I’ll add a Teensy 4.1 socket representation and wire the named control/telemetry nets. First I’ll check whether Pi/Teensy header parts already exist in the schematic/library; if a full Teensy socket part isn’t available, I’ll use a 48-pin dual-row header/socket with explicit net labels for the Teensy functions.
Confirmed the fallback plan: use either two 1x24 female socket strips or a 2x24 48-pin socket if available, then label the Teensy 4.1 functions explicitly.
Still to do once credits are available:
Add the Raspberry Pi 5 40-pin GPIO header.
Add the Teensy 4.1 socket representation, likely as two 1x24 female headers if no exact 2x24 socket exists.
Wire:
Teensy pin 1 TX1 -> Pi UART RX
Teensy pin 0 RX1 -> Pi UART TX
Teensy A0 / pin 14 -> shunt amplifier output net
Two Teensy PWM pins -> voltage adjust and current limit control nets
This project captures requirements for a VoltiX Pro 320-style 2-in-1 diagnostic station: a programmable bench power supply combined with phone/device protocol testing, module expansion, and a touchscreen interface.
Architecture update: the control system is split between a Raspberry Pi 5 master SBC and a Teensy 4.1 real-time hardware controller.
Intended Use
Bench diagnostic and repair station for phones, tablets, batteries, displays, vibrators/sensors, chip reads/writes, and fast-charge/power testing.
Intended for electronics repair technicians, prototyping benches, and advanced hobbyist diagnostic workflows.
Current scope is a concept/specification only; no schematic has been created yet.
What the Device Should Do
Provide a regulated adjustable DC output from 0.2 V to 30 V.
Supply up to 10 A, with stated total output power target of 320 W.
Show real-time voltage, current, power, and graph/status information on a touchscreen.
Support multi-device charging/testing and protocol detection.
Support plug-and-play expansion modules for phone, battery, display, and data/debug workflows.
Support online updates and cloud/data features if a networked compute subsystem is selected.
Main Features
320 W high-precision regulated power supply.
Adjustable output: 0.2–30 V, 0–10 A.
Real-time voltage/current/power display and output monitoring.
Multi-port simultaneous testing.
Multi-protocol fast-charge and diagnostic support.
4.3 inch color touchscreen UI.
Raspberry Pi 5 master controller for UI, database, networking, and high-level orchestration.
Teensy 4.1 real-time controller for ADC sampling, battery data protocol reading, protection interlocks, and buck-stage control.
Modular expansion board interface.
Protection features: over-current, over-voltage, over-temperature, short-circuit, and low-ripple/high-stability behavior.
System Architecture
Updated control partition: Raspberry Pi 5 handles UI/database logic; Teensy 4.1 handles deterministic measurement and hardware control. Pi-to-Teensy communication will be either direct USB serial, dedicated 3.3 V UART, or both.
flowchart TD
AC[AC 100-240 V Input] --> PSU[Isolated AC-DC Power Stage]
PSU --> DCBUS[DC Bus]
DCBUS --> PROGRAM[Programmable Buck Output 0.2-30 V 0-10 A]
PROGRAM --> OUT[Banana / DC Output Ports]
DCBUS --> AUX[AUX Regulators 12 V / 5 V / 3.3 V]
AUX --> MCU[Main Controller]
MCU --> TOUCH[4.3 inch Touch Display]
MCU --> ADC[Voltage / Current / Temp Measurement]
MCU --> PROTO[USB-C / Lightning / Protocol Analyzer]
MCU --> MODULE[Expansion Module Connector]
PROTO --> DUT[Device Under Test Ports]
MODULE --> MODS[Plug-in Diagnostic Modules]
Hardware Subsystems
Power Input and Isolation
Poster lists AC 100–240 V, 50/60 Hz input.
Architecture decision: use an internal, certified, isolated AC-DC mains module as a separate replaceable assembly.
The main PCB must remain SELV low-voltage only. It receives isolated DC from the mains module through a DC connector and must not route live/neutral mains copper.
The AC inlet, fuse, switch, earth bonding, line filter, and AC-DC module primary wiring belong on the isolated mains module / wiring harness, not on the logic or programmable-output PCB.
Recommended module class: enclosed or chassis-mount isolated AC-DC supply, universal input, protective earth connection, safety approvals, output around 36 V DC, power rating >= 360 W.
Programmable Output Stage
Target output: 0.2–30 V, 0–10 A, max 320 W.
Requires precision current and voltage regulation, current limiting, thermal monitoring, and output enable control.
Needs low-ohmic current sense, high-current layout, heat sinking, and calibration support.
Measurement and Monitoring
Voltage/current/power measurement with real-time UI display.
Current range should cover low-current phone-board diagnostics and high-current load testing.
Thermal sensors should monitor power stage, enclosure air, and possibly output connectors.
Main Controller and UI
Raspberry Pi 5 is selected as the embedded Linux SBC for UI, database logic, networking, and high-level system orchestration.
4.3 inch color touchscreen target from poster.
Needs firmware update path and persistent calibration storage.
Real-Time Hardware Controller
Teensy 4.1 is selected as the dedicated real-time controller.
Responsibilities: high-speed ADC sampling, output voltage/current metrics, battery data protocol reading, custom buck control, fast fault handling, and watchdog behavior independent of Linux.
Teensy must be able to disable the output without Raspberry Pi involvement.
