Smart 12V Power Controller Design

flux

2:24

Planning component placement.

Proposing board adjustments.

Assessing keepouts for layout.

Clarifying board specifications.

Determining board dimensions and placements.

Accessing knowledge base.

Checking if I can make the changes for you.

Finalizing component placements and board size.

I can resize the PCB to 190 mm × 110 mm now. After that, use the placement plan below to manually place parts. All coordinates are in mm, origin at board bottom‑left, positive X to the right, positive Y up. Keep 5 mm edge keepout everywhere, and 10 mm keepout around each M8 stud.
Top edge: eight M8 studs (custom STUD_M8_RINGPAD, 8.5 mm PTH, 20 mm OD, 10 mm keepout)
  • Y = 105
  • X positions (left to right, 22 mm pitch): 20, 42, 64, 86, 108, 130, 152, 174
  • Net mapping:
    • X=20 BAT+
    • X=42 BAT−
    • X=64 LOAD+
    • X=86 LOAD−
    • X=108 PV_OUT+
    • X=130 PV_OUT−
    • X=152 EXT_OUT+
    • X=174 EXT_OUT−
Mounting holes (M3, 90 × 70 rectangle)
  • Hole1: (50, 20)
  • Hole2: (140, 20)
  • Hole3: (50, 90)
  • Hole4: (140, 90)
Star ground and current sensor
  • Place star‑ground tie at (42, 92) near U3
  • U3 ACS71240: (42, 92), rotate 0°. Route the main VBAT path past U3 per your sense direction.
Power entry and reverse‑polarity + TVS
  • U1 LM5050‑1: (28, 92), R=0°
  • D1 SMBJ12A: (24, 86), R=0°
  • D2 SMBJ12A: (32, 86), R=0°
  • Keep U1, D1, D2 close to BAT studs (X=20/42), with very short/wide copper to studs and to VBAT bus.
Coil rail, global enable, and low‑side drivers
  • +12V_COIL rail: route from F_COIL output to coil connectors; keep isolated from logic until entry to drivers.
  • F1 coil fuse: (165, 78), R=90°
  • J4 COIL_ENABLE 1×3: (115, 60), R=0° (Pin1=COIL_ENABLE, Pin2=GND, Pin3=+5V_LOGIC)
Right edge: coil connectors (2‑pin 5.08 mm)
Low‑side MOSFET drivers (close to their connectors; gates face inward)
  • Q3 (LOAD): (172, 80), R=180°
    • D5: (178, 84), R=0° (close to J_KLOAD_COIL pins)
    • R19: (168, 78), R22: (168, 76)
  • Q1 (PV): (172, 60), R=180°
    • D3: (178, 64), R=0°
    • R17: (168, 58), R20: (168, 56)
  • Q2 (EXT): (172, 40), R=180°
    • D4: (178, 44), R=0°
    • R18: (168, 38), R21: (168, 36)
Logic, comparators, and headers (left/center)
  • U2 LM393: (70, 62), R=0°. Keep its hysteresis/sense resistors within 5 mm of pins.
  • J_OUT 1×8: (12, 70), R=90° (Pin1 at top)
  • J_IN 1×8: (12, 50), R=90°
  • J_ADC 1×8: (12, 30), R=90°
  • J_PWR 1×4: (28, 30), R=0°
Bottom edge: PV/EXT sense and buzzer
  • J_PV_SENSE: (20, 6), R=0°
    • R26 110k: (26, 10)
    • R25 10k: (26, 8)
    • C14 100 nF: (26, 6)
  • J_EXT_SENSE: (46, 6), R=0°
    • R24 68k: (52, 10)
    • R23 10k: (52, 8)
    • C15 100 nF: (52, 6)
  • BZ1 TMB12A05: (80, 8), R=0°
  • Q4 (buzzer MOSFET): (74, 10), R4 gate series: (72, 10)
Inductors/placeholders for buck area (logic power)
  • L1: (100, 62), L2: (110, 62). Reserve local area for 12V→5V buck controller and bulk caps; keep away from comparators and ADC headers.
Notes for manual placement
  • Keep all decoupling caps (C1–C13) within 2–3 mm of their IC power pins; shortest loop to ground via.
  • Run the high‑current plane along the top under the studs; no signal vias/traces inside each stud’s 10 mm keepout.
  • Maintain clear separation between high‑current copper (top edge) and logic (lower half). Leave a routing channel between headers and drivers.
  • After placement, use airwires to assess routing feasibility and adjust spacing before autorouting (knowledge base: leave space for routing and vias; use airwires to visualize paths).
  • Keep OV/UV thresholds exactly 14.8/14.4 V and 11.6/12.2 V; don’t alter those networks during placement.
Would you like me to apply the PCB resize to 190 × 110 mm now? Once resized, follow the coordinates above to place the components manually, and I can iterate on any conflicts you notice during routing.
82 days

