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Connector Candidate Evaluation Example
Purpose
This document provides a filled example evaluation using the checklist in Connector Candidate Spec Checklist. It is intended to show how three connector approaches could be compared for the internal CAN-based link between the real-time board and the upper control board.
Project Assumptions
  • Internal board-to-board interconnect inside the EV charger
  • Preferred CAN-oriented allocation with:
    • 24 V distributed across 2 parallel pins
    • 6 GND pins total in the full option
    • adjacent CAN_H / CAN_L placement
    • CAN-adjacent GND for improved return path and EMI behavior
    • optional status and debug pins
  • Connector target size: around 30 positions for the full option, with reduced-population variants acceptable if the chosen family supports the same pin-field concept
  • Retention and assembly reliability matter more than absolute miniaturization
Candidate Set Used in This Example

Table


CandidateTypeExample Positioning
Candidate AFine-pitch mezzanine board-to-boardCompact and clean, but higher assembly sensitivity
Candidate BMid-pitch locking board-to-boardBalanced electrical, mechanical, and assembly fit
Candidate CWire-to-board harness connectorStrong serviceability, but weaker density and routing efficiency
Candidate A Evaluation
Candidate Header
  • Candidate name: Candidate A
  • Manufacturer: Example
  • Series / family: Fine-pitch mezzanine B2B
  • MPN: Example-A
  • Mating part MPN: Example-A-Mate
  • Lifecycle status: Active
  • Package / mounting style: SMT mezzanine
  • Board orientation: Parallel board stack
  • Stack height / cable style: Low-profile stack
  • Evaluation owner: Hardware
  • Revision / date: Rev A / 2026-04-13
A. Electrical Fit
  • Pin count fit: PASS
  • Power pin strategy: PASS
  • Ground pin strategy: PASS
  • CAN_H / CAN_L adjacency: PASS
  • CAN-adjacent grounds: PASS
  • Current rating per power pin: MARGINAL but acceptable with parallel pin strategy
  • Voltage rating: PASS
  • Contact resistance: PASS
  • Isolation / mixed-use suitability: PASS
B. Signal Integrity / EMC Fit
  • Differential pair friendliness: GOOD
  • Stub control: GOOD
  • Return path support: GOOD
  • Power/signal crossover pressure: MEDIUM
  • Shield / bond support: LIMITED
  • EMC red flags: Low to medium risk due to compact pitch and routing density
C. Mechanical Fit
  • Orientation fit: PASS
  • Height fit: PASS
  • Area fit: PASS
  • Retention strength: MARGINAL
  • Coplanarity sensitivity: HIGH
  • Mating robustness: MEDIUM
  • Polarization: PASS
D. Manufacturing / Assembly Fit
  • Assembly flow compatibility: PASS
  • Fine-pitch assembly risk: HIGH
  • Inspection accessibility: MARGINAL
  • Rework difficulty: HIGH
  • Final mating practicality: MEDIUM
  • Yield risk: MEDIUM to HIGH
E. Service / Bring-up Fit
  • Debug friendliness: MEDIUM
  • Disconnect / reconnect ease: MEDIUM
  • Mis-mating risk: LOW
  • Pin-1 clarity: PASS
F. Sourcing / Commercial Fit
  • Lifecycle: PASS
  • Lead time: MEDIUM RISK
  • Prototype cost: HIGH
  • Production cost: MEDIUM to HIGH
  • Alternate path: LIMITED
  • Supply visibility: MEDIUM
G. System-Specific Checks
  • 24 V parallel pins: PASS
  • 6 GND allocation: PASS
  • CAN pair adjacency: PASS
  • CAN-adjacent grounds: PASS
  • Optional status pins: PASS
  • Optional debug UART: PASS
  • Optional shield/bond pin: MARGINAL
H. Hard-Gate Summary
  • Pin count: PASS
  • Power / ground allocation: PASS
  • CAN placement: PASS
  • Mechanical fit: PASS
  • Assembly risk: CONDITIONAL PASS
  • Lead time: CONDITIONAL PASS
  • Lifecycle: PASS
I. Quantitative Snapshot

Table


ItemValue
Total pins30
Usable signal pins after power/ground allocationModerate
Power current marginAcceptable with parallel pins
PitchFine
Mated heightLow
Locking featureWeak to moderate
Prototype costHigh
Production costMedium to high
Lead timeMedium risk
J. Risk Log

