EV Charger Schematic Review

flux

已开始处理你的请求，但现在账户没有可用 ACUs，AI 功能暂时不可用，所以我不能继续调用工具完成修改。
目前本轮已完成：
  • 读取并理解任务：按顺序整理这些 sheet，并加入 K_CHG / K_DIS 硬件互锁后重新 ERC。
  • 检查了当前 K_CHG / K_DIS 线圈驱动相关连接：
    • 两个接触器线圈目前都直接由 24V_RELAY_AFTER_ESTOP 供电；
    • K_CHG_COIL_LOW 和 K_DIS_COIL_LOW 分别由 Q1/Q2 低边 NMOS 驱动；
    • 目前尚未加入真正的硬件互锁触点。
  • 确认当前 schematic 视觉整理还没有实际完成；上一条进度里“cleanup completed”不代表已经完成可视排版。
还需要继续做：
  • 添加 K_CHG / K_DIS 硬件互锁，建议用对方的 NC 辅助触点串入本接触器线圈供电路径：
    • 24V_RELAY_AFTER_ESTOP -> K_DIS_NC_INTERLOCK -> K_CHG coil
    • 24V_RELAY_AFTER_ESTOP -> K_CHG_NC_INTERLOCK -> K_DIS coil
  • 按顺序渲染/展示：
    1. CP_GENERATION_AND_MONITOR
    2. CC_PP_RC_R4_AND_DISCHARGE_IDENTIFICATION
    3. CHARGE_AND_DISCHARGE_CONTACTOR_CONTROL
    4. AC_MAIN_PATH_AND_BIDIRECTIONAL_MEASUREMENT
    5. POWER_MCU_COMMUNICATION
  • 重新运行 ERC，并修复或记录剩余 unresolved items。
H

hanlinzhen

flux

I can’t run analysis, auto-placement, or routing right now because the account has no available ACUs, so AI execution features are unavailable.
What was accomplished so far in this session:
  • The EV charge controller/test board was refined into a review-stage logical schematic.
  • The pilot architecture was corrected to use PILOT_OUT, with CP/CC/PP interpretation notes updated.
  • R1_CP was defined as the mandatory 1.000 kΩ, 0.1%, 0.5 W GB/T control-guide equivalent series resistor, with CP monitoring on the CP_OUT side.
  • Discharge-identification branches and full-board schematic notes were added.
  • A later request to clean schematic sheets and add K_CHG/K_DIS hardware interlock was started conceptually but not completed due to ACU limits.
What remains to be done:
  • Inspect current PCB state to determine whether placement, routing, or both are needed.
  • If placement is incomplete, run auto-layout/component placement.
  • If placement is usable but airwires remain, run routing.
  • Apply the resulting layout/routing changes automatically.
  • Run board checks/DRC afterward.
  • Keep this project marked REVIEW REQUIRED for HV, relay pinout, creepage/clearance, thermal, EMC, protection, and manufacturing readiness.
Manual PCB checklist
Check placement status
Find unrouted nets
Verify HV clearance
Review BOM risks

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Files

Schematic

Layout

3D View

Full Board Schematic Pass
Scope
Review-stage component-level hierarchical schematic pass for the full EV charge controller/test board. No PCB placement, footprints, routing, Gerbers, or manufacturing outputs were created.
Implemented Sheet Groups
  • TOP_LEVEL_INTERFACES
  • POWER_MCU_COMMUNICATION
  • CP_GENERATION_AND_MONITOR
  • CC_PP_RC_R4_AND_DISCHARGE_IDENTIFICATION
  • CHARGE_AND_DISCHARGE_CONTACTOR_CONTROL
  • AC_MAIN_PATH_AND_BIDIRECTIONAL_MEASUREMENT
  • REVIEW_AND_TEST_STATE_TABLE
Key Architecture
Top-Level Interfaces
  • External isolated 24VDC input: 24V_IN_RAW -> F_24V_IN -> 24V_FUSED -> D_24V_REV -> protected 24V_IN, with D_24V_TVS clamp to GND.
  • AC input terminals: L_IN, N_IN, PE_IN.
  • Vehicle terminals: L_VEH, N_VEH, PE_OUT, CP_OUT, CC_PP_OUT.
  • External discharge terminals: L_DIS_OUT, N_DIS_OUT, PE_DIS_OUT.
  • PE continuity: PE_IN, PE_OUT, and PE_DIS_OUT are permanently continuous and never switched.
Power / MCU / Communication
  • STM32G474RET6 MCU, LMR33630 24V->5V, AP63203 5V->3V3, W5500 Ethernet placeholder, ADM2587E isolated RS-485.
  • External upstream RCD/MCB is assumed. No RCD or MCB is included on this board.
  • 24V input protection placeholders are present but REVIEW REQUIRED for ratings and coordination.
CP Generation and Monitor
  • CP_OUT and PE_OUT only.
  • Isolated +/-15V CP analogue supply placeholder: WRE2415S-1WR2 represented by WRE2412S library placeholder.
  • MCP4922 + REF5050 + OPA197 stages + ADG1419 high-Z/disconnect.
  • Mandatory R1_CP = 1.000kΩ, 0.1%, 0.5W between CP source switching circuit and CP_OUT.
  • CP monitor is connected on the vehicle/CP_OUT side of R1_CP, relative to PE_OUT.
  • CP_OUT never connects to CC_PP_OUT.
CC/PP RC/R4 and Discharge Identification
  • Passive-only network; no CC/PP-to-PE voltage sensing.
  • Normal route: PE_OUT -> [selected R4 OR S3 bypass] -> selected RC -> K_RC_ENABLE -> CC_PP_OUT.
  • R4 and RC selections are independent and series-connected.
  • Direct discharge routes: PE_OUT -> K_DIS_GB/EU/US -> R_DIS_GB/EU/US -> CC_PP_OUT.
  • All relay paths released = CC_PP_OUT open circuit.
Charge and Discharge Contactor Control
  • K_CHG: two-pole L/N charge contactor candidate HF170F/24-2H1DTF.
  • K_DIS: independent two-pole L/N discharge-output contactor placeholder.
  • K_CHG and K_DIS must never be closed simultaneously.
  • E_STOP_NC is represented as the hardwired 24V_RELAY_AFTER_ESTOP coil supply feeding both contactors.
  • Both contactor pinouts/footprints remain VERIFY AGAINST SUPPLIER DRAWING OR SAMPLE.
AC Main Path and Bidirectional Measurement
  • Charge path: L_IN/N_IN -> K_CHG -> L_VEH/N_VEH.
  • Discharge path: L_VEH/N_VEH -> K_DIS -> L_DIS_OUT/N_DIS_OUT.
  • CT placeholder on L_VEH for bidirectional current measurement.
  • Vehicle-side common bus voltage measurement uses existing symmetric divider/AFE on L_VEH and N_VEH.
  • RMS voltage/current and signed real power direction are firmware/reporting functions; measurement hardware is review-stage only.
  • Heavy 32A copper routing requirements remain documentation only; no layout was created.
Test State Table

