MustafaMulla29/rp2040-bldc-motor-controller-new

A USB‑C PD–powered RP2040 BLDC motor controller PCB with 3.3 V logic, MCT8329A sensorless commutation, three MOSFET half-bridges, protected power switching, USB data, controls, and motor connectors.

Version
0.3.82
License
unset
Stars
0

circuit/schematic-layout.json

{
  "sheets": [
    {
      "name": "guide",
      "title": "Connection guide",
      "index": 0
    },
    {
      "name": "usb_pd",
      "title": "Configurable USB-C power input",
      "index": 1
    },
    {
      "name": "logic_power",
      "title": "Power switch and 3.3 V supply",
      "index": 2
    },
    {
      "name": "pd_load",
      "title": "PD motor feed / reverse isolation",
      "index": 3
    },
    {
      "name": "programming",
      "title": "USB programming and debug",
      "index": 4
    },
    {
      "name": "processor",
      "title": "RP2040 supervisor",
      "index": 5
    },
    {
      "name": "motor_control",
      "title": "MCT8329A driver and sensing",
      "index": 6
    },
    {
      "name": "controls",
      "title": "Speed, ARM and hardware inhibit",
      "index": 7
    },
    {
      "name": "bridge",
      "title": "Three-phase power bridge",
      "index": 8
    }
  ],
  "sections": [
    {
      "sheet": "bridge",
      "name": "bridge_power",
      "title": "bridge power"
    },
    {
      "sheet": "bridge",
      "name": "bus_reservoir",
      "title": "bus reservoir"
    },
    {
      "sheet": "bridge",
      "name": "motor_output",
      "title": "One removable motor connector / U V W"
    },
    {
      "sheet": "controls",
      "name": "mct_arm",
      "title": "Hardware motor disable / USB inhibit"
    },
    {
      "sheet": "controls",
      "name": "mct_arm_switch",
      "title": "mct arm switch"
    },
    {
      "sheet": "controls",
      "name": "mct_throttle",
      "title": "mct throttle"
    },
    {
      "sheet": "logic_power",
      "name": "logic_buck",
      "title": "AP63203 fixed 3.3 V buck regulator"
    },
    {
      "sheet": "logic_power",
      "name": "power_input_bypass",
      "title": "power input bypass"
    },
    {
      "sheet": "logic_power",
      "name": "power_output_discharge",
      "title": "power output discharge"
    },
    {
      "sheet": "logic_power",
      "name": "power_switch",
      "title": "power switch"
    },
    {
      "sheet": "logic_power",
      "name": "power_switch_bias",
      "title": "power switch bias"
    },
    {
      "sheet": "motor_control",
      "name": "mct",
      "title": "MCT8329A sensorless gate driver"
    },
    {
      "sheet": "motor_control",
      "name": "mct_bus_bypass",
      "title": "mct bus bypass"
    },
    {
      "sheet": "motor_control",
      "name": "mct_defaults",
      "title": "Default direction, brake and clock"
    },
    {
      "sheet": "motor_control",
      "name": "mct_reg_bypass",
      "title": "mct reg bypass"
    },
    {
      "sheet": "motor_control",
      "name": "mct_service",
      "title": "mct service"
    },
    {
      "sheet": "motor_control",
      "name": "mct_status",
      "title": "I2C and status pull-ups"
    },
    {
      "sheet": "motor_control",
      "name": "mct_vreg_bypass",
      "title": "mct vreg bypass"
    },
    {
      "sheet": "pd_load",
      "name": "motor_voltage",
      "title": "Motor-bus monitor"
    },
    {
      "sheet": "pd_load",
      "name": "pd_load",
      "title": "Fused motor power / transient isolation"
    },
    {
      "sheet": "processor",
      "name": "mcu_adc",
      "title": "ADC supply filter"
    },
    {
      "sheet": "processor",
      "name": "mcu_core",
      "title": "1.1 V core supply bypass"
    },
    {
      "sheet": "processor",
      "name": "mcu_crystal",
      "title": "mcu crystal"
    },
    {
      "sheet": "processor",
      "name": "mcu_flash",
      "title": "QSPI flash / boot strap"
    },
    {
      "sheet": "processor",
      "name": "mcu_led",
      "title": "mcu led"
    },
    {
      "sheet": "processor",
      "name": "mcu_logic",
      "title": "mcu logic"
    },
    {
      "sheet": "processor",
      "name": "mcu_reset",
      "title": "Reset and status LED"
    },
    {
      "sheet": "programming",
      "name": "bootsel",
      "title": "bootsel"
    },
    {
      "sheet": "programming",
      "name": "prog_detect",
      "title": "prog detect"
    },
    {
