INA219 Current Measurement Audit

Task unable to complete.

2:13

Thought for 16 sec — Identifying necessary skills

Accessing knowledge.

Running 5 design checks.

Reading schematic for J1, F2, Q2 and 7 more.

Completed 5 design checks — found 39 issues.

Running 5 design checks... (28 sec)

Reading layout for Q2, F2, D3 and 5 more.

Thought for 10 sec

flux

Work done

Audited the scoped Q2 input-protection area and verified the corrected schematic connectivity.
DRC still reports scoped layout problems: VIN_FUSED airwire between F2:P2 and Q2:D, VIN_PROTECTED airwires involving Q2:S, D6:K, and R6:P2, plus stale/dangling trace remnants and an overlap at Q2:D.
Created the detailed status file: Q2 Input Protection Routing Remediation Status.

Success criteria review

❌ Stale traces were identified but not removed in this run.
❌ The physical path is not yet fully routed as J1 P1 -> F2 -> VIN_FUSED -> Q2 -> VIN_PROTECTED -> D3/C7/FB2 -> VIN_FILTERED.
❌ DRC is not clean in the scoped area; airwires/dangling/overlap issues remain.
✅ The corrected schematic topology still supports reverse-polarity blocking, but the PCB must be cleaned/rerouted before fabrication.

Next steps

Perform the physical trace cleanup/reroute in the PCB editor for the listed scoped items, then rerun DRC to confirm the Q2 input-protection area is clear.

Locate routing issues

Fix Q2 remnants

Route VIN_PROTECTED

Run targeted DRC

Resistance

1kΩ

J1 P1 - F1 P1

L1 2 - U1 FEEDBACK

Q3 D - D5 K

U6 IN- - K1 A1

Q2 G - R6 P1

U6 IN- - K1 A1

R6 P2 - Q2 S

L1 1 - U1 OUTPUT

U6 VS - U2 3V3

Q1 B - R1 2

R5 P1 - D6 A

FB2 2 - U1 VIN

L1 2 - U1 FEEDBACK

U6 VS - U2 3V3

Q1 B - R1 2

K1 NO - RELAY_OUT P2

L1 2 - U1 FEEDBACK

U6 VS - U2 3V3

FB2 2 - U1 VIN

L1 2 - U1 FEEDBACK

Q1 C - K1 A2

L1 2 - U1 FEEDBACK

R6 P2 - Q2 S

Q3 D - D5 K

FB2 2 - U1 VIN

U6 VS - U2 3V3

U6 SDA - U2 IO21

L1 1 - U1 OUTPUT

FB2 2 - U1 VIN

U6 IN- - K1 A1

L1 2 - U1 FEEDBACK

Q3 D - D5 K

Q2 G - R6 P1

Q1 C - K1 A2

R1 1 - U2 IO23

L1 1 - U1 OUTPUT

K1 COM - RELAY_OUT P1

U6 SCL - U2 IO22

R5 P1 - D6 A

U6 SDA - U2 IO21

Q1 C - K1 A2

U6 VS - U2 3V3

L1 2 - U1 FEEDBACK

Q1 B - R1 2

K1 COM - RELAY_OUT P1

K1 NO - RELAY_OUT P2

R1 1 - U2 IO23

Q3 D - D5 K

J1 P1 - F1 P1

L1 2 - U1 FEEDBACK

U6 SDA - U2 IO21

Q3 D - D5 K

U6 SCL - U2 IO22

Q3 D - D5 K

U6 SCL - U2 IO22

Resistance

4.7kΩ

FB2

Capacitance

100nF

Capacitance

100nF

Resistance

4.7kΩ

D3 A - J1 P2

U1 GND_TAB - U1 ~ON~/OFF

R2 2 - Q1 E

U2 GND3 - U6 GND

U1 GND_TAB - U1 ~ON~/OFF

RELAY_OUT

U6 A1 - C1 2

RSHUNT

Resistance

0.22 Ω

U1 GND_TAB - U1 ~ON~/OFF

Resistance

100kΩ

U6 A1 - C1 2

U1 GND_TAB - U1 ~ON~/OFF

D3 A - J1 P2

U6 A1 - C1 2

Resistance

100kΩ

Capacitance

100nF

Inductance

68uH

Capacitance

100uF

D3 A - J1 P2

R2 2 - Q1 E

R5 P2 - D5 A

R2 2 - Q1 E

Capacitance

100nF

D3 A - J1 P2

Resistance

10kΩ

U6 A1 - C1 2

D3 A - J1 P2

U1 GND_TAB - U1 ~ON~/OFF

Capacitance

100uF

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BOM / Schematic / Documentation / Net-Label Consistency Audit

Scope: AUDIT ONLY for electrical design data. No schematic, PCB, component, net, or layout edits were made. This file was created as the requested audit deliverable.

