Rover Blueprint Review

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AGRO-NAV Electrical Review
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flux

Completed
The project is now named AGRO-NAV Rover Controller and contains an 88-component, 66-net complete rover-electronics schematic. It replaces the unsafe LM7805, L298N, and IRF520 approach with protected switching-power rails, external 30 A motor-driver interfaces, fused load branches, IRLZ44N actuator outputs, I²C level shifting, E-stop gating, and transient/flyback protection.
Supporting files created:
The initial build check reported only an intentional Arduino VIN warning because the Mega is powered through 5V_LOGIC. An independent review also finished, but I could not retrieve and reconcile its final report before execution stopped.
Open items
  • Confirm each motor’s measured stall current and the actuator stall current.
  • Recalculate branch fuses, master fuse, wiring gauge, connectors, and driver ratings from those measurements.
  • The current conservative budget is approximately 40.7 A continuous and 92.8 A non-diversified peak; the 60 A master fuse is provisional.
  • Review and apply any findings from the completed independent-review thread.
  • Schematic symbols remain auto-spread rather than manually organized.
Recommended next steps
  1. Reconcile the independent-review report and correct any findings.
  2. Measure or provide the exact motor and actuator models.
  3. Perform a final schematic/ERC review.
  4. Proceed to PCB constraints and layout only after the schematic review is closed.
Execution stopped because your ACUs ran out.
Received notification from "AGRO-NAV Electrical Review" that it finished — picking the work back up.

flux

The independent electrical-review report completed, but I could not retrieve or reconcile its findings, and no additional schematic changes were made in this turn. The project remains at the previously reported 88 components and 66 nets, with motor/actuator current validation, provisional fuse sizing, final ERC review, and any review-driven corrections still open.
Execution stopped because your ACUs ran out.
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Files

Schematic

Layout

3D View

Schematic is Auto-placed

The schematic has been arranged automatically. Flux can redraw it to be more readable, with components placed in related groups and wires drawn more legibly. This takes about 10-60 mins.

Board Bring-Up Plan
Safety Setup
  1. Keep all motors, pump, solenoid, actuator, and servo disconnected.
  2. Fit current-limited bench supply in place of the SLA for initial tests: 12.0 V, 0.5 A limit.
  3. Leave F1–F4 and F6 removed. Fit only the electronics branch fuse F5.
  4. Verify polarity at J1 and continuity through J2/J3/J4 before power.
  5. Confirm the E-stop loop at J21 is open so all safe-enable outputs remain low.
Stage 1 — Unpowered Checks
  • Resistance from VBAT_PROTECTED to PGND_STAR: no short.
  • Resistance from 5V1_PI, 5V_LOGIC, 6V_SERVO, and 3V3_SENSORS to their returns: no short.
  • Verify D1, D2, D3, and D4 polarity against the schematic.
  • Verify R22–R27 are implemented as the intended star copper links/terminals, not undersized resistors.
Stage 2 — Protected 12 V Bus
  1. Install/bypass the external master fuse only with a low bench current limit.
  2. Close the master switch interface J3.
  3. Verify J4 reverse-protection module input/output orientation.
  4. Expected: VBAT_PROTECTED follows the bench supply with only the module's specified drop.
  5. Reverse-polarity test only if the selected module explicitly supports it and the bench supply is current-limited.
Pass: no heating, no current-limit activation, correct bus polarity.
Stage 3 — Converter Rails
Enable one converter at a time.

