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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Power Budget Analysis — GLECS V4 Motor Controller
Source
USB-C PD input negotiated by CH224K to 12V. User requires a 65W+ USB-C PD charger. 12V rail feeds protection, relay coil, AMS1117-5.0, and LMR33630 5V rail.
Estimated Loads
Table
| Rail | Load | Typical | Peak |
|---|---|---|---|
| 12V | SRD-12VDC-SL-C relay coil | 30-37.5mA | 40mA |
| 12V | AMS1117-5.0 feeding STM32 Blue Pill VIN | 60mA | 150mA |
| 12V | LMR33630 input for LTE 5V rail | reflected | reflected |
| 5V LTE | SIMCom A7672S rail via buck | 300mA | 2A transient allowance |
| 3.3V module | STM32 Blue Pill onboard rail + sensors + LEDs | 60mA | 150mA |
Reflected Input Current
Assume LMR33630 efficiency 88% at 12V to 5V.
- LTE 5V peak: 5V × 2A / (12V × 0.88) ≈ 0.95A from 12V.
- Relay + MCU/sensors peak: ≈0.19A.
- Estimated 12V peak: ≈1.14A.
Sizing Implication
The requested 500mA PTC is undersized for LTE transmit peaks if the A7672S really draws 2A at its power rail. For reliable LTE operation use at least a 1.5A hold-current input protection device or accept possible nuisance trips/brownouts. I will keep the requested 500mA PTC footprint/value but document it as a risk.
Thermal Note
AMS1117-5.0 from 12V dissipates (12V-5V)×I. At 100mA this is 0.7W, requiring copper area and thermal verification. The Blue Pill module normally contains its own 3.3V regulator, so the AMS1117 should only feed modest logic loads, not the LTE module.
Source
Estimated Loads
Reflected Input Current
Sizing Implication
Thermal Note