Updated 1 layout rule

0:11

Set Layout's size to "190mm 110mm

"

82 days
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  • Ground
    Ground
    A common return path for electric current. Commonly known as ground.
    jharwinbarrozo
    20.5M
  • Net Portal
    Net Portal
    Wirelessly connects nets on schematic. Used to organize schematics and separate functional blocks. To wirelessly connect net portals, give them same designator. #portal
    jharwinbarrozo
    43.0M
  • Power Net Portal
    Power Net Portal
    Wirelessly connects power nets on schematic. Identical to the net portal, but with a power symbol. Used to organize schematics and separate functional blocks. To wirelessly connect power net portals, give them the same designator. #portal #power
    jharwinbarrozo
    11.4M
  • Generic Resistor
    Generic Resistor
    A generic fixed resistor ideal for rapid circuit topology development. Its footprint automatically adapts based on the selected package case code—supporting 0402, 0603, 0805, 1203, and many other standard SMD packages, as well as axial horizontal and vertical configurations. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard resistor values: 1.0 ohm, 10 ohm, 100 ohm, 1.0k ohm, 10k ohm, 100k ohm, 1.0M ohm 1.1 ohm, 11 ohm, 110 ohm, 1.1k ohm, 11k ohm, 110k ohm, 1.1M ohm 1.2 ohm, 12 ohm, 120 ohm, 1.2k ohm, 12k ohm, 120k ohm, 1.2M ohm 1.3 ohm, 13 ohm, 130 ohm, 1.3k ohm, 13k ohm, 130k ohm, 1.3M ohm 1.5 ohm, 15 ohm, 150 ohm, 1.5k ohm, 15k ohm, 150k ohm, 1.5M ohm 1.6 ohm, 16 ohm, 160 ohm, 1.6k ohm, 16k ohm, 160k ohm, 1.6M ohm 1.8 ohm, 18 ohm, 180 ohm, 1.8K ohm, 18k ohm, 180k ohm, 1.8M ohm 2.0 ohm, 20 ohm, 200 ohm, 2.0k ohm, 20k ohm, 200k ohm, 2.0M ohm 2.2 ohm, 22 ohm, 220 ohm, 2.2k ohm, 22k ohm, 220k ohm, 2.2M ohm 2.4 ohm, 24 ohm, 240 ohm, 2.4k ohm, 24k ohm, 240k ohm, 2.4M ohm 2.7 ohm, 27 ohm, 270 ohm, 2.7k ohm, 27k ohm, 270k ohm, 2.7M ohm 3.0 ohm, 30 ohm, 300 ohm, 3.0K ohm, 30K ohm, 300K ohm, 3.0M ohm 3.3 ohm, 33 ohm, 330 ohm, 3.3k ohm, 33k ohm, 330k ohm, 3.3M ohm 3.6 ohm, 36 ohm, 360 ohm, 3.6k ohm, 36k ohm, 360k ohm, 3.6M ohm 3.9 ohm, 39 ohm, 390 ohm, 3.9k ohm, 39k ohm, 390k ohm, 3.9M ohm 4.3 ohm, 43 ohm, 430 ohm, 4.3k ohm, 43K ohm, 430K ohm, 4.3M ohm 4.7 ohm, 47 ohm, 470 ohm, 4.7k ohm, 47k ohm, 470k ohm, 4.7M ohm 5.1 ohm, 51 ohm, 510 ohm, 5.1k ohm, 51k ohm, 510k ohm, 5.1M ohm 5.6 ohm, 56 ohm, 560 ohm, 5.6k ohm, 56k ohm, 560k ohm, 5.6M ohm 6.2 ohm, 62 ohm, 620 ohm, 6.2k ohm, 62K ohm, 620K ohm, 6.2M ohm 6.8 ohm, 68 ohm, 680 ohm, 6.8k ohm, 68k ohm, 680k ohm, 6.8M ohm 7.5 ohm, 75 ohm, 750 ohm, 7.5k ohm, 75k ohm, 750k ohm, 7.5M ohm 8.2 ohm, 82 ohm, 820 ohm, 8.2k ohm, 82k ohm, 820k ohm, 8.2M ohm 9.1 ohm, 91 ohm, 910 ohm, 9.1k ohm, 91k ohm, 910k ohm, 9.1M ohm #generics #CommonPartsLibrary