Table


RiskSeverityLikelihoodMitigationOwner
Fine-pitch assembly sensitivityHighMediumConfirm assembler capability and stencil processHW
Rework difficultyHighMediumLimit early revision changes and keep debug access elsewhereHW
Retention marginMediumMediumReview enclosure support or add mechanical supportME
K. Decision Summary
  • Hard-gate result: PASS WITH CAUTION
  • Recommended use: Backup
  • Why this candidate is strong: Excellent density and good CAN pair organization in a compact footprint
  • Main concerns: Assembly difficulty, rework effort, and moderate retention margin
  • Required follow-up actions: Validate assembly process capability and connector retention in the mechanical stack
Candidate B Evaluation
Candidate Header
  • Candidate name: Candidate B
  • Manufacturer: Example
  • Series / family: Mid-pitch locking board-to-board
  • MPN: Example-B
  • Mating part MPN: Example-B-Mate
  • Lifecycle status: Active
  • Package / mounting style: SMT or hybrid locking B2B
  • Board orientation: Parallel board stack
  • Stack height / cable style: Medium stack
  • Evaluation owner: Hardware
  • Revision / date: Rev A / 2026-04-13
A. Electrical Fit
  • Pin count fit: PASS
  • Power pin strategy: PASS
  • Ground pin strategy: PASS
  • CAN_H / CAN_L adjacency: PASS
  • CAN-adjacent grounds: PASS
  • Current rating per power pin: PASS
  • Voltage rating: PASS
  • Contact resistance: PASS
  • Isolation / mixed-use suitability: PASS
B. Signal Integrity / EMC Fit
  • Differential pair friendliness: GOOD
  • Stub control: GOOD
  • Return path support: GOOD
  • Power/signal crossover pressure: LOW
  • Shield / bond support: GOOD
  • EMC red flags: LOW
C. Mechanical Fit
  • Orientation fit: PASS
  • Height fit: PASS
  • Area fit: PASS
  • Retention strength: GOOD
  • Coplanarity sensitivity: MEDIUM
  • Mating robustness: GOOD
  • Polarization: PASS
D. Manufacturing / Assembly Fit
  • Assembly flow compatibility: PASS
  • Fine-pitch assembly risk: LOW to MEDIUM
  • Inspection accessibility: GOOD
  • Rework difficulty: MEDIUM
  • Final mating practicality: GOOD
  • Yield risk: LOW to MEDIUM
E. Service / Bring-up Fit
  • Debug friendliness: GOOD
  • Disconnect / reconnect ease: GOOD
  • Mis-mating risk: LOW
  • Pin-1 clarity: PASS
F. Sourcing / Commercial Fit
  • Lifecycle: PASS
  • Lead time: MEDIUM
  • Prototype cost: MEDIUM
  • Production cost: MEDIUM
  • Alternate path: GOOD
  • Supply visibility: GOOD
G. System-Specific Checks
  • 24 V parallel pins: PASS
  • 6 GND allocation: PASS
  • CAN pair adjacency: PASS
  • CAN-adjacent grounds: PASS
  • Optional status pins: PASS
  • Optional debug UART: PASS
  • Optional shield/bond pin: PASS
H. Hard-Gate Summary
  • Pin count: PASS
  • Power / ground allocation: PASS
  • CAN placement: PASS
  • Mechanical fit: PASS
  • Assembly risk: PASS
  • Lead time: PASS
  • Lifecycle: PASS
I. Quantitative Snapshot

Table


ItemValue
Total pins30
Usable signal pins after power/ground allocationGood
Power current marginGood
PitchMid
Mated heightMedium
Locking featureStrong
Prototype costMedium
Production costMedium
Lead timeMedium
J. Risk Log

Table


RiskSeverityLikelihoodMitigationOwner
Connector height interaction with enclosureMediumLowConfirm z-height budget against enclosure stackME
Medium lead-time variabilityMediumMediumIdentify alternate within same family earlySCM
K. Decision Summary
  • Hard-gate result: PASS
  • Recommended use: Primary
  • Why this candidate is strong: Best balance of CAN-friendly pin field, retention, manufacturability, serviceability, and sourcing resilience
  • Main concerns: Needs confirmation of final height and preferred sourcing lane
  • Required follow-up actions: Check exact stack height, shortlist 2-3 family members, and confirm assembler preference
Candidate C Evaluation
Candidate Header
  • Candidate name: Candidate C
  • Manufacturer: Example
  • Series / family: Wire-to-board harness connector
  • MPN: Example-C
  • Mating part MPN: Example-C-Mate
  • Lifecycle status: Active
  • Package / mounting style: Wire-to-board with crimp or discrete cable assembly
  • Board orientation: Cable-linked boards
  • Stack height / cable style: Harness
  • Evaluation owner: Hardware
  • Revision / date: Rev A / 2026-04-13
A. Electrical Fit
  • Pin count fit: PASS
  • Power pin strategy: PASS
  • Ground pin strategy: PASS
  • CAN_H / CAN_L adjacency: POSSIBLE but less elegant than board-to-board options
  • CAN-adjacent grounds: POSSIBLE with harness planning
  • Current rating per power pin: GOOD
  • Voltage rating: PASS
  • Contact resistance: PASS
  • Isolation / mixed-use suitability: PASS
B. Signal Integrity / EMC Fit
  • Differential pair friendliness: MEDIUM
  • Stub control: MEDIUM to WEAK
  • Return path support: MEDIUM
  • Power/signal crossover pressure: MEDIUM
  • Shield / bond support: MEDIUM
  • EMC red flags: More harness-dependent than board-to-board solutions
C. Mechanical Fit
  • Orientation fit: PASS if cable solution is allowed
  • Height fit: GOOD
  • Area fit: MEDIUM
  • Retention strength: GOOD
  • Coplanarity sensitivity: LOW
  • Mating robustness: GOOD
  • Polarization: PASS
D. Manufacturing / Assembly Fit
  • Assembly flow compatibility: MEDIUM
  • Fine-pitch assembly risk: LOW
  • Inspection accessibility: GOOD
  • Rework difficulty: LOW to MEDIUM
  • Final mating practicality: MEDIUM
  • Yield risk: MEDIUM due to harness handling
E. Service / Bring-up Fit
  • Debug friendliness: GOOD
  • Disconnect / reconnect ease: GOOD
  • Mis-mating risk: LOW
  • Pin-1 clarity: PASS
F. Sourcing / Commercial Fit
  • Lifecycle: PASS
  • Lead time: GOOD
  • Prototype cost: MEDIUM
  • Production cost: MEDIUM to HIGH because of harness content
  • Alternate path: GOOD
  • Supply visibility: GOOD
G. System-Specific Checks
  • 24 V parallel pins: PASS
  • 6 GND allocation: PASS
  • CAN pair adjacency: CONDITIONAL PASS
  • CAN-adjacent grounds: CONDITIONAL PASS
  • Optional status pins: PASS
  • Optional debug UART: PASS
  • Optional shield/bond pin: PASS
H. Hard-Gate Summary
  • Pin count: PASS
  • Power / ground allocation: PASS
  • CAN placement: CONDITIONAL PASS
  • Mechanical fit: PASS
  • Assembly risk: PASS
  • Lead time: PASS
  • Lifecycle: PASS
I. Quantitative Snapshot