      "sheet": "programming",
      "name": "reset",
      "title": "reset"
    },
    {
      "sheet": "programming",
      "name": "swd",
      "title": "swd"
    },
    {
      "sheet": "programming",
      "name": "usb_data",
      "title": "J1 DATA / USB 2.0 device / 5 V only"
    },
    {
      "sheet": "usb_pd",
      "name": "pd_current",
      "title": "pd current"
    },
    {
      "sheet": "usb_pd",
      "name": "pd_service",
      "title": "pd service"
    },
    {
      "sheet": "usb_pd",
      "name": "pd_sink",
      "title": "USB-C PD sink / selectable PDO"
    },
    {
      "sheet": "usb_pd",
      "name": "pd_switch",
      "title": "Reverse-blocking input switch"
    },
    {
      "sheet": "usb_pd",
      "name": "pd_voltage",
      "title": "pd voltage"
    },
    {
      "sheet": "usb_pd",
      "name": "pd_pullups",
      "title": "Host I2C and status pull-ups"
    },
    {
      "sheet": "usb_pd",
      "name": "pd_reset_bias",
      "title": "Reset default state"
    },
    {
      "sheet": "processor",
      "name": "mcu_3v3_bypass_1",
      "title": "3.3 V decoupling"
    },
    {
      "sheet": "processor",
      "name": "mcu_3v3_bypass_2",
      "title": "3.3 V decoupling"
    }
  ],
  "notes": [
    {
      "sheet": "usb_pd",
      "x": -12.24,
      "y": 7.92,
      "lines": [
        "PWR: 5/9/15/20 V PD"
      ]
    },
    {
      "sheet": "usb_pd",
      "x": -6.256,
      "y": 5.76,
      "lines": [
        "STUSB4500 supply bypass"
      ]
    },
    {
      "sheet": "usb_pd",
      "x": 0.0,
      "y": 7.92,
      "lines": [
        "Reverse-blocking input switch"
      ]
    },
    {
      "sheet": "usb_pd",
      "x": 6.8,
      "y": 7.92,
      "lines": [
        "Motor-branch current monitor"
      ]
    },
    {
      "sheet": "usb_pd",
      "x": 1.7,
      "y": 0.996,
      "lines": [
        "Host I2C / status pull-ups"
      ]
    },
    {
      "sheet": "usb_pd",
      "x": -10.88,
      "y": -2.664,
      "lines": [
        "VBUS voltage divider"
      ]
    },
    {
      "sheet": "usb_pd",
      "x": 3.74,
      "y": -3.888,
      "lines": [
        "PD service / reset"
      ]
    },
    {
      "sheet": "programming",
      "x": -12.24,
      "y": 7.2,
      "lines": [
        "DATA: USB-C \u2192 ESD protection \u2192 RP2040"
      ]
    },
    {
      "sheet": "programming",
      "x": 5.1,
      "y": 6.48,
      "lines": [
        "SWD debug / recovery"
      ]
    },
    {
      "sheet": "programming",
      "x": -11.56,
      "y": -1.584,
      "lines": [
        "5 V cable detection"
      ]
    },
    {
      "sheet": "programming",
      "x": 5.44,
      "y": 1.872,
      "lines": [
        "BOOTSEL: close to GND for USB boot"
      ]
    },
    {
      "sheet": "programming",
      "x": 5.44,
      "y": -1.44,
      "lines": [
        "RUN: close to GND to reset"
      ]
    },
    {
      "sheet": "processor",
      "x": -13,
      "y": 7.92,
      "lines": [
        "1.1 V core bypass"
      ]
    },
    {
      "sheet": "processor",
      "x": -12.24,
      "y": 5.112,
      "lines": [
        "QSPI flash / BOOTSEL"
      ]
    },
    {
      "sheet": "processor",
      "x": -11.56,
      "y": -2.88,
      "lines": [
        "12 MHz crystal"
      ]
    },
    {
      "sheet": "processor",
      "x": 6.8,
      "y": -4.176,
      "lines": [
        "ADC supply filter"
      ]
    },
    {
      "sheet": "processor",
      "x": 8.16,
      "y": 1.44,
      "lines": [
        "Status LED"
      ]
    },
    {
      "sheet": "bridge",
      "x": -12.24,
      "y": 8.244,
      "lines": [
        "Three identical half bridges; gate drives from sheet 7"
      ]
    },
    {
      "sheet": "bridge",
      "x": -10.2,
      "y": -3.456,
      "lines": [
        "Motor-bus reservoir / service"
      ]
    },
    {
      "sheet": "bridge",
      "x": -2.04,
      "y": -2.952,
      "lines": [
        "Common 10 mOhm shunt"
      ]
    },
    {
      "sheet": "bridge",
      "x": 10.54,
      "y": 6.624,
      "lines": [
        "Three 4 mm sockets"
      ]
    },
    {
      "sheet": "usb_pd",
      "x": -12.24,
      "y": -8.424,
      "lines": [
        "Reference: STUSB4500 datasheet, Fig. 10 (MCU application). Provision 9 V default; select voltage by I2C.",
        "PD9 \u2192 motor feed, sheet 4. VBUS_RAW \u2192 logic supply, sheet 3. Host I2C/status \u2192 RP2040, sheet 6."