Protocol / Device Test Ports
Poster-visible supported protocols include:
USB Power Delivery: PD2.0 / PD3.0 / PPS
Qualcomm Quick Charge: QC2.0 / QC3.0 / QC4+
SCP / FCP / AFC
VOOC / DASH / WARP
PE / BC1.2 / Apple 2.4A
Samsung AFC / MTK PE+
Expansion Modules
Expansion board interface for battery, display, vibrator/sensor, data, chip read/write, and charging test modules.
Needs keyed connector, hot-plug detection, power limiting, ESD protection, and module identification.
Interfaces and Connections
Internal AC input only through a separate certified isolated mains module / harness.
Isolated DC bus input to main PCB, nominal target 36 V DC, sized for at least 10 A continuous plus margin.
Programmable DC output terminals / banana jacks.
USB-C / protocol test port.
Lightning and Micro USB support may require licensed or user-supplied adapters.
Expansion module connector.
Raspberry Pi 5 to Teensy 4.1 internal communication link: USB serial or dedicated 3.3 V UART.
Touchscreen UI.
USB-C service/update port.
Optional network interface for cloud updates/storage.
Power and Runtime Expectations
Bench-powered device; no internal runtime target unless a battery backup is added.
Input from poster: AC 100–240 V, 50/60 Hz.
Output: 0.2–30 V, 0–10 A, 320 W max.
Internal auxiliary rails likely required: 12 V fans/relays, 5 V USB/peripherals, 3.3 V logic.
Dedicated 5V_PI rail: 5.1 V nominal, 5 A continuous target for Raspberry Pi 5.
Separate clean 5V_CTRL rail for Teensy 4.1, ADC, references, and low-noise control electronics.
Power Tree and Power Budget
Table
Rail / Load
Expected Function
Preliminary Current / Power
AC-DC mains module
Separate isolated certified module
AC 100–240 V input, 36 V DC output target, >= 360 W
Main isolated DC bus
Feeds programmable output stage
36 V nominal, >= 10 A continuous input path
Programmable output
DUT / repair output
0.2–30 V, 0–10 A, 320 W max
12 V auxiliary
Fans, relays, gate drivers
TBD
5 V auxiliary
USB, display backlight, modules
TBD
3.3 V logic
MCU, ADC, protocol ICs
TBD
Additional control rails:
Table
Rail / Load
Expected Function
Preliminary Current / Power
5V_PI
Raspberry Pi 5 supply
5.1 V, 5 A continuous target
5V_CTRL
Teensy 4.1 and control electronics
5 V, 1 A provisional
3V3_CTRL
ADC/reference/logic derived from control rail
TBD after ADC/reference selection
Power decision: internal AC-DC version selected, but mains remains on a physically separate certified isolated module. The main PCB design starts at the isolated DC output of that module.
Manufacturing and Assembly Expectations
High-current PCB design with wide copper, thermal vias, and connector current ratings appropriate for >10 A DC bus current.
No mains traces on the main PCB. Maintain physical separation between the mains module and SELV electronics.
The mains module/harness still needs professional safety review: earth bonding, strain relief, fusing, insulation, creepage/clearance, enclosure fire rating, and accessible-metal grounding.
Consider a 4-layer board minimum for control electronics; power stage may need heavier copper or a separate module.
Include test points for all rails, current sense nodes, output voltage sense, programming/debug, and expansion power.
Firmware-Relevant Hardware Requirements
Output setpoint control for voltage and current.
Raspberry Pi 5 sends validated setpoint commands to Teensy 4.1; Teensy enforces local safety limits.
ADC sampling for voltage, current, temperature, and module status.
Pi-to-Teensy protocol must use framed packets with sequence number and CRC.
Teensy must implement heartbeat/watchdog timeout and local fault latching.
Touchscreen UI rendering and event handling.
Calibration storage and calibration workflow.
USB-C PD / fast-charge protocol control and detection.
Expansion module identification and hot-plug management.
Protection-event logging and fault recovery.
Physical Design Expectations
Poster lists approximate dimensions:
220 mm x 130 mm x 90 mm
4.3 inch color touchscreen
Front panel with output connectors, controls, and display.
Enclosure requires ventilation and thermal design for 320 W operation.
Layout planning must reserve separate zones for mains module, high-power buck stage, analog measurement, Teensy real-time control, Raspberry Pi/UI, and external protocol connectors.
Important Design Decisions
Treat the uploaded poster as a concept reference, not a finished engineering specification.
Use a separate certified isolated AC-DC module internally; do not implement the offline flyback/PFC stage on the main PCB.
Main PCB begins at isolated 36 V DC input and contains programmable DC output regulation, sensing, control, UI, protocol, and module expansion.
Use Raspberry Pi 5 as master SBC and Teensy 4.1 as real-time controller.
Hold connector placement until Pi/Teensy module form factor, communication link, touchscreen type, and power-entry method are confirmed.
Separate high-current regulation, logic/UI, and protocol/module sections for safety, noise, and maintainability.
Assumptions
The user wants to capture/design a similar diagnostic station concept from the image.
No exact mechanical CAD, compliance target, or detailed protocol implementation has been provided yet.
Assumed isolated DC bus voltage is 36 V nominal so the programmable buck can generate up to 30 V output with headroom.
Assumed the AC-DC module is purchased/certified rather than designed from raw mains.
Assumed Raspberry Pi 5 and Teensy 4.1 are stock modules unless the user confirms custom integrated circuitry.
Change Notes
Initial specification created from uploaded product poster.
Project renamed from random draft name to VoltiX Pro 320 Concept.
User selected internal AC-DC version with mains isolated on a separate module; main PCB remains SELV low-voltage only.
User upgraded control architecture to Raspberry Pi 5 master SBC plus Teensy 4.1 real-time hardware controller; connector placement paused pending clarification.