Schematic Design Analysis

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Below is a schematic-level analysis based solely on the provided design information:
1. Regulator & Feedback Network Connections
  • Issue: U3 (SY6280) Pin Misassignment
    – Observation: The net labeled VIN shows that both the VIN and EN pins of U3 are tied together. For the SY6280 (pins: VOUT, GND, ISET, EN, VIN), the EN pin should be driven (typically via a pull‐up or by logic) rather than being hardwired with the input voltage.
    – Recommendation: Separate U3’s EN from its VIN. Tie EN to the proper logic (or use a resistor divider/pull‑up if that is the intent) per the datasheet recommendation.
  • Issue: Shared Divider Resistor (R3) Across Different Nets
    – Observation: Resistor R3 has one terminal on net FB (used for U1’s feedback) and the other on net VIN (which also carries U3 VIN/EN). This forces an unexpected connection between two regulator sections that should be independent.
    – Recommendation: Redefine the feedback divider so that each regulator (U1 and U3) has its own, isolated divider network. In particular, re‑assign R3’s connections so that the divider for U1’s FB is not shorted to U3’s power section.
  • Issue: Conflicting Voltage Divider Formulas
    – Observation: The text note “SETTING OUTPUT VOLTAGE” shows two formulas:
    • VOUT=VREF×(1+R6R9)V_{OUT}=V_{REF} \times \Bigl(1+\frac{R6}{R9}\Bigr)
    • VOUT=VREF×(1+R6(R1+R4))V_{OUT}=V_{REF} \times \Bigl(1+\frac{R6}{(R1+R4)}\Bigr)
      This suggests either a design revision or a leftover note from an earlier revision.
      – Recommendation: Decide on one feedback network configuration. Remove or update the annotation to reflect the chosen resistor divider between the correct regulator output and its FB pin.
2. Power Distribution & Net Labeling
  • Issue: Duplicate and Ambiguous Net Labels
    – Observation: Several portals use similar or duplicate names (for example, multiple “Ground” objects, “12_5V” vs. “12V_DIV” nets) and some nets appear in more than one context (e.g. “VIN” carries U3 VIN and also ties in divider elements for U1).
    – Recommendation:
    • Ensure that each power rail (battery, solar, USB, regulated outputs) is clearly defined with a unique net name.
    • Verify that regulator inputs, outputs, and feedback networks use separate nets unless intentional.
    • Use consistent naming (for example, avoid “12_5V” and “12V_DIV” if they refer to the same rail or divider) so that the intended connectivity is unambiguous during layout and DRC checks.
  • Issue: Potential Overlap of Regulator Sections
    – Observation: The sharing of net VIN between U3 (a SY6280 regulator) and the feedback divider of U1 (RT8059) suggests that their power paths might interfere.
    – Recommendation: Completely separate the power and control nets for each converter so that no accidental bridging (for instance, tying U3’s EN/VIN with U1’s divider) occurs.
3. Decoupling Capacitors & Bypass Networks
  • Issue: Decoupling Capacitor Placement Uncertainty
    – Observation: Although several capacitors (e.g. C1, C2, C8, C9) are present on the schematic, their placement relative to the regulator ICs is not explicitly shown. Given the high switching frequency of devices like the MT3608 and likely for the RT8059, nearby bypass/external output capacitors are critical.
    – Recommendation:
    • Confirm that each regulator has at least one decoupling capacitor placed as close as possible to its VIN, VOUT, and FB pins (if recommended), following datasheet recommendations.
    • If not already done, move the decoupling capacitors (for example, C2 for U3’s VIN and C8 for the FB divider) to minimize parasitic inductance.
4. Current Limiting & LED Drive
  • Issue: LED Current Limiting
    – Observation: The schematic includes two LED components (D5 and D2) with forward voltages and current ratings given, but there is no series resistor explicitly associated with them. Directly connecting an LED to a power rail without a current‐limiting resistor can cause overcurrent damage.
    – Recommendation:
    • Insert an appropriate current-limiting resistor in series with each LED. For example, for a red LED with a forward voltage around 2.0 V and a target current of 20 mA at a 5V supply, calculate the resistor as:
      R=5V−2V0.02A=150 Ω.R= \frac{5V - 2V}{0.02A} = 150\,\Omega.
5. General Signal Integrity & Connectivity
  • Issue: Inconsistent Pin and Net Assignments
    – Observation: Some components (for instance, the connections of U4 [CN3063] used for battery charging) show mixed signals across different nets (e.g., its FB and ISET nodes share nets with divider or other signals).
    – Recommendation:
    • Recheck each IC’s pin assignment against its datasheet. For U4, verify that the pins for temperature, charge control (~DONE, ~CHARG) and feedback are routed to the appropriate nets.
    • Ensure that signal nets, especially those that interface with control or feedback pins, are not inadvertently tied to power rails.
  • Issue: Layout Considerations Not Shown on Schematic
    – Observation: While this analysis is schematic-level, note that good PCB practices (such as short, wide power traces, adequate spacing for high-frequency switching nodes, and proper ground plane continuity) are essential for minimizing EMI and other signal integrity issues.
    – Recommendation:
    • During layout, verify that high-frequency switching nodes from converters like MT3608 and RT8059 are kept short with their decoupling components, and use proper trace width and via stitching to maintain a robust low‑impedance ground.

