRC baselines. Custom symbols: LTC4040EUFD, AO4406A, SimpleRTK2B_Pro_Socket. - Fixed duplicated U2, stale no-connects, A4->A3 sheet; ERC 0 errors. Docs: - Canonical electrical-design-state + production delta (Block B values table, 5b/5c/5d/5e) + design/rationale/connections/BOM swept to the Jul-2 assumptions ledger (Conexiones-por-Bloque xlsx). - Guia de Conexion Protoboard: LaTeX source now maintained in-repo -> v2.1 PDF. - CircuiTikZ sheet + wiring Beamer: block 11 (NTC->PB1) + guinda ignition legend. - Client decks: Avance v1.1 (overclaims fixed) + RCA v1.1 (2-jul addendum). Repo hygiene: - .gitignore: live rtk-config (SIM/APN/NTRIP creds) now ignored and REMOVED from tracking (NOTE: rotate those credentials - they exist in prior commits); KiCad .bak/snapshots/.history, LaTeX intermediates, Office locks ignored+purged. - Removed rogue .history gitlinks that broke git status.
10 KiB
10 KiB
| tags | project | author | date | status | ||||
|---|---|---|---|---|---|---|---|---|
|
Project Drogheda | Helgen CTO | 2026-06-20 | Active |
BOM Maestro — HBOX + Gabinete (24 V)
Updated master BOM for the 24 V Drogheda unit (the dominant ICAVE variant). Costs in MXN, from
Selección de componentes para gabinete2.xlsxand the H-BOX BOM sheet. This supersedes the older loose BOM. For 12/48/110/230 V variants only the cabinet power/protection parts change (see source sheet).
Why this exists: the earlier BOM drifted from reality. This pins the as-built parts (so diagnosis/PCB work targets the right hardware) and flags the change-list for the production fix.
1. HBOX — internal unit (per unit, 24 V)
| # | Item | Marca / Modelo | Qty | MXN | Notes |
|---|---|---|---|---|---|
| 1 | H-BOX Case | Helgen Series1 (ASA print) | 1 | 100 | UV-stable, ~95–100 °C — adequate |
| 2 | H-BOX Top | Helgen Series1 (ASA) | 1 | 50 | |
| 3 | DC PSU bracket | Helgen Series1 (ASA) | 1 | 20 | |
| 4 | Battery Case | Helgen Series1 (ASA) | 1 | 30 | houses 18650 |
| 5 | SIM | Telcel micro | 1 | 100 | per-unit data plan |
| 6 | GNSS RTK | Ardusimple simpleRTK2B Pro (AS-RTK2B-PROF9P-L1L2-NH-00) | 1 | 3,340 | ZED-F9P |
| 7 | 4G/NTRIP | Ardusimple 4G NTRIP Master (AS-XBEE-4G-NA-UFL-00) | 1 | 2,440 | XBee LTE |
| 8 | MCU watchdog | DFRobot STM32F411 Blackpill | 1 | 104 | runs blackpillrtkcode_v2 |
| 9 | GNSS antenna | Ardusimple AS-ANT2B-ANN-L1L2-50SMA | 1 | 700 | multiband |
| 10 | LTE antenna | Unit Electronics AR1582 (SMA→IPEX) | 2 | 42 | 4G diversity |
| 11 | Headers F 6/8/10-pin | 2.54 mm | 1ea | 10 | board interconnect |
| 12 | 5 V supply | Mean Well SD-15B-05 (18–36 V→5 V, 3 A) | 1 | 300 | ✅ industrial — keep |
| 13 | Boost / charger | Adafruit PowerBoost 1000C (2465) | 1 | 400 | battery path — review |
| 14 | Ignition cond. | DFRobot DFR1015 buck | 1 | 106 | v3: ON-BOARD — GX16 pin 3 = raw ignition (12–24 V) → DFR1015 → PA5 (digital) |
| 15 | Battery | Hyvel 18650 1S4P (FG-0889, 3.6 V) | 1 | 204 | ⚠ charge ≤45 °C — decide |
| 16 | Status LED + holder | Steren 5 mm + bezel | 1 | 3 | PB0 path |
| 17 | Resistor | 1.5 kΩ (use TBC — see watchdog-schematic) | 1 | 1 | verify value |
| 18 | HBOX↔cabinet | GX16-5 macho/hembra | 1 | 22 | ✅ locking — keep |
| 19 | Watchdog discretes | 2N3904, IRF9540N, 2N7000, R (1k/10k/220Ω) | — | — | → consolidate on PCB |
| 20 | Dupont terminals | red + black | 2 | 4 | ⚠ vibration — eliminate |
| 21 | Wire, glands, screws, label, switch | genérico / Steren | — | ~110 | NPT 3/8 gland |
| HBOX subtotal | ≈ 8,041 |
2. Gabinete — cabinet (per unit, 24 V)
| Item | Marca / Modelo | Qty | MXN |
|---|---|---|---|
| Enclosure IP67 (ABS) | Yetlebox P3901 (39×29×16) | 1 | 1,435 |
| DIN rail | Weidmüller TS 35×7.5 | 1 | 50 |
| Neutral terminals | Weidmüller WDU 2.5 | 5 | 58 |
| Ground terminals | Weidmüller WPE4 | 4 | 154 |
| Fuse-holder terminal | Phoenix PT 6-FSI/C (3212166) | 3 | 900 |
| End stops | Wago 249-116 | 4 | 56 |
| Ignition SSR | Weidmüller TOS 24VDC 2A | 1 | 684 |
| Surge (SPD) | Phoenix TTC-6-TVSD-C-24DC-PT-I | 2 | 1,076 |
| Breaker | Phoenix TMC 81C 05A | 1 | 484 |
| Supply → 24 V | Mean Well DDR-60G-24 | 1 | 748 |
| Fuse (blade) | automotriz 2 A | 3 | 6 |
| Cable / ferrules / glands / labels | Indiana / Weidmüller / Helgen | — | ~110 |
| Shipping to port | — | 1 | 600 |
| Cabinet subtotal | ≈ 6,365 |
≈ Total per 24 V unit: ~14,400 MXN (HBOX ~8,041 + cabinet ~6,365). An
alternate supplier ("Israel" column in the sheet) shows ~1,284 MXN/cabinet
savings at 24 V — sourcing decision lives here in 09_.