Table


ItemValue
Total pins30 equivalent possible
Usable signal pins after power/ground allocationGood
Power current marginGood
PitchModerate to large
Mated heightFlexible
Locking featureStrong
Prototype costMedium
Production costMedium to high
Lead timeGood
J. Risk Log

Table


RiskSeverityLikelihoodMitigationOwner
Harness-induced EMC variationMediumMediumControl pair routing and harness build rulesHW
Additional assembly stepMediumMediumReview assembly flow and test fixture impactMFG
Cable management inside enclosureMediumMediumCoordinate early with mechanical layoutME
K. Decision Summary
  • Hard-gate result: PASS WITH CONDITIONS
  • Recommended use: Secondary backup
  • Why this candidate is strong: Robust and serviceable, with better tolerance to board placement variation
  • Main concerns: CAN/EMI performance is more harness-dependent and system packaging becomes more complex
  • Required follow-up actions: Validate enclosure routing path and CAN behavior with representative harness build
Comparative Ranking

Table


RankCandidatePositionWhy
1Candidate BPrimaryBest overall balance across electrical, EMI, mechanical, assembly, and sourcing criteria
2Candidate CBackupStrong mechanical and service fit, but less clean for CAN/EMI and packaging
3Candidate ABackup with cautionStrong density, but assembly and rework risk are higher than needed for this design stage
Overall Recommendation
  • Preferred direction: Mid-pitch locking board-to-board connector family
  • Backup direction: Wire-to-board harness if enclosure layout or service approach favors a cable link
  • Use fine-pitch mezzanine only if aggressive density becomes necessary and the assembly flow is proven early
Follow-up Checks Before Freezing Connector Choice
  • Confirm exact 24 V current allocation per pin and temperature rise margin
  • Confirm 30-position pin field still matches the latest CAN-oriented allocation
  • Confirm whether B2B_CAN_WAKE and B2B_CAN_STB_CTRL are needed or remain DNP options
  • Confirm connector height and keepout against enclosure constraints
  • Confirm assembler preference and rework capability
  • Confirm supply-chain status and alternate path for the chosen family
  • Purpose

  • Project Assumptions

  • Candidate Set Used in This Example

  • Candidate A Evaluation

  • Candidate Header

  • A. Electrical Fit

  • B. Signal Integrity / EMC Fit

  • C. Mechanical Fit

  • D. Manufacturing / Assembly Fit

  • E. Service / Bring-up Fit

  • F. Sourcing / Commercial Fit

  • G. System-Specific Checks

  • H. Hard-Gate Summary

  • I. Quantitative Snapshot

  • J. Risk Log

  • K. Decision Summary

  • Candidate B Evaluation

  • Candidate Header

  • A. Electrical Fit

  • B. Signal Integrity / EMC Fit

  • C. Mechanical Fit

  • D. Manufacturing / Assembly Fit

  • E. Service / Bring-up Fit

  • F. Sourcing / Commercial Fit

  • G. System-Specific Checks

  • H. Hard-Gate Summary

  • I. Quantitative Snapshot

  • J. Risk Log

  • K. Decision Summary

  • Candidate C Evaluation

  • Candidate Header

  • A. Electrical Fit

  • B. Signal Integrity / EMC Fit

  • C. Mechanical Fit

  • D. Manufacturing / Assembly Fit

  • E. Service / Bring-up Fit

  • F. Sourcing / Commercial Fit

  • G. System-Specific Checks

  • H. Hard-Gate Summary

  • I. Quantitative Snapshot

  • J. Risk Log

  • K. Decision Summary

  • Comparative Ranking

  • Overall Recommendation

  • Follow-up Checks Before Freezing Connector Choice

  • Related Documents