Project: 12-24 -> esp controller
Audit date: 2026-05-11

Verdict

FAIL for release documentation.

The live schematic, BOM, and PCB layout are broadly consistent with each other for the actual placed physical parts, but the project documentation is not release-clean because Design Notes still refer to obsolete/nonexistent protection-stage designators F1, Q3, and D5, while the current schematic/BOM/layout use F2, Q2, and D3. In addition, D2 is electrically the LM2596 catch/freewheel diode, but its component role text currently describes back-power / OR-ing behavior, which conflicts with the actual schematic function.

Data Sources Reviewed

Current schematic component summary and netlist.
Current BOM.
Current PCB layout component list / component bounds.
Current DRC/ERC review result.
Existing project files:
- project-specification
- design-notes
- input-protection-and-buck-power-stage-audit
- lm2596-buck-converter-stage-audit
- related relay / INA219 / ESP32 audit files via project-file search.

High-Level Findings

Schematic ↔ BOM consistency

PASS for physical schematic components.

All actual non-portal, non-ground schematic components appear in the BOM, and all BOM designators correspond to actual schematic components:

R1, R2, R3, R4, R5, R6, RSHUNT, FB2, C1, C2, C3, C4, C5, C7, U1, U2, U6, J1, RELAY_OUT, D1, D2, D3, D6, Q1, Q2, K1, L1, F2

The schematic also contains many Net Portal and Ground helper objects, but these are intentionally excluded from BOM and PCB where appropriate.

BOM ↔ PCB layout consistency

PASS for actual placed physical component designators.

The PCB layout includes the same actual physical designators present in the BOM:

R1, R3, FB2, C5, C7, R4, U2, RELAY_OUT, RSHUNT, D3, R5, D1, Q1, R6, D2, K1, J1, C3, L1, D6, Q2, C2, C4, R2, F2, U1, U6, C1

No layout element for obsolete F1, Q3, or D5 was found in the inspected PCB component list.

Documentation consistency

FAIL.

The current Design Notes file still says the selected protection-stage components are:

F1: SMD1206P075TF/30 PPTC fuse
Q3: QM6015D P-channel MOSFET
D5: SMBJ26A-13-F TVS

But the actual schematic/BOM/layout use:

F2: 1206L100/33NR PPTC fuse
Q2: DMPH6250SQ-7 P-channel MOSFET
D3: SMBJ26A-TR TVS

Therefore release documentation is inconsistent with the actual design database.

Net-label / portal consistency

FAIL for obsolete labels in schematic helper portals.

Current schematic net names are clean and do not include obsolete component designator names; however, several portal/ground helper designators still contain obsolete references:

J1 P1 - F1 P1 — obsolete F1; actual fuse is F2.
Q3 D - D5 K — obsolete Q3 and D5; actual devices are Q2 and D3.
R5 P2 - D5 A — obsolete D5; actual TVS is D3.

These helper labels do not appear to change electrical connectivity by themselves, but they are documentation/maintainability hazards and should be corrected before release documentation signoff.

D2 role ambiguity

FAIL.

Actual schematic connection:

D2:Cathode is on BUCK_SW with U1:OUTPUT and L1:1.
D2:Anode is on GND.

That makes D2 the LM2596 buck catch/freewheel Schottky diode.

Current component role text says:

Prevents harmful back-power interaction between rails while allowing simple prototype power OR-ing

That is inconsistent with the actual electrical function. The BOM/component description must be corrected to identify D2 only as the LM2596 catch/freewheel diode, not as a back-power protection or OR-ing diode.

Exact Current Relevant Nets

Input/protection nets

Table

Net	Current connections
`VIN_RAW`	`J1:P1`, `F2:P1`
`VIN_FUSED`	`F2:P2`, `Q2:S`, `D6:K`, `R6:P2`
`VIN_GATE`	`Q2:G`, `D6:A`, `R5:P1`, `R6:P1`
`VIN_PROTECTED`	`Q2:D`, `D3:K`, `C7:P1`, `FB2:1`
`VIN_FILTERED`	`FB2:2`, `C1:1`, `C3:P1`, `U1:VIN`
`GND`	`J1:P2`, `D3:A`, `C7:P2`, `C1:2`, `C3:P2`, U1/U2/U6 grounds, and other returns

