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I’m reconciling the completed build against the live project, then I’ll correct and independently verify the schematic before the layout checkpoint.

flux

I reconciled the latest executor report with the live project: the schematic is still empty (0 components, 0 nets). The executor only completed preliminary architecture review; it made no project mutations before ACUs were exhausted.
Completed this session
  • Retrieved and reviewed the full Project Specification.
  • Confirmed the intended scope: protected 18650 charge/power path, external-antenna ESP32-S3, display, microphones, slam switches, RGB boost, and factory test/programming access.
  • Confirmed that no schematic, BOM, design notes, or ERC results currently exist.
Remaining work
  • Create the load-based power budget and select/verify exact production parts.
  • Build and wire every schematic block, then add Design Notes and firmware/bring-up documentation.
  • Independently run ERC and power-path review, fix findings, and pause for schematic approval before PCB placement.
Work is blocked until additional ACUs are available.
Create power budget
Select production parts
Draft schematic blocks
Document design requirements
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Project Specification
Status: Draft / architecture review
Project Overview
Production-intent IJW Pro Quiz System wireless buzzer/slammer. The terminal communicates with a dedicated USB receiver over ESP-NOW and combines a round display, four slam-plate sensor switches, dual voice microphones, perimeter RGB lighting, replaceable 18650 power, and magnetic charging.
Intended Use
Premium commercially manufactured quiz-show terminal. Priorities: reliability, repeatability, serviceability, RF performance, audio quality, low-error assembly, and professional PCBA production.
What the Device Should Do
  • Communicate with the receiver using ESP-NOW.
  • Detect actuation through four corner pressure switches; enclosure hard stops absorb slam force.
  • Drive a 1.28-inch 240x240 GC9A01-compatible round SPI display.
  • Capture team-answer speech through matched west/east digital MEMS microphones.
  • Drive a continuous 5 V addressable perimeter RGB band.
  • Operate from a replaceable protected single 18650 cell.
  • Charge through a four-contact magnetic pogo input while the main system is off.
  • Support identification, pairing, firmware updates, factory programming, and production test.
Main Features
  • ESP32-S3-class module with external-antenna connection.
  • Four high-cycle-life PCB-mounted momentary switches.
  • Two factory-assembled I2S MEMS microphones.
  • Locking connectors for display, RGB band, charging harness, and any remote power switch.
  • Battery charging, protection, monitoring, thermal sensing, and power-path control.
  • Labelled pogo-accessible test points.
System Architecture
Diagram



  
    
  
  
    
  
