      ]
    },
    {
      "sheet": "programming",
      "x": -12.24,
      "y": -8.424,
      "lines": [
        "References: RP2040 minimal board, Fig. 11; ST USBLC6-2 application schematic.",
        "J1 is 5 V only. USB / SWD / RUN / BOOTSEL \u2192 sheet 6.  logic power \u2192 sheet 3."
      ]
    },
    {
      "sheet": "processor",
      "x": -12.24,
      "y": -8.424,
      "lines": [
        "Reference: Raspberry Pi Hardware design with RP2040, Fig. 11 (minimal board).",
        "USB / recovery: sheet 5. PD I2C: sheet 2. Motor interface: sheet 7."
      ]
    },
    {
      "sheet": "bridge",
      "x": -12.24,
      "y": -8.424,
      "lines": [
        "Reference: TI MCT8329A, Fig. 8-1. N-channel high/low-side pairs; common current shunt.",
        "J10/J11/J12: U/V/W sockets + purchased 3.5 mm female / 4 mm male adapters. VMOTOR: sheet 3."
      ]
    },
    {
      "sheet": "logic_power",
      "x": -12.92,
      "y": 7.632,
      "lines": [
        "PD input or DATA USB \u2192 isolated 3.3 V logic supply"
      ]
    },
    {
      "sheet": "logic_power",
      "x": -12.92,
      "y": -0.216,
      "lines": [
        "SW4 POWER: OFF removes motor power and clamps ARM_BASE low."
      ]
    },
    {
      "sheet": "logic_power",
      "x": -12.92,
      "y": -8.064,
      "lines": [
        "USB communication remains available in OFF. No battery or charger is fitted.",
        "R142 = 1.5k sets approx. 1.64 A nominal motor-feed limit; verify tolerance and heating.",
        "D6 returns transients to local TVS; U12/Q7 block USB backfeed. Use coast stop; no sustained regeneration."
      ]
    },
    {
      "sheet": "pd_load",
      "x": -12.24,
      "y": 7.2,
      "lines": [
        "PD9 \u2192 F1 \u2192 U12/Q7 \u2192 PD_LOAD \u2192 U11 switch \u2192 VMOTOR"
      ]
    },
    {
      "sheet": "pd_load",
      "x": -12.24,
      "y": -7.2,
      "lines": [
        "U12/Q7 block reverse current into the USB source. D4 is for transients only.",
        "Firmware must use coast stop and voltage/current supervision; bench braking-energy tests remain required."
      ]
    },
    {
      "sheet": "usb_pd",
      "x": 6.8,
      "y": 1.224,
      "lines": [
        "R13 x gain 20 = 0.4 V/A",
        "Excludes the 3.3 V logic branch."
      ]
    },
    {
      "sheet": "pd_load",
      "x": -12.24,
      "y": 6.192,
      "lines": [
        "Fuse / reverse-current blocking"
      ]
    },
    {
      "sheet": "pd_load",
      "x": 5.44,
      "y": 6.192,
      "lines": [
        "Motor-bus voltage feedback"
      ]
    },
    {
      "sheet": "pd_load",
      "x": 5.44,
      "y": -1.08,
      "lines": [
        "ADC_VMOTOR = VMOTOR x 15 / 235",
        "Feedback to RP2040, sheet 6."
      ]
    },
    {
      "sheet": "programming",
      "x": 4.08,
      "y": -5.04,
      "lines": [
        "SW1: hold during reset for USB boot.",
        "SW2: resets the RP2040; not motor POWER."
