PCB Feasibility
Thought for 17 sec
I’ll route the PCB now: run the routing pre-check, set conservative trace-width priorities for power/control nets, auto-route the board, then review remaining airwires/DRC issues.
Worked for 33 sec
Routing could not continue because the account currently has no available ACUs, so AI layout/routing tools are unavailable.
Accomplished this session:
- Started the routing phase and prepared the routing checklist.
- Confirmed the intended routing flow: pre-check → set routing rules/width priorities → auto-route → DRC/airwire cleanup.
- Loaded the routing/remediation procedures needed for the next step.
Open items:
- Run routing pre-check again.
- Set power/control routing widths and priorities.
- Run the full-board auto-router.
- Review and fix remaining airwires/DRC issues.
- Add high-current copper/pour strategy after initial routing; auto-routing alone is not sufficient for the 40 A power path.
Suggested next steps:
- Add ACUs to the account.
- Then send “continue routing” and I’ll resume from the routing pre-check.
Continue routing
Set 40A strategy
Manual routing steps
Check DRC airwires
Define net priorities
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One-Phase Validation Variant Plan
Purpose
Before any PCB layout for the full four-phase 3 kW programmable CV/CC supply, validate a single buck phase at reduced risk. The one-phase variant is a controlled bring-up subset of the full schematic, not a replacement architecture.
Variant Scope
Populate and test only Phase 1 power components and shared control/auxiliary blocks needed to operate that phase:
- Phase 1 high-side/low-side MOSFETs and gate driver
- Phase 1 inductor, shunt, current modulator/sense path, and output capacitor subset
- DC bus input interface and precharge/protection needed for safe bench operation
- C2000 controller, JTAG, watchdog/reset, trip comparator, CAN/debug as needed
- 24 V auxiliary input, 12 V gate rail, 5 V rail, and 3.3 V rail
- One representative off-board contactor/relay output path if required for test sequencing
Do not populate phases 2–4 power components for the first validation spin unless a specific interleaving test requires them.
Initial Electrical Limits
Use conservative bring-up limits until waveforms and thermals are verified:
- Input bus: current-limited bench DC source first, then isolated AC/DC module after low-power validation
- Output voltage: start below 20 V, then step upward toward the full range only after stable control is confirmed
- Phase current: start below 2 A, then step toward 10 A class testing with thermal monitoring
- Gate drive: verify dead time and shoot-through margin before applying substantial bus voltage
Required Validation Tests
- Power rails: verify AUX_24V, 12V_GATE, 5V, 3V3, regulator switching waveforms, ripple, and startup sequencing.
- MCU bring-up: program over JTAG, verify clocking, watchdog behavior, trip input response, ADC/SDFM data paths, and PWM outputs disabled by default.
- Gate driver dry run: validate HI/LI logic, HO/LO drive levels, bootstrap charging, dead time, and fault-disable behavior without high bus energy.
- Low-voltage buck test: apply low bus voltage with current limit, confirm correct switching node waveform, inductor current ramp, duty-cycle control, and no shoot-through.
- Closed-loop CV test: regulate into a resistive load at low voltage/current, validate output sense scaling and loop stability.
- CC/current-limit test: verify shunt/current feedback, hardware trip comparator, firmware current limit, and recovery behavior.
- Thermal test: increase current in steps while logging MOSFET, diode/clamp, shunt, inductor, gate driver, and capacitor temperature.
- Fault tests: output short through a current-limited setup, watchdog reset, controller reset, loss of auxiliary rail, and contactor command inhibition.
Design Open Items Before Layout
- TPL9202 is not a valid direct 24 V contactor-coil driver. If contactor coils are 24 V, replace the driver family or add external 24 V-rated low-side switches with inductive clamps.
- Verify all LM76003/LM76002 component ratings, especially inductor saturation/RMS current, capacitor voltage derating, and input capacitor ripple current.
- Verify TPS3431 watchdog timing values from the datasheet before release.
- Add proper input/output test points only where needed for bring-up.
- Decide whether off-board contactor feedback connectors are populated, reserved, or moved to a dedicated input-expander/protection block.
Pass Criteria for Advancing to Four Phases
Proceed to the full four-phase PCB only after the one-phase variant demonstrates:
- Clean rail startup/shutdown and no regulator overstress
- Correct PWM/gate timing with measured dead-time margin
- No shoot-through or uncontrolled switching during reset/fault states
- Stable CV and CC operation over the intended one-phase validation range
- Hardware trip and watchdog responses independent of firmware main-loop health
- Acceptable thermal margin at the target one-phase current
- Documented fixes for any snubber, gate resistor, current-sense, or compensation changes discovered during testing
Purpose
Variant Scope
Initial Electrical Limits
Required Validation Tests
Design Open Items Before Layout
Pass Criteria for Advancing to Four Phases