Summary of Corrections

IssueLocation/Component(s)Correction/Optimization
U3 EN tied to VINU3 (SY6280) EN and VIN pinsSeparate these signals; drive EN via appropriate logic/control rather than directly tying to VIN.
Shared resistor R3 across FB and VINR3 between U1 feedback network and U3 VINIsolate the divider networks; assign separate resistor(s) for each regulator’s FB node.
Conflicting voltage divider note“SETTING OUTPUT VOLTAGE” text noteUpdate the note to reflect a single, verified divider scheme for the chosen regulator.
Ambiguous and duplicate net labelsMultiple power nets (VIN, 12_5V, 12V_DIV, Ground, etc.)Re‑label and segregate power/feedback nets to ensure clear and isolated paths.
Decoupling capacitor placement uncertaintyAcross regulators (e.g. U1, U3, MT3608)Verify placements in layout to be as close as possible to the respective IC pins.
Missing LED current limit resistorsLED components D5 and D2Insert series resistors (≈150 Ω for 5V operation with 2V forward drop at 20 mA).
Potential misconnection of U4 signalsU4 (CN3063) charge controllerDouble-check each pin’s connection against its datasheet to ensure proper function.
By addressing these specific areas, you will reduce the risk of electrical conflicts and improve both the performance and reliability of the power management board.
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use python to plot a bar graph showing the most expensive components in this des...
collinsemasi

collinsemasi

@copilot use python to plot a bar graph showing the most expensive components in this design
1y

copilot

Code Interpreter 
Python
import matplotlib.pyplot as plt
import numpy as np

# Component data with their prices
components = {
    "WJ500V-5.08-2P": 0.0735,
    "GRM188R61A106KE69D": 0.0103,
    "0603WAF2002T5E": 0.001,
    "AC0603FR-072KL": 0.002,
    "SY6280A AC": None,  # Price not provided
    "AC0603FR-0715KL": 0.0021,
    "0603WAF1503T5E": 0.001,
    "RT8059GJ5": 0.14089,
    "GRM188R61A475KE15D": 0.0092,
    "0603WAF3001T5E": 0.001,
    "MT3608L": 0.0398,
    "CN3063": 0.5507,
    "GRM188R71H104KA93D": 0.0043,
    "SWPA4030S100MT": 0.0654,
    "SS34": 0.02585,
    "RC0603FR-071K5L": 0.0012,
    "GCM1885C2A680JA16D": 0.016
}