      ]
    },
    {
      "sheet": "processor",
      "x": -6.6,
      "y": 7.92,
      "lines": [
        "Active GPIO: motor, USB and PD",
        "Unused GPIOs end with NC crosses."
      ]
    },
    {
      "sheet": "motor_control",
      "x": -12.24,
      "y": 7.92,
      "lines": [
        "Internal regulator bypass"
      ]
    },
    {
      "sheet": "motor_control",
      "x": -12.24,
      "y": 4.464,
      "lines": [
        "Switched motor supply"
      ]
    },
    {
      "sheet": "motor_control",
      "x": -12.24,
      "y": 1.656,
      "lines": [
        "3.3 V logic input / VREG"
      ]
    },
    {
      "sheet": "motor_control",
      "x": 6.12,
      "y": 7.56,
      "lines": [
        "Service pads / I2C"
      ]
    },
    {
      "sheet": "motor_control",
      "x": 3.4,
      "y": 7.4,
      "lines": [
        "Charge pump"
      ]
    },
    {
      "sheet": "motor_control",
      "x": 6.12,
      "y": 2.664,
      "lines": [
        "Bootstrap capacitors",
        "Each returns to its phase,",
        "not to board ground."
      ]
    },
    {
      "sheet": "motor_control",
      "x": -12.24,
      "y": -2.6,
      "lines": [
        "Default LOW inputs"
      ]
    },
    {
      "sheet": "motor_control",
      "x": -1.36,
      "y": -2.6,
      "lines": [
        "I2C / fault / speed-feedback pull-ups"
      ]
    },
    {
      "sheet": "motor_control",
      "x": -12.24,
      "y": -6.4,
      "lines": [
        "SP/SN: dedicated Kelvin pair to R81 (sheet 9).",
        "LSS: gate-current return; keep separate from sense paths until the shunt land."
      ]
    },
    {
      "sheet": "motor_control",
      "x": -12.24,
      "y": -8.424,
      "lines": [
        "Reference: TI MCT8329A pin functions and MCT8329EVM Fig. 8-5.",
        "RP2040: sheet 6. Hardware inhibit and user controls: sheet 8. Gates / phases: sheet 9."
      ]
    },
    {
      "sheet": "controls",
      "x": -12.24,
      "y": 7.2,
      "lines": [
        "Speed setting: knob -> ADC"
      ]
    },
    {
      "sheet": "controls",
      "x": 3.4,
      "y": 7.2,
      "lines": [
        "ARM request: button -> GPIO"
      ]
    },
    {
      "sheet": "controls",
      "x": -12.24,
      "y": 0.72,
      "lines": [
        "RV1 requests speed; it does not drive the motor directly.",
        "R80/C81 filter the ADC input; R85 defines the open-wiper state."
      ]
    },
    {
      "sheet": "controls",
      "x": 3.4,
      "y": 0.72,
      "lines": [
        "SW3 press pulls ARM_REQUEST_N LOW.",
        "R86/C82 provide pull-up and filtering."
      ]
    },
    {
      "sheet": "controls",
      "x": -12.24,
      "y": -0.648,
      "lines": [
        "Hardware inhibit: default OFF"
      ]
    },
    {
      "sheet": "controls",
      "x": 2.04,
      "y": -2.52,
      "lines": [
        "R70 holds DRVOFF HIGH: drive disabled.",
        "Q5 can pull it LOW when MCU ARM is HIGH.",
        "Q6 inhibits ARM when PD_OK2_N is HIGH.",
        "SW4 OFF also clamps ARM_BASE LOW (sheet 3)."
      ]
    },
    {
      "sheet": "controls",
      "x": -12.24,
      "y": -8.424,
      "lines": [
        "Requires a verified selected PD contract plus deliberate firmware arming.",
        "Motor-control firmware is not yet qualified. RP2040: sheet 6; DRVOFF input: sheet 7."
      ]
    },
    {
      "sheet": "bridge",
      "x": 0.68,
      "y": -5.04,
      "lines": [
        "R81: 10 mV/A before internal amplification.",
        "SP/SN are sense connections; LSS carries gate-return current."
      ]
    },
    {
      "sheet": "motor_control",
      "x": 6.12,
      "y": -0.072,
      "lines": [
        "Pin 27: SPEED / WAKE input.",
        "Pin 33: unused DAC / analog input."