Buck nets

Table

Net	Current connections
`BUCK_SW`	`U1:OUTPUT`, `D2:Cathode`, `L1:1`
`5V`	`L1:2`, `U1:FEEDBACK`, `C2:1`, `C4:P1`, `U2:EXT_5V`, `RSHUNT:P1`, `U6:IN+`, `D1:cathode`
`GND`	`D2:Anode`, `U1:GROUND`, `U1:GND_TAB`, `U1:~ON~/OFF`, `C1:2`, `C2:2`, `C3:P2`, `C4:P2`

Required Table

Table

Component / reference	Actual function	Current designator in schematic/BOM/layout	Problem	Required correction
PPTC input fuse	Series resettable fuse from `VIN_RAW` to `VIN_FUSED`	`F2`	`Design Notes` still refer to `F1`; schematic portal `J1 P1 - F1 P1` also references obsolete `F1`.	Update documentation and helper labels to `F2`; remove all `F1` release references unless documenting old revision history.
P-channel reverse-polarity MOSFET	High-side reverse-polarity protection element between `VIN_FUSED` and `VIN_PROTECTED`	`Q2`	`Design Notes` still refer to `Q3`; portal label `Q3 D - D5 K` references obsolete `Q3`.	Update documentation and helper labels to `Q2`. Also keep prior electrical audit note that Q2 orientation needs correction before fabrication.
Input TVS diode	Unidirectional TVS from `VIN_PROTECTED` to `GND`	`D3`	`Design Notes` still refer to `D5`; portal/ground helper labels `Q3 D - D5 K` and `R5 P2 - D5 A` reference obsolete `D5`.	Update documentation/helper labels to `D3`.
LM2596 catch diode	Buck freewheel/catch Schottky diode from `BUCK_SW` cathode to `GND` anode	`D2`	Role Details describe back-power / OR-ing, not catch diode. This makes the BOM description ambiguous/wrong.	Change description to “LM2596 buck catch/freewheel Schottky diode, cathode to BUCK_SW, anode to GND.” Do not describe D2 as back-power protection.
Input connector	12V–24V DC input connector; `P1 = VIN_RAW`, `P2 = GND`	`J1`	Actual net mapping is clear, but release-facing polarity labeling is not explicit enough in connector properties/silkscreen documentation.	Document/label `J1 P1 = +12V–24V`, `J1 P2 = GND`.
Dry-contact output connector	Relay contact output; `P1 = RELAY_COM`, `P2 = RELAY_NO`	`RELAY_OUT`	BOM groups `J1` and `RELAY_OUT` under the same 2-position screw-terminal part, which is electrically valid but can confuse assembly/order documentation because one is power input and one is dry-contact output.	Keep same MPN if intended, but release docs should list them as separate functional line items: `J1 Power Input` and `RELAY_OUT Dry Contact Output`.
Ferrite bead	EMI filter from `VIN_PROTECTED` to `VIN_FILTERED` before U1 VIN	`FB2`	No designator mismatch found. Current role matches schematic function.	No correction needed for naming. Confirm rating per prior input-stage audit before production.
Gate-source zener clamp	Zener clamp from Q2 source net to gate net	`D6`	No designator mismatch found, but `Design Notes` text says gate-source clamp for `Q3`.	Keep `D6`; update associated text to say Q2 gate-source clamp.
Gate pull-down resistor	Pulls `VIN_GATE` to GND	`R5`	Electrical function matches, but helper label `R5 P2 - D5 A` references obsolete `D5`.	Update helper label/doc text to reference `D3:A/GND` or just `GND`.
Gate-source bias resistor	Bias resistor from `VIN_FUSED` to `VIN_GATE`	`R6`	No designator mismatch found.	No naming correction needed.
Buck regulator	Fixed 5V LM2596 regulator	`U1`	No designator mismatch found. Prior audit found layout/value-rating issues, but not naming inconsistency.	No naming correction needed.
Buck inductor	LM2596 output inductor from `BUCK_SW` to `5V`	`L1`	Component property `Designator Prefix` appears as `D` in schematic data even though current designator is `L1`.	Correct property metadata to prefix `L` if release/BOM tooling uses this field.
INA219 current monitor	Relay coil high-side current monitor	`U6`	No designator mismatch found.	No correction needed.
Relay	5V SPDT relay, coil driven by Q1, contacts exported to `RELAY_OUT`	`K1`	No designator mismatch found.	No correction needed.
Relay driver transistor	Low-side NPN relay coil driver	`Q1`	No designator mismatch found.	No correction needed.
Flyback diode	Relay coil flyback diode	`D1`	No designator mismatch found.	No correction needed.
ESP32 DevKit	Controller module powered via `EXT_5V`, GPIO23 relay control, GPIO21/22 I2C	`U2`	No designator mismatch found. Prior audit found back-power risk, but not naming inconsistency.	No naming correction needed; implement power isolation per separate ESP32 audit.