    jharwinbarrozo
    1.5M
  • Generic Capacitor
    Generic Capacitor
    A generic fixed capacitor ideal for rapid circuit topology development. You can choose between polarized and non-polarized types, its symbol and the footprint will automatically adapt based on your selection. Supported options include standard SMD sizes for ceramic capacitors (e.g., 0402, 0603, 0805), SMD sizes for aluminum electrolytic capacitors, and through-hole footprints for polarized capacitors. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard capacitor values: 1.0pF, 10pF, 100pF, 1000pF, 0.01uF, 0.1uF, 1.0uF, 10uF, 100uF, 1000uF, 10000uF 1.1pF, 11pF, 110pF, 1100pF 1.2pF, 12pF, 120pF, 1200pF 1.3pF, 13pF, 130pF, 1300pF 1.5pF, 15pF, 150pF, 1500pF, 0.015uF, 0.15uF, 1.5uF, 15uF, 150uF, 1500uF 1.6pF, 16pF, 160pF, 1600pF 1.8pF, 18pF, 180pF, 1800pF 2.0pF, 20pF, 200pF, 2000pF 2.2pF, 22pF, 220pF, 2200pF, 0.022uF, 0.22uF, 2.2uF, 22uF, 220uF, 2200uF 2.4pF, 24pF, 240pF, 2400pF 2.7pF, 27pF, 270pF, 2700pF 3.0pF, 30pF, 300pF, 3000pF 3.3pF, 33pF, 330pF, 3300pF, 0.033uF, 0.33uF, 3.3uF, 33uF, 330uF, 3300uF 3.6pF, 36pF, 360pF, 3600pF 3.9pF, 39pF, 390pF, 3900pF 4.3pF, 43pF, 430pF, 4300pF 4.7pF, 47pF, 470pF, 4700pF, 0.047uF, 0.47uF, 4.7uF, 47uF, 470uF, 4700uF 5.1pF, 51pF, 510pF, 5100pF 5.6pF, 56pF, 560pF, 5600pF 6.2pF, 62pF, 620pF, 6200pF 6.8pF, 68pF, 680pF, 6800pF, 0.068uF, 0.68uF, 6.8uF, 68uF, 680uF, 6800uF 7.5pF, 75pF, 750pF, 7500pF 8.2pF, 82pF, 820pF, 8200pF 9.1pF, 91pF, 910pF, 9100pF #generics #CommonPartsLibrary
    jharwinbarrozo
    1.5M
  • Generic Inductor
    Generic Inductor
    A generic fixed inductor suitable for rapid circuit topology development. The footprint automatically adapts based on the selected package, supporting standard SMD sizes (e.g., 0402, 0603, 0805) as well as well-known inductor packages such as SDR1806, PA4320, SRN6028, and SRR1260. Standard inductor values: 1.0 nH, 10 nH, 100 nH, 1.0 µH, 10 µH, 100 µH, 1.0 mH 1.2 nH, 12 nH, 120 nH, 1.2 µH, 12 µH, 120 µH, 1.2 mH 1.5 nH, 15 nH, 150 nH, 1.5 µH, 15 µH, 150 µH, 1.5 mH 1.8 nH, 18 nH, 180 nH, 1.8 µH, 18 µH, 180 µH, 1.8 mH 2.2 nH, 22 nH, 220 nH, 2.2 µH, 22 µH, 220 µH, 2.2 mH 2.7 nH, 27 nH, 270 nH, 2.7 µH, 27 µH, 270 µH, 2.7 mH 3.3 nH, 33 nH, 330 nH, 3.3 µH, 33 µH, 330 µH, 3.3 mH 3.9 nH, 39 nH, 390 nH, 3.9 µH, 39 µH, 390 µH, 3.9 mH 4.7 nH, 47 nH, 470 nH, 4.7 µH, 47 µH, 470 µH, 4.7 mH 5.6 nH, 56 nH, 560 nH, 5.6 µH, 56 µH, 560 µH, 5.6 mH 6.8 nH, 68 nH, 680 nH, 6.8 µH, 68 µH, 680 µH, 6.8 mH 8.2 nH, 82 nH, 820 nH, 8.2 µH, 82 µH, 820 µH, 8.2 mH #generics #CommonPartsLibrary