      ]
    },
    {
      "sheet": "logic_power",
      "x": 7.48,
      "y": -1.44,
      "lines": [
        "U11 input bypass"
      ]
    },
    {
      "sheet": "processor",
      "x": 5.5,
      "y": 8.6,
      "lines": [
        "RP2040 + flash / 3.3 V bypass"
      ]
    },
    {
      "sheet": "processor",
      "x": 5.5,
      "y": 3.85,
      "lines": [
        "C40\u201345: IOVDD; C49: VREG_IN; C51: USB_VDD.",
        "C52: bulk; C53: flash U6. Place at supply pins on PCB.",
        "Bank ratings: 100 nF = 50 V; 1 / 10 uF = 25 V."
      ]
    }
  ],
  "components": {
    "J19": {
      "sheet": "usb_pd",
      "section": "pd_sink",
      "x": -11.56,
      "y": 3.96
    },
    "U1": {
      "sheet": "usb_pd",
      "section": "pd_sink",
      "x": -3.4,
      "y": 0.0,
      "width": 3.48,
      "height": 5.43,
      "pinArrangement": {
        "leftSide": {
          "pins": [
            18,
            1,
            2,
            4,
            5
          ],
          "direction": "top-to-bottom"
        },
        "rightSide": {
          "pins": [
            16,
            9,
            15,
            20,
            14,
            17,
            11,
            7,
            8,
            19,
            6
          ],
          "direction": "top-to-bottom"
        },
        "topSide": {
          "pins": [
            23,
            21,
            3,
            24
          ],
          "direction": "left-to-right"
        },
        "bottomSide": {
          "pins": [
            10,
            25,
            12,
            13,
            22
          ],
          "direction": "left-to-right"
        }
      },
      "pinStyle": {
        "pin1": {
          "marginTop": 0.2
        },
        "pin2": {
          "marginTop": 0.2
        },
        "pin4": {
          "marginTop": 0.2
        },
        "pin5": {
          "marginTop": 0.2
        },
        "pin9": {
          "marginTop": 0.2
        },
        "pin15": {
          "marginTop": 0.2
        },
        "pin20": {
          "marginTop": 0.2
        },
        "pin14": {
          "marginTop": 0.2
        },
        "pin17": {
          "marginTop": 0.2
        },
        "pin11": {
          "marginTop": 0.2
        },
        "pin7": {
          "marginTop": 0.2
        },
        "pin8": {
          "marginTop": 0.2
        },
        "pin19": {
          "marginTop": 0.2
        },
        "pin6": {
          "marginTop": 0.2
        },
        "pin21": {
          "marginLeft": 0.2
        },
        "pin3": {
          "marginLeft": 0.2
        },
        "pin24": {
          "marginLeft": 0.2
        },
        "pin25": {
          "marginLeft": 0.2
        },
        "pin12": {
          "marginLeft": 0.2
        },
        "pin13": {
          "marginLeft": 0.2
        },
        "pin22": {
          "marginLeft": 0.2
        }
      }
    },
    "C1": {
      "sheet": "usb_pd",
      "section": "pd_switch",
      "x": -1.02,
      "y": 5.76,
      "rotation": -90
    },
    "C2": {
      "sheet": "usb_pd",
      "section": "pd_sink",
      "x": -6.8,
      "y": 3.6,
      "rotation": -90
    },
    "C3": {
      "sheet": "usb_pd",
      "section": "pd_sink",
      "x": -5.1,
      "y": 3.6,
      "rotation": -90
    },
    "R1": {
      "sheet": "usb_pd",
      "section": "pd_sink",
      "x": -7.1,
      "y": 0.576,
      "rotation": -90
    },
    "R2": {
      "sheet": "usb_pd",
      "section": "pd_switch",
      "x": 2.04,
      "y": 3.384,
      "rotation": -90
    },
    "R5": {
      "sheet": "usb_pd",
      "section": "pd_reset_bias",
      "x": 0.68,
      "y": -2.52,
      "rotation": -90
    },
    "R6": {
      "sheet": "usb_pd",
      "section": "pd_pullups",
      "x": 3.468,
      "y": -2.016,
      "rotation": -90
    },
    "R7": {
      "sheet": "usb_pd",
      "section": "pd_pullups",
      "x": 1.904,
      "y": -2.016,
      "rotation": -90
    },
    "R8": {
      "sheet": "usb_pd",
      "section": "pd_pullups",
      "x": 5.032,
      "y": -2.016,
      "rotation": -90
    },
    "R9": {
      "sheet": "usb_pd",
      "section": "pd_pullups",
      "x": 6.596,
      "y": -2.016,
      "rotation": -90
    },
    "R10": {
      "sheet": "usb_pd",
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