# Remove components with unknown prices
components = {k: v for k, v in components.items() if v is not None}

# Sort components by price in descending order
sorted_components = dict(sorted(components.items(), key=lambda item: item[1], reverse=True))

# Prepare data for plotting
component_names = list(sorted_components.keys())
component_prices = list(sorted_components.values())

# Plotting
plt.figure(figsize=(10, 6))
plt.bar(component_names, component_prices, color='navy')
plt.xlabel('Component')
plt.ylabel('Price in USD')
plt.title('Most Expensive Components in the Design')
plt.xticks(rotation=45, ha='right')
plt.tight_layout()
plt.show()
https://cdn2.flux.ai/flux-comment-files/files/commentFileId-1e753b3f66c159dd2defcffae19da242dfc1d92ced5c766e67b65e0e3ae05ea7.png?GoogleAccessId=copilot-etl-work-service-acct%40graviton-mvp.iam.gserviceaccount.com&Expires=4878442613&Signature=E88XU9H0Tu5cj31iAa5IzXEtoKj30U388bcBnASvfXibAlj1zRhDLoWt2hI49NLAL%2FiQbd0T7U0dxHqCc%2B2le2huugMZztKhs6BUWlKSp7olK2dXZkFZq3w1YwpUkH7zxENEbtlv0zpfbn1akKEtBxk5GSTewwajLKobSghcZKykN5qnHQjsPMp9o8hT%2BHzcAa8UhQXRV0bZkEKw%2BQlUDGoeOYkWU44pzYqEJAmYbuFC18tIvmlSG6OE%2FHY6Hvk0Tr73RE%2Fei%2BeeVUJgX1jagvGRZnKUAII91iLRdhHJXyJiIgkmSjoVySeb7iWW1u0x8GEZY8mm%2Ba2Bh6aPw%2FDbCw%3D%3D
Here's a bar graph showing the most expensive components in your design. The CN3063 is the priciest component at $0.5507, followed by the RT8059GJ5 at $0.14089, and the WJ500V-5.08-2P at $0.0735. If you have any questions or need further analysis, feel free to ask!
1y
collinsemasi

collinsemasi

In a table format recommend alternative parts (at least 2) that have similar electrical characteristics as the top 2 most expensive parts in this project.
1y

copilot

Here are recommended alternative parts for the top two most expensive components in your project, the CN3063 and the RT8059GJ5:

Table

Original PartAlternative Part 1Alternative Part 2Key Characteristics
CN3063MCP73831TP4056- Single-cell Li-ion Charger- Up to 500mA Charging Current- Linear Charging
RT8059GJ5TPS62085MP1584- Step-Down Converter- 1A Output Current- Adjustable Output Voltage
Key Characteristics Explanation:
  • MCP73831: A popular lithium-ion battery charger IC which provides a constant current/constant voltage charging algorithm with selectable precondition and charge termination.
  • TP4056: Another widely used single-cell lithium-ion battery charger IC, which also supports constant current/constant voltage charging.
  • TPS62085: A step-down converter that supports similar input voltage and output current ranges, ideal for portable electronics.
  • MP1584: A compact and efficient step-down regulator with a wide input voltage range and convenient adjustable output, often used in DIY projects.
These substitutes are common in the industry and should meet similar electrical requirements as the original parts. Always ensure to check the complete specifications to verify compatibility with your design requirements.
1y
J1
VBAT
  • Ground
    Ground
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  • Power Net Portal
    Power Net Portal
    Wirelessly connects power nets on schematic. Identical to the net portal, but with a power symbol. Used to organize schematics and separate functional blocks. To wirelessly connect power net portals, give them the same designator. #portal #power
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  • Generic Resistor
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    A generic fixed resistor for rapid developing circuit topology. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard resistor values: 1.0Ω 10Ω 100Ω 1.0kΩ 10kΩ 100kΩ 1.0MΩ 1.1Ω 11Ω 110Ω 1.1kΩ 11kΩ 110kΩ 1.1MΩ 1.2Ω 12Ω 120Ω 1.2kΩ 12kΩ 120kΩ 1.2MΩ 1.3Ω 13Ω 130Ω 1.3kΩ 13kΩ 130kΩ 1.3MΩ 1.5Ω 15Ω 150Ω 1.5kΩ 15kΩ 150kΩ 1.5MΩ 1.6Ω 16Ω 160Ω 1.6kΩ 16kΩ 160kΩ 1.6MΩ 1.8Ω 18Ω 180Ω 1.8KΩ 18kΩ 180kΩ 1.8MΩ 2.0Ω 20Ω 200Ω 2.0kΩ 20kΩ 200kΩ 2.0MΩ 2.2Ω 22Ω 220Ω 2.2kΩ 22kΩ 220kΩ 2.2MΩ 2.4Ω 24Ω 240Ω 2.4kΩ 24kΩ 240kΩ 2.4MΩ 2.7Ω 27Ω 270Ω 2.7kΩ 27kΩ 270kΩ 2.7MΩ 3.0Ω 30Ω 300Ω 3.0KΩ 30KΩ 300KΩ 3.0MΩ 3.3Ω 33Ω 330Ω 3.3kΩ 33kΩ 330kΩ 3.3MΩ 3.6Ω 36Ω 360Ω 3.6kΩ 36kΩ 360kΩ 3.6MΩ 3.9Ω 39Ω 390Ω 3.9kΩ 39kΩ 390kΩ 3.9MΩ 4.3Ω 43Ω 430Ω 4.3kΩ 43KΩ 430KΩ 4.3MΩ 4.7Ω 47Ω 470Ω 4.7kΩ 47kΩ 470kΩ 4.7MΩ 5.1Ω 51Ω 510Ω 5.1kΩ 51kΩ 510kΩ 5.1MΩ 5.6Ω 56Ω 560Ω 5.6kΩ 56kΩ 560kΩ 5.6MΩ 6.2Ω 62Ω 620Ω 6.2kΩ 62KΩ 620KΩ 6.2MΩ 6.8Ω 68Ω 680Ω 6.8kΩ 68kΩ 680kΩ 6.8MΩ 7.5Ω 75Ω 750Ω 7.5kΩ 75kΩ 750kΩ 7.5MΩ 8.2Ω 82Ω 820Ω 8.2kΩ 82kΩ 820kΩ 8.2MΩ 9.1Ω 91Ω 910Ω 9.1kΩ 91kΩ 910kΩ 9.1MΩ #generics #CommonPartsLibrary
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    1.5M
  • Generic Capacitor
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  • Generic Inductor
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    A generic fixed inductor for rapid developing circuit topology. *You can now change the footprint and 3D model at the top level anytime you want. This is the power of #generics
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    Terminal
    An electrical connector acting as reusable interface to a conductor and creating a point where external circuits can be connected.
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  • RMCF0805JT47K0
    RMCF0805JT47K0
    47 kOhms ±5% 0.125W, 1/8W Chip Resistor 0805 (2012 Metric) Automotive AEC-Q200 Thick Film #forLedBlink
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  • 875105359001
    875105359001
    10uF Capacitor Aluminum Polymer 20% 16V SMD 5x5.3mm #forLedBlink #commonpartslibrary #capacitor #aluminumpolymer #radialcan
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  • CTL1206FYW1T
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Inspect

Chart Visualization: BRAVE POWER MANAGEMENT BOARD

Chart Visualization: BRAVE POWER MANAGEMENT BOARD
Description

Created
Last updated by collinsemasi
1 Contributor(s)
collinsemasi

Controls

Properties

Availability & Pricing

DistributorQty 1
Arrow$0.86–$2.41
Digi-Key$0.72–$2.81
LCSC$1.73–$3.46
Mouser$2.91–$3.54
Verical$0.50–$1.90

Assets