    jharwinbarrozo
    15.8k
  • Terminal
    Terminal
    An electrical connector acting as reusable interface to a conductor and creating a point where external circuits can be connected.
    natarius
  • RMCF0805JT47K0
    RMCF0805JT47K0
    General Purpose Thick Film Standard Power and High-Power Chip Resistor 47 kOhms ±5% 0.125W, 1/8W Chip Resistor 0805 (2012 Metric) Automotive AEC-Q200 Thick Film Features: - RMCF – standard power ratings - RMCP – high power ratings - Nickel barrier terminations standard - Power derating from 100% at 70ºC to zero at +155ºC - RoHS compliant, REACH compliant, and halogen free - AEC-Q200 compliant
    jharwinbarrozo
    1.2M
  • 875105359001
    875105359001
    10 µF 16 V Aluminum - Polymer Capacitors Radial, Can - SMD 30mOhm 2000 Hrs @ 105°C #commonpartslibrary #capacitor #aluminumpolymer #radialcan
    jharwinbarrozo
    1.2M
  • CTL1206FYW1T
    CTL1206FYW1T
    Yellow 595nm LED Indication - Discrete 1.7V 1206 (3216 Metric)
    jharwinbarrozo
    1.1M
Inner Purple Robot Vacuum thumbnail
Smart 12V Power / Charging / Protection Controller (Ideal Diode + PV MPPT + EXT CC/CV + OV/UV + Arduino)

Properties

Diagram



  
    
  
  
    
  



""Power Entry and Protection""


""Charge Source Control""


""Load Distribution""


""Sensing and Monitoring""


""Relay Drivers""


""Arduino Uno Interface""


""User Signaling""






































































































"Battery studs M6 or M8"
"Main fuse 60-80A"
"Reverse polarity ideal diode"
"TVS clamp"
"12V bus"
"Star ground tie at battery negative"
"12V to node_5V buck"
"PV input"
"PV MPPT buck"
"Relay K_PV"
"EXT DC input"
"EXT CC/CV buck-boost"
"Relay K_EXT"
"Charge bus to battery"
"Overvoltage comparator 14.8V trip 14.4V reset"
"Disable charge sources"
"Charge source interlock"
"Relay K_LOAD_MAIN"
"Switched node_12V load bus"
"Fuse Lights"
"Lights connector"
"Fuse Audio"
"Audio connector"
"Fuse USB"
"USB connector"
"Fuse Inverter"
"Inverter connector"
"Undervoltage comparator 11.6V trip 12.2V reset"
"Disconnect loads"
"VBAT divider plus RC filter"
"Hall current sensor IBAT"