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flux

The HY2120 Kelvin-sensing work completed, but I could not retrieve and reconcile its final report before execution ended.
Confirmed work from this session:
  • Added dedicated Kelvin branches from:
    • U6 VSS → RS1 BATT_NEG-side land
    • U6 CS/R38 → Q2 source land
  • Removed the previous remote sense branches.
  • Preserved component placement, USB routing, MOTOR_B Kelvin routing, high-current copper, and the 0.10 mm spacing rule.
  • Latest verified board state:
    • 0 airwires
    • 0 blocking DRC errors
    • 17 intentional redundant-copper groups retained
  • The last reviewed qualification still had two unresolved release gates:
    • Proving isolation of the Q2 Kelvin pickup via from Bottom/Mid-Layer-2 load-current copper.
    • Conservatively bounding the internal RS1–Q1–Q2 copper resistance and confirming positive margin below the HY2120’s 170 mV minimum overcurrent threshold.
The final executor was specifically working on those two gates, but its result was not available for reconciliation. Therefore, the board is not yet approved for manufacturing, and no new manufacturing exports were generated.
Remaining work:
  1. Retrieve and review the final Kelvin-sensing report.
  2. Confirm the 10.565 A / 500 ms hot overcurrent margin.
  3. Run an independent final ERC/DRC and protection-path review.
  4. Verify JLCPCB BOM stock and via/stencil requirements.
  5. Update firmware and bring-up documentation.
  6. Regenerate Gerbers, BOM, CPL, STEP, PDF, and IPC-D-356 files.
Execution stopped because your ACUs ran out.

Project Specification
Purpose
Compact battery-powered proximity-triggered actuator controller.
Core requirements
  • ESP32-S3 module-based controller.
  • TF-Luna LiDAR connected by UART and operating continuously.
  • Two 18650 cells in series: nominal 7.4 V, 8.4 V full charge.
  • Cells charged externally; no onboard charger.
  • Onboard 2S battery protection including overcharge, undervoltage, overcurrent/short-circuit protection, and cell balancing.
  • Drive a two-wire automotive door-lock actuator directly from the protected 2S pack.
  • Low-profile MOSFET H-bridge replaces electromechanical relays due to the 10 mm total height limit.
  • Trigger sequence starts as forward/push pulse, short neutral dead time, reverse/close pulse, then neutral.
  • Firmware-adjustable timing and cycle count; future mode supports three rapid cycles.
  • Hardware and firmware must prevent destructive shoot-through and enforce a maximum actuator-on timeout.
Mechanical constraints
  • PCB no larger than 40 mm × 75 mm.
  • Total assembled height, including PCB, components, connectors, and solder joints, no greater than 10 mm.
  • External battery cells, external 8.4 V charger, TF-Luna, and actuator are off-board.
  • Use low-profile SMD construction and low-profile cable connectors.
Preliminary power budget
  • Actuator current is not specified by the seller. Design high-current path provisionally for 10 A short pulses and verify using a measured stall-current test before production.
  • TF-Luna is continuous and will dominate standby load; size its supply from verified datasheet current.
  • ESP32-S3 rail must support radio current peaks even if wireless features are initially unused.
  • Derive regulated logic/sensor rails from the protected 2S pack using efficient switching regulation where required.
Interfaces
  • TF-Luna: UART RX/TX plus verified supply voltage and ground.
  • Actuator: two high-current outputs from H-bridge.
  • Battery: B+, cell midpoint, B− for onboard 2S protection.
  • Programming/debug: compact ESP32-S3 native USB or low-profile programming pads, selected to preserve the height envelope.
Validation criteria
  • Schematic follows each selected IC datasheet reference circuit.
  • Safe neutral state at boot, reset, brownout, and firmware crash.
  • No H-bridge shoot-through under any MCU GPIO state.
  • Current path and connectors tolerate the provisional 10 A pulse target.
  • PCB fits 40 × 75 mm and every fitted component remains within 10 mm assembled height.
  • Final motor-current rating remains provisional until the actuator stall current is measured.
  • Purpose

  • Core requirements

  • Mechanical constraints

  • Preliminary power budget

  • Interfaces

  • Validation criteria