feat(hardware): 100V Manual ON buck cell (LM5164)
CI / firmware-native (push) Successful in 56s
qa-cicd-environments / qa-kxkm-s3-memory-budget (push) Successful in 7m8s
qa-cicd-environments / qa-sim-host (push) Successful in 1m47s
qa-cicd-environments / qa-kxkm-s3-build (push) Successful in 10m52s

Context: the Manual ON rail of the motherboard uses an MCP16331
(50 V max input), out of spec for the 48 V (13s) variant whose bus
reaches 54.6 V at full charge.

Approach: new standalone power sheet derived from power.kicad_sch,
with the buck cell rebuilt around the LM5164 (100 V, synchronous,
integrated boot diode) and sized from the datasheet design
procedure; wiring by local net labels for readability; verified by
ERC against the original sheet.

Changes:
- Add hardware/pcb-bmu-v2/power_48v.kicad_sch (rev 0.1-draft):
  LM5164DDAR at 5.0 V / 202 kHz - RON 61.9k, L 100 uH (Isat>=1.2 A),
  CBOOT 2.2 nF, COUT 2x22 uF/25 V, FB divider 316k/100k (1.2 V ref),
  type-3 ripple network 330k + 3.3 nF + 82 pF C0G, EN tied to VIN,
  PGOOD no-connect
- Freewheel diode D5 and bootstrap D9/C17 removed (synchronous
  topology, integrated bootstrap diode)
- Input caps C15/C16: 10 uF/50 V -> 2.2 uF/100 V X7R
- ERC: 78 violations vs 90 on the source sheet (orphan hierarchical
  labels cleaned, no dangling items added)
- Design note and presentation deck updated (cell schematic figure)

Impact: every electrical block of the 48 V variant is now designed;
remaining work is integrating the cell into the motherboard root
sheet, the HSOP-8 layout, and bench validation.
This commit is contained in:
L'électron rare
2026-07-05 20:31:42 +02:00
parent b5a13c23c9
commit 077d95d49c
4 changed files with 6582 additions and 4 deletions
File diff suppressed because one or more lines are too long
Binary file not shown.
@@ -62,8 +62,8 @@ identiques : la sous-carte 48 V est interchangeable avec la 30 V.
| Élément | v2 actuel | Problème | Remplacement |
|---|---|---|---|
| Buck Manual ON | MCP16331, **Vin max 50 V** | 54,6 V hors spec | **LM5164** (100 V, synchrone) ou module isolé 975 V ; feedback à recalculer (sortie ~5 V inchangée) |
| C12/C13 entrée buck | 10 µF **50 V** | sous-dimensionnés | 10 µF **100 V** |
| Buck Manual ON | MCP16331, **Vin max 50 V** | 54,6 V hors spec |**cellule dessinée** (2026-07-05, `hardware/pcb-bmu-v2/power_48v.kicad_sch`, ERC 78 vs 90 baseline) : **LM5164DDAR** 5,0 V / 202 kHz — RON 61,9 k, L 100 µH (Isat ≥ 1,2 A), CBOOT 2,2 nF/50 V, COUT 2×22 µF/25 V, FB 316 k/100 k (réf 1,2 V), réseau ripple type 3 : 330 k + 3,3 nF + 82 pF C0G ; EN→VIN ; PGOOD NC ; la roue libre D5 et le bootstrap D9/C17 disparaissent (synchrone, boot intégré) |
| C15/C16 entrée buck | 10 µF **50 V** | sous-dimensionnés | ✅ 2×**2,2 µF/100 V** X7R (datasheet) — dans power_48v.kicad_sch |
| DRC | classe 30 V | isolement 54,6 V | repasser le DRC avec clearance puissance ≥ 0,5 mm (IPC-2221) — les zones v2 semblent déjà larges, à confirmer |
| Fusible par branche | dimensionné 7s/18 Ah | pack 24,5 Ah | recalculer (I_max voie + I_circ toléré) |
@@ -119,6 +119,6 @@ Trois points durs identifiés dans le code + deux calibrations :
| Lot | Contenu | Ampleur |
|---|---|---|
| Sous-carte 48 V | ✅ **fait** (2026-07-05) : `hardware/pcb-bmu-v2/BMU_switch_mosfet_48v/` — schéma (ERC = baseline) + PCB routé (DRC = baseline, 0 pad non connecté) ; R6/R7 en 0402 | livré en draft 0.2 |
| Carte mère v2.1 | buck 100 V + condos + DRC | petit |
| Carte mère v2.1 | ✅ cellule buck 100 V dessinée (`power_48v.kicad_sch`) ; reste : intégration dans la feuille racine + layout (SOT-23-6 → HSOP-8) + DRC | cellule livrée |
| Firmware | variante Kconfig + 3 fichiers + profils SOC | petit |
| Banc | protocole §6, dont caractérisation BMS packs | **le vrai travail** |
File diff suppressed because it is too large Load Diff