3. ✅ What's already good (don't re-buy / don't duplicate)
- Cabinet is industrial-grade: SPD + breaker + isolated SSR ignition + Mean Well 24 V. The HBOX needn't re-implement input surge/protection.
- SD-15B-05 (24→5 V, 3 A) is a real industrial supply — keep.
- GX16-5 locking HBOX↔cabinet connector — keep (good vibration practice).
4. ⚠ Change-list for the production fix (feeds the PCB + hackathon)
| Change | From → To | Why | Ref |
|---|---|---|---|
| Inner case | ASA — keep (adequate); optional metal / plate-mount | conduction, not material, is the lever | RCA, hardware-brief §2b |
| Internal wiring | Dupont/hand-wire → PCB + locking connectors | vibration intermittents | hardware-brief §4 |
| Battery path | RESOLVED 2026-06-24: keep 18650 1S4P + LTC4040 charger (NTC temp-qualified; MCU cuts charge when cell hot). Proto stand-in = TP4056+MT3608 | runtime needed → fix the charging, not the cell | watchdog-electrical-design-state.md |
| Fuse | verify the 2 A blade vs measured worst-case + inrush | client's "under-rated fuse" | RCA H5 |
| Watchdog discretes | 2N3904/IRF9540N/pull-ups → integrated load switch on PCB | fewer parts, defined turn-on | hardware-brief §4 |
| SIM | micro-SIM buried → front-panel SIM or MFF2 eSIM | maintainability | hardware-brief §6.2 |
| Thermal | v3.0: waterproof duct + Blackpill smart fan (active managed) + conduct to plate / sunshade | a ducted fan removes heat without breaking IP67 | hardware-brief §2b, RCA |
5. Watchdog PCB v3 — Block B/E/H/I additions (2026-07-02)
Production parts added by the 2026-07-02 capture session — LTC4040 sized to the ~12 Ah 1S4P pack; Blocks per 03-Architecture-Hardware/watchdog-production-schematic-delta §4 (B) / §5 (E) / §5b (H) / §5c (I). Values are the sized set (RPROG → 2.42 A ≈ C/5; PFI trip 4.60 V; backup 4.79 V; charge = 4.00 V Li-ion via straps). Fab gate: bench-validate the LTC4040 backup transition + temp-qualified charge cutoff before ordering boards.