Checklist Results

Table

#	Check	Result	Notes
1	Every component in schematic exists in BOM	PASS	All physical schematic components are present in BOM. Net portals/ground helpers are intentionally excluded.
2	Every BOM component exists in schematic	PASS	All BOM designators map to physical schematic components.
3	Designators consistent between notes, schematic, PCB layout, and BOM	FAIL	`Design Notes` and portal/helper labels still use obsolete `F1/Q3/D5`; actual schematic/BOM/layout use `F2/Q2/D3`.
4	Portal/net labels do not reference obsolete component names	FAIL	Helper labels include `J1 P1 - F1 P1`, `Q3 D - D5 K`, and `R5 P2 - D5 A`.
5	D2 role is not ambiguous	FAIL	D2 is electrically the buck catch diode, but component role text says back-power / OR-ing.
6	F1 vs F2 naming is resolved	FAIL	Actual is `F2`; documentation/helper labels still say `F1`.
7	Q2 vs Q3 naming is resolved	FAIL	Actual is `Q2`; documentation/helper labels still say `Q3`.
8	D3 vs D5 naming is resolved	FAIL	Actual is `D3`; documentation/helper labels still say `D5`.
9	Connector J1 and RELAY_OUT are not grouped in a way that causes ordering/BOM confusion	WARN	BOM groups both as the same part, which is technically correct, but release docs should separate their functions to avoid assembly confusion.
10	Component descriptions match actual electrical function	FAIL	D2 role description is wrong; Design Notes list obsolete parts and MPNs for the input protection stage.

Release Documentation Status

FAIL — not release-ready.

Release documentation should not be issued until the following documentation/metadata corrections are made:

Replace all current-revision references to F1 with F2 where referring to the actual input PPTC.
Replace all current-revision references to Q3 with Q2 where referring to the actual PMOS reverse-protection stage.
Replace all current-revision references to D5 with D3 where referring to the actual input TVS.
Correct D2 Role Details / BOM description to catch/freewheel diode only.
Split connector documentation into two functional items even if they share the same screw-terminal MPN:
- J1 = 12V–24V power input, P1 = +VIN, P2 = GND.
- RELAY_OUT = dry-contact relay output, P1 = COM, P2 = NO.
Correct L1 metadata so its designator prefix/property matches an inductor (L), not D, if release exports use that property.

Final PASS/FAIL

FAIL for release documentation.

The underlying schematic/BOM/layout databases are internally consistent for the actual physical parts, but release-facing documentation and helper labels are inconsistent enough to create procurement, assembly, and debug confusion. The most important corrections are F1 -> F2, Q3 -> Q2, D5 -> D3, and correcting D2 from a back-power/OR-ing description to the LM2596 catch-diode role.

Verdict
Data Sources Reviewed
High-Level Findings
Schematic ↔ BOM consistency
BOM ↔ PCB layout consistency
Documentation consistency
Net-label / portal consistency
D2 role ambiguity
Exact Current Relevant Nets
Input/protection nets
Buck nets
Required Table
Checklist Results
Release Documentation Status
Final PASS/FAIL

Reviews

Documents

Project Specification

Design Notes

Relay / INA219 Shunt Fix

Prototype Fabrication Audit — Golf Ball Dispenser Controller

Relay Dry-Contact Net Isolation Audit

Relay Driver Stage Audit

Input Protection and Buck Power Stage Audit

INA219 Relay Coil Current Sense Audit

LM2596 Buck Converter Stage Audit

ESP32 DevKit Power Interface Back-Power Audit

BOM / Schematic / Documentation / Net-Label Consistency Audit

Manufacturing-Oriented PCB Layout Review Audit

Bench Validation Plan — First Assembled Prototype

Q2 Input Protection Routing Remediation Status

Assets

Assets are files uploaded to this project which can be used in various ways.

Project Name

Description

Golf ball dispenser controller with protected 12V-24V DC input, LM2596 5V buck, ESP32 control, INA219 relay-coil sensing, and dry-contact relay output.

Properties

Properties describe core aspects of the project.

Pricing & Availability

Distributor	Qty 1
Arrow	$6.08–$9.50
Digi-Key	$25.76–$27.71
LCSC	$5.21–$5.34
Mouser	$13.99–$14.05
TME	$10.13
Verical	$4.35–$8.42

Controls

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