Table

RailTest points / connectorAcceptance
5V1_PIJ5 output / C75.05–5.20 V unloaded, stable under 5 A-rated load test
5V_LOGICJ6 output / C84.90–5.10 V
6V_SERVOJ7 output / C95.8–6.1 V, no collapse during servo transient test
3V3_SENSORSJ8 output / C103.20–3.40 V
Check converter input current and case temperature at 10.5 V input, because that is the worst current condition for buck modules.
Stage 4 — Controllers
  1. Connect Arduino Mega only; leave Raspberry Pi disconnected.
  2. Confirm 5V_LOGIC remains within tolerance.
  3. Upload the Firmware Starter.
  4. Confirm all output commands are low immediately after reset.
  5. Connect Raspberry Pi to 5V1_PI; verify both Pi 5 V header pins and all grounds.
  6. Confirm Pi boots without undervoltage indication during CPU stress.
  7. Connect the USB data-only link J29/J30 and confirm /dev/ttyACM* or /dev/ttyUSB* appears on the Pi.
Pass: no back-powering when either controller rail is off, stable USB communication, no resets.
Stage 5 — E-Stop and Safe Enables
  1. With J21 open, verify ESTOP_OK, LEFT_EN_SAFE, RIGHT_EN_SAFE, and ACT_EN_SAFE are low.
  2. Close the NC E-stop loop; ESTOP_OK should go high.
  3. Command one enable at a time from firmware and verify the matching safe-enable output.
  4. Open J21 while enabled; all three safe enables must fall low immediately without firmware action.
  5. Verify the Raspberry Pi and Arduino remain powered.
Stage 6 — Sensor Interfaces
  • J22 GPS: confirm 5 V supply, ~3.3 V maximum at GPS_RX_3V3, and NMEA data on Serial1 RX.
  • J23/J24 I2C: confirm 3.3 V idle levels on SDA/SCL and discover both device addresses.
  • J25 HC-SR04: verify 5 V supply and timeout-safe Echo measurement.
  • J26 DHT11: verify data idle high and successful reads.
  • J27 soil sensor: verify A0 changes through the wet/dry range without exceeding 5 V.
  • J28 servo: first test with a separate current-limited 6 V supply; verify common ground and command centering.
Stage 7 — Limit Switches and Actuator Driver
  1. Verify J19/J20 inputs are high with switches open and low when grounded/closed.
  2. Prefer normally-closed wiring so a broken cable reads as a stop condition in firmware.
  3. Connect the actuator driver without the actuator and verify PWM, DIR, ENABLE, and FAULT logic.
  4. Connect actuator with F4 installed and a conservative current limit.
  5. Test short movements away from each limit; never drive into a hard stop during initial bring-up.
Stage 8 — Pump and Solenoid
Solenoid
  • Install F6, connect J16, and command short pulses.
  • Verify Q2 and D3 temperature and clean release.
Pump
  • Install F3, connect J15, and start with fluid path open.
  • Measure startup, running, and blocked-flow current.
  • Verify Q1 heatsink temperature, D2 temperature, and D4 behavior.
  • Stop if Q1 case temperature rises rapidly or the 12 V bus rings excessively.
Stage 9 — Motor Drivers
  1. Test one driver and one motor first with wheels off the ground.
  2. Verify DIR polarity and PWM response.
  3. Add the second motor in parallel and measure current sharing.
  4. Repeat for the other side.
  5. Test E-stop under low speed.
  6. Measure free-run, loaded, acceleration, and brief stall current.
  7. Recalculate F1/F2 and master fuse values from measurements before field testing.
Final Field Gate
Field operation is allowed only after:
  • All branch currents and temperatures are recorded.
  • E-stop interrupts drive/actuator enables reliably.
  • Converter rails remain in tolerance during simultaneous Pi load, servo movement, and motor acceleration.
  • Battery voltage does not collapse below controller limits.
  • Wiring, fuses, terminals, and enclosure are mechanically secured and protected from moisture.

  • Safety Setup

  • Stage 1 — Unpowered Checks

  • Stage 2 — Protected 12 V Bus

  • Stage 3 — Converter Rails

  • Stage 4 — Controllers

  • Stage 5 — E-Stop and Safe Enables

  • Stage 6 — Sensor Interfaces

  • Stage 7 — Limit Switches and Actuator Driver

  • Stage 8 — Pump and Solenoid

  • Solenoid

  • Pump

  • Stage 9 — Motor Drivers

  • Final Field Gate