| Block | Ref | Item | Value / Package | Qty | LCSC |
|---|---|---|---|---|---|
| B | U6 | Battery-backup manager (charger + power-path + 2.5 A boost) | LTC4040EUFD — QFN-24 4×5 mm, EP=GND | 1 | verify |
| B | Q7 | VIN→VSYS disconnect NFET (gate = IGATE) | AO4406A-class, 30 V ≥10 A ≤15 mΩ — SOIC-8 | 1 | verify |
| B | RS | Input current-limit sense (3.1 A) | 8 mΩ 1 % — 1206 sense | 1 | verify |
| B | RPROG | Charge program (2.42 A ≈ C/5) | 825 Ω 1 % — 0603 | 1 | verify |
| B | RPF1 / RPF2 | PFI divider (trip 4.60 V falling) | 287 k / 100 k, 1 % — 0603 | 1+1 | verify |
| B | RFB1 / RFB2 | Backup FB divider (4.79 V; RST −7.5 %) | 499 k / 100 k, 1 % — 0603 | 1+1 | verify |
| B | L6 | Charger/boost inductor (SW↔BAT) | 2.2 µH, Isat ≥8 A, DCR <20 mΩ — 8040 | 1 | verify |
| B | CVIN | U6 VIN input caps | 10 µF X5R + 2.2 µF — 0805/0603 | 1+1 | verify |
| B | CVSYS | VSYS backup-transition hold-up (≥100 µF low-ESR) | 2×47 µF 1210 + 10 µF | 3 | verify |
| B | CBAT | U6 BAT cap | 22 µF X5R — 0805/1206 | 1 | verify |
| B | RNTB | Cell-NTC bias | 10 k 1 % low-drift — 0603 | 1 | verify |
| B | P4 | Battery connector (BAT+ / BAT− / NTC) | JST-XH 3-pos (was 2-pos) | 1 | verify |
| B | JP2 / JP3 / JP4 | Chemistry straps F2=1 / F1=0 / F0=1 → 4.00 V Li-ion (to VSYS/GND, not 3V3) | solder jumper | 3 | — |
| E | P11 | Power-cutoff loop (MAIN5V → SYS5V; ship with jumper plug) | JST-XH 2-pos | 1 | verify |
| H | K1 | Modo-B fail-safe bypass relay (NC = direct uplink) | HFD23/005-class SPDT signal relay, 5 V coil | 1 | verify |
| H | Q6 | K1 coil low-side driver | MMBT3904 — SOT-23 | 1 | verify |
| H | R40 / R41 | Base series / base pull-down (default OFF) | 1 k / 10 k — 0603 | 1+1 | verify |
| H | D6 | Coil flyback | 1N4148 — SOD-123 | 1 | verify |
| H | P13 | Modo-B uplink (F9P_TX2 / 4G_DIN / GND) | JST-XH 3-pos | 1 | verify |
| I | R42 | NTC divider top | 10 k 1 % — 0603 | 1 | verify |
| I | C24 | PB1 ADC settling | 100 nF — 0603 | 1 | verify |
| I | P12 | Hot-spot NTC (10 k, B≈3950 — at battery/modem) | JST-XH 2-pos | 1 | verify |
| H | K1 note | Capture uses the Omron G6E-134P-ST-US 5 V land pattern (Relay_SPDT_Omron_G6E); HFD23 alt = footprint swap |
— | — | verify |
5b. Carrier-board additions — Block J sockets + Block K modem buck (2026-07-02 PM)
The PROD board is now the HBOX carrier: all three modules on female headers (delta doc §5d/§5e). Board 120×100 mm. XBee VCC = 3.3 V (the Pro-class HP-socket spec — not 5 V), made by a dedicated buck on SW_5V so the watchdog's stack power-cycle also reboots the modem.
| Block | Ref | Item | Value / Package | Qty | LCSC |
|---|---|---|---|---|---|
| J | MOD1 | UNO-pattern female headers for the simpleRTK2B Pro | 2.54 mm PinSocket 1×10 + 1×8 + 1×8 + 1×6 (8.5 mm stack height) | 1 set | verify |
| J | J7 / J8 | XBee socket for the 4G NTRIP Master | PinSocket 1×10, 2.00 mm, rows 22.35 mm | 2 | verify |
| K | U7 | 3V3_MODEM buck (SW_5V → 3.33 V, ≥1.5 A pk) | MP1584EN — SOIC-8-EP | 1 | C107226 |
| K | L7 | Buck inductor | 10 µH ≥2 A — 8028 | 1 | verify |
| K | R60 / R61 | FB divider → 3.33 V | 100 k / 31.6 k, 1 % — 0603 | 1+1 | verify |
| K | Dbk2 | Freewheel | SS34 — DO-214AC | 1 | C8678 |
| K | Cbst2 / Rfreq2 / Rcomp2 / Ccomp2 | BST / fsw / comp (same as Block A; ⚠ bench-tune) | 10 nF / 100 k / 40.2 k / 2.2 nF — 0603 | 4 | verify |
| K | C40 / C41 / C43 | In / out / LTE-burst bulk | 22 µF + 22 µF + 100 µF/6.3 V elco | 3 | verify |
Open Questions
- Confirm the installed blade-fuse value (2 A may be under-rated for LTE inrush).
Battery decision→ 1S4P + LTC4040 (NTC temp-qualified charging). Pack = ~12 Ah (1S4P, ~3 Ah/cell; the "40 Ah" label was a mistake — corrected 2026-06-30). Sizes the LTC4040 charge current (2.5 A max ≈ C/5, gentle) + safety timer.- Lock supplier per line (Helgen vs alternate quote) for the August batch.
Related
- CLAUDE · 03-Architecture-Hardware/cabinet-electrical-bom · 03-Architecture-Hardware/hardware-respec-and-pcb-brief · 03-Architecture-Hardware/watchdog-schematic
- 03-Architecture-Hardware/watchdog-electrical-design-state ·
watchdog-protoboard-BOM-3boards.xlsx+watchdog-LISTA-DE-COMPRAS-ES.xlsx(proto BOMs, 3 boards)