Table

StateK_CHGK_DISCP_OUTCC_PP_OUTNotes
All-open safe stateOpenOpenHigh-Z unless explicitly enabledOpen circuitDefault safe review target
Normal chargeMay close after checksOpen1kHz CP through R1_CPRC/R4 route may be selectedK_CHG and K_DIS interlock required
Test modeControlled by test sequenceOpenProgrammable +/- platform CPProgrammable passive selectionsHardware ratings/watchdog remain active
Engineering modeControlled under service/authOpen unless test requiresCP high-Z or programmablePassive network selectableE-stop/watchdog/ratings remain active
GB discharge candidateOpenMay close if allowedHigh-Z unless GB CP test explicitly activeK_DIS_GB route onlyNo simultaneous normal RC/R4 route
EU discharge candidateOpenMay close if allowedHigh-ZK_DIS_EU route onlyCP generator must not connect to CC_PP_OUT
US discharge reserveOpenMay close if allowedHigh-ZK_DIS_US DNP reserve onlyVehicle-specific; no universal US value claimed
Normal stopOpen after RMS current <1A for 500msOpenContinuous +12V before releaseOpen/passive safeSequence REVIEW REQUIRED
Emergency stopImmediately de-energizedImmediately de-energizedHigh-Z/driver disabledOpenE_STOP_NC hardwired coil supply interruption
Preliminary BOM Additions / Changes in This Pass

Table

RefItemNotes
F_24V_INMF-R050-2 resettable fuse placeholder24V input protection; rating REVIEW REQUIRED
D_24V_REVSS34 reverse-polarity diode placeholderThermal/drop REVIEW REQUIRED
D_24V_TVSSMAJ33A TVS placeholderSurge/EMC coordination REVIEW REQUIRED
K_CHGHF170F/24-2H1DTF placeholderTwo-pole charge contactor candidate
K_CHG_LPOLE/K_CHG_NPOLELogical K_CHG polesExcluded from final BOM; represent L/N switching
K_DISDischarge contactor placeholderIndependent two-pole discharge-output contactor
K_DIS_LPOLE/K_DIS_NPOLELogical K_DIS polesExcluded from final BOM; represent L/N switching
Q2, D2, U15, R_Q2_GATE, R_Q2_PDK_DIS coil driver/feedback placeholdersValues/ratings REVIEW REQUIRED
J_L_DIS_OUT, J_N_DIS_OUT, J_PE_DIS_OUTM6 terminal placeholdersFootprint/current/thermal REVIEW REQUIRED
R1_CP1.000kΩ, 0.1%, 0.5WMandatory GB/T control-guide equivalent R1
ERC-Style Unresolved Items
  • Schematic is logical/component-level but visually unclean; several label/rail proximity warnings are expected before schematic cleanup.
  • K_CHG and K_DIS physical pinouts and footprints must be verified from supplier drawings/samples.
  • K_CHG/K_DIS mutual exclusion is represented logically; explicit hardware interlock remains REVIEW REQUIRED.
  • 24V input fuse/reverse/TVS coordination requires real part selection and calculations.
  • Exact WRE2415S-1WR2 part remains represented by a placeholder.
  • CP analogue gain/stability, CP high-Z leakage, and CP monitor isolation/protection require detailed analogue review.
  • CC/PP passive network relay contact ratings, creepage/clearance, and default-open behavior require review.
  • Vehicle-side voltage/current measurement is measurement-only, not protective isolation.
  • Thermal, EMC, surge, creepage/clearance, and manufacturing decisions remain REVIEW REQUIRED.

  • Scope

  • Implemented Sheet Groups

  • Key Architecture

  • Top-Level Interfaces

  • Power / MCU / Communication

  • CP Generation and Monitor

  • CC/PP RC/R4 and Discharge Identification

  • Charge and Discharge Contactor Control

  • AC Main Path and Bidirectional Measurement

  • Test State Table

  • Preliminary BOM Additions / Changes in This Pass

  • ERC-Style Unresolved Items