PCB Design Step-by-Step Guide
create a new document Build GLECS V4 Motor Controller PCB. Follow these steps in exact order, complete each step fully before moving to next:
STEP 1 — BOARD OUTLINE ONLY:
Create board outline 150x100mm. Add 4 mounting holes 3.2mm NPTH at corners (5,5) (145,5) (5,95) (145,95). Nothing else yet.
STEP 2 — ISOLATION SLOT ONLY:
Draw isolation slot on Edge.Cuts at X=60mm, width 1.5mm, from Y=5mm to Y=95mm. Add keepout rule — absolutely no copper, no traces, no vias within 0.5mm of slot on either side. Confirm slot exists before continuing. This slot divides board into LEFT switching zone (X=0 to X=59mm) and RIGHT logic zone (X=61mm to X=150mm).
STEP 3 — PLACE SWITCHING ZONE COMPONENTS (LEFT SIDE ONLY X=2 to X=58):
Place these components only in left zone:
- J2 screw terminal 3P 5mm LCSC C557652 at X=8 Y=78 (12V power input)
- J3 screw terminal 3P 5mm LCSC C557652 at X=8 Y=22 (motor output)
- F1 fuse 500mA 1812 LCSC C12559 at X=25 Y=10
- D1 SM6T12A TVS LCSC C133698 at X=38 Y=10
- K1 SRD-12VDC relay LCSC C30431 at X=28 Y=65
- D2 1N4007 diode LCSC C727111 at X=28 Y=48
- U5 ULN2003ADR SOIC-16 LCSC C164883 at X=42 Y=55
- U4 PC817C DIP-4 LCSC C115500 at X=54 Y=55
- R10 330R 0603 LCSC C98220 at X=56 Y=48 Do not place anything in right zone yet. STEP 4 — PLACE LOGIC ZONE COMPONENTS (RIGHT SIDE ONLY X=62 to X=148): Place these components only in right zone:
- J1 DC barrel jack LCSC C111567 at X=68 Y=92
- U1 AMS1117-5V SOT-223 LCSC C6187 at X=82 Y=78
- C1 1000uF radial LCSC C503217 at X=93 Y=78
- U9 LMR33630 SOIC-8EP LCSC C1355643 at X=110 Y=90
- L1 2.2uH inductor SRN6028 LCSC C167118 at X=125 Y=90
- U2 STM32 Blue Pill module at X=105 Y=55
- U3 A7672S 4G module at X=130 Y=70
- J4 SMA edge connector LCSC C1509229 at X=148 Y=72
- U6 DS18B20 TO-92 LCSC C376006 at X=130 Y=34
- U7 DHT22 module at X=120 Y=20
- U8 ACS724 SOIC-8 LCSC C52034468 at X=100 Y=20
- SW1 tactile switch LCSC C406160 at X=72 Y=44
- J5 4-pin header LCSC C91552 at X=138 Y=45
- J6 6-pin SWD header LCSC C2685206 at X=72 Y=55
- Star GND copper pad 4x4mm at X=88 Y=48
- Place all decoupling caps 100nF 0603 within 2mm of each IC power pin
- Place bulk caps 22uF 0805 near U1 and U9 outputs
- R1 1k, R2-R3 4.7k, R4-R5 10k, R6 100k, R7-R8 33k all 0603 near STM32 STEP 5 — ROUTE SWITCHING ZONE ONLY: Route only left zone traces. Stay strictly within X=2 to X=58mm:
- 12V power rail 1mm trace: J2 pin1 → F1 → D1 → K1 coil pin2
- GND_SW rail 0.5mm: J2 pin3 → K1 coil pin1 → U5 GND → D2 cathode
- Relay control 0.5mm: U5 output → K1 coil
- Relay output 1mm: K1 NO contact → J3
- D2 flyback across K1 coil pins Do not route any trace that crosses X=60mm yet. STEP 6 — ROUTE LOGIC ZONE ONLY: Route only right zone traces. Stay strictly within X=62 to X=148mm:
- 12V rail 1mm: J1 → F1 area → U1 input → U9 input
- 5V rail 0.8mm: U1 output → C1 → STM32 VIN
- Buck rail 0.8mm: U9 output → L1 → U3 power
- GND 0.5mm: all logic GND to star ground pad at X=88 Y=48
- UART 0.25mm: STM32 PA9 PA10 → U3 RX TX
- Sensor 0.25mm: STM32 PA2 → U6, PA3 → U7, PA0 → U8
- I2C 0.25mm: STM32 PB6 PB7 → J5
- SWD 0.25mm: STM32 PA13 PA14 → J6
- RF 1mm 50ohm: U3 antenna → J4 SMA Do not route any trace that crosses X=60mm yet. STEP 7 — ROUTE ISOLATION CROSSING LAST: Only one signal crosses the isolation slot — route it now:
- STM32 PA1 → R10 330R → U4 PC817 LED anode (logic side)
- U4 PC817 collector → U5 ULN2003 input (switching side) These traces enter and exit through the PC817 pins which are the ONLY legal crossing point. STEP 8 — COPPER POURS:
- Bottom layer left zone: solid GND_SW copper pour
- Bottom layer right zone: solid GND copper pour
- No copper under A7672S antenna area STEP 9 — DRC AND FIX: Run full DRC. Fix every single error. Verify isolation slot has 0.5mm clearance. Target 0 errors. STEP 10 — EXPORT: Export Gerber ZIP for JLCPCB. Export BOM CSV with Comment Designator Footprint LCSC-Part-Number Qty columns. Export CPL CSV with Designator Mid-X Mid-Y Layer Rotation columns — coordinates as plain numbers no mm units
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GLECS V4 Industrial Motor Controller — Project Specification
Purpose
Remote start/stop control interface for a 415V 3-phase industrial motor using STM32 logic and 4G SMS commands. The PCB provides low-voltage relay/contact control and must be integrated with certified industrial motor protection, contactor, overload, enclosure, and emergency-stop systems.
PCB Requirements
- Board: 150 x 100 mm, 2-layer FR4, 1.6 mm, ENIG, green soldermask, white silkscreen.
- Mounting: 4x 3.2 mm NPTH at (5,5), (145,5), (5,95), (145,95).
- Isolation slot: routed NPTH cut at X=60 mm, 1.5 mm wide, Y=5 to 95 mm, with >=0.5 mm copper clearance both sides.
- Zones: switching zone X=2..58 mm, logic zone X=62..148 mm.
Functional Blocks
- 12V input protection and distribution.
- 5V buck rail for LTE module.
- 5V LDO rail/VIN for STM32 Blue Pill module.
- STM32F103C8T6 Blue Pill controller.
- SIMCom A7672S LTE module with SMA antenna connector.
- Optically isolated relay driver using PC817 and ULN2003.
- Relay contact terminal interface.
- DS18B20, DHT22, ACS724 sensing interfaces.
- SWD, OLED/I2C, UART, status LEDs, and test points.
Safety Notes
This design involves industrial motor control and references 415V 3-phase equipment. Final use requires certified contactors/overload protection, e-stop chain, enclosure, earthing, creepage/clearance review, EMC testing, and qualified electrician validation.
Purpose
PCB Requirements
Functional Blocks
Safety Notes