Magnetic 5 V charging input
ESD / reverse-current / input protection
Li-ion charger and power path
Replaceable 18650 + NTC
Cell protection
Main system power switch/load switch
3.3 V regulator
5 V RGB boost
ESP32-S3 module
Dual I2S microphones
Round SPI display interface
Four pressure switches
RGB level shifter
5 V perimeter RGB connector
U.FL external antenna
Hardware Subsystems
  1. Charging input protection and charger/power-path management.
  2. Replaceable-cell protection, current protection, NTC, and voltage measurement.
  3. Switched system power, low-noise 3.3 V rail, and high-current 5 V RGB boost rail.
  4. ESP32-S3 MCU/module, boot/reset network, native programming/debug pads, and external RF antenna.
  5. SPI display harness and backlight control.
  6. Matched dual I2S microphone channels with local filtering/decoupling.
  7. Four debounced/protected switch inputs.
  8. RGB level shifting, series damping, bulk capacitance, protection, and locking output connector.
  9. Factory test and programming pads.
Interfaces and Connections
  • Magnetic charge harness: four contacts allocated 2x +5 V and 2x GND.
  • Display: power, GND, SPI SCLK, MOSI, CS, D/C, reset, backlight control; exact harness pinout is pending the selected display assembly.
  • RGB: locking 3-pin +5 V / DATA / GND connector, designed for at least 1.5-2 A peak subject to final strip configuration.
  • Power switch: board-mounted or locking harness; charging remains active in OFF.
  • Antenna: short 50-ohm U.FL/IPEX pigtail to an enclosure-mounted 2.4 GHz antenna.
Power and Runtime Expectations
  • Source: single replaceable 18650 Li-ion cell.
  • Charging source: regulated 5 V magnetic pogo dock.
  • Charging must remain active indefinitely and while the main system is switched off.
  • Low quiescent current is important, but no runtime target has yet been supplied.
  • Software brightness limiting is allowed but electrical protection and component ratings must independently tolerate the defined peak envelope.
Power Tree and Preliminary Budget Basis
  • Protected cell/system node: approximately 3.0-4.2 V.
  • 3.3 V digital/audio rail: ESP32-S3, microphones, display logic, level shifter, monitoring.
  • 5 V boosted rail: perimeter RGB strip and display only if its selected assembly requires 5 V.
  • Design basis pending exact parts: 3.3 V rail >= 0.8 A peak; RGB output >= 2 A at 5 V. At a 3.0 V cell and 88% boost efficiency, a 10 W RGB peak alone implies about 3.8 A battery current, so the final LED count/brightness envelope is a critical architecture input.
Manufacturing and Assembly Expectations
  • Professional PCBA by PCBWay or similar.
  • Factory assembly of module, switches, MEMS microphones, power electronics, connectors, passives, protection, and test pads.
  • Keyed locking internal connectors; no Dupont-style connections or routine soldered flying leads.
  • Prefer documented, reputable, long-life components available from mainstream distribution/assembly channels.
  • Four-layer construction is expected to be preferable; final recommendation follows power/RF/audio analysis.
Firmware-Relevant Hardware Requirements
  • ESP-NOW, display SPI, dual-microphone I2S/PDM-compatible capture, RGB output, four switch inputs, battery ADC, charger status, pairing/ID, boot/reset, and factory programming/debug.
  • Avoid ESP32-S3 strapping and flash/PSRAM-reserved pins for attached loads.
Physical Design Expectations
  • Board: 95 mm x 95 mm square, sensible corner radii, no corner mounting holes, no north/south protrusions.
  • Coordinate origin at board centre; north +Y, east +X.
  • Strict central keep-out: 22 mm x 90 mm, centred at X=0/Y=0, representing the battery housing/structural spine.
  • Fixed switch centres: NW (-37.5,+37.5), NE (+37.5,+37.5), SW (-37.5,-37.5), SE (+37.5,-37.5) mm.
  • Two true internal 3 mm circular cut-outs on Y=0, mirrored east/west and halfway between the central structure and each outer edge. With the stated 22 mm spine as the inner datum, preliminary centres are X=+/-29.25 mm; this interpretation must be confirmed against enclosure CAD before committing.
  • Two microphones on Y=0, mirrored, each outward of its corresponding cut-out and inward of the PCB edge. Exact X coordinate depends on the selected microphone port/gasket geometry.
  • No component body may intrude into the central battery/support volume.
  • Preferred antenna zone: north edge, offset to one side of the central spine, with a defined all-layer RF keep-out and separation from switch hardware, microphones, battery conductors, and RGB power routing.
Important Design Decisions
  • Use a certified ESP32 module rather than a bare RF chip.
  • Use a unified ground system with careful placement and current-return control rather than split grounds.
  • Keep charging connected ahead of the main system power disconnect.
  • Use an external antenna and short pigtail because the central battery/support structure compromises an onboard antenna location.
  • Treat the RGB peak current as a system-level constraint, not merely a connector rating.
Assumptions and Open Interfaces
  • Final LED type, LED count, maximum commanded brightness, and desired runtime are not yet fixed.
  • Exact display module/harness pinout and mounting geometry are not yet fixed.
  • Magnetic pogo connector/harness part and mating geometry are not yet fixed.
  • Power-switch mechanical format and harness/board-mount choice are not yet fixed.
  • Enclosure material, antenna mounting method, and available RF clearance are not yet fixed.
  • The 3 mm cut-out midpoint calculation uses the 22 mm battery-spine side as the inner boundary; central display-support diameter may alter this datum.
  • Exact switch actuator height/travel and microphone acoustic gasket geometry require enclosure coordination before final footprint commitment.
Success Criteria for the Current Phase
  • Functional architecture and exact part recommendations documented.
  • Preliminary power/thermal budget completed.
  • Preliminary schematic and BOM completed and reviewed.
  • Fixed board geometry/keep-outs captured without guessing unresolved mating dimensions.
  • ERC/design review completed before requesting approval to begin PCB placement.
Change Notes
  • Initial specification transcribed from the supplied product requirements on 2026-08-25.

  • Project Overview

  • Intended Use

  • What the Device Should Do

  • Main Features

  • System Architecture

  • Hardware Subsystems

  • Interfaces and Connections

  • Power and Runtime Expectations

  • Power Tree and Preliminary Budget Basis

  • Manufacturing and Assembly Expectations

  • Firmware-Relevant Hardware Requirements

  • Physical Design Expectations

  • Important Design Decisions

  • Assumptions and Open Interfaces

  • Success Criteria for the Current Phase

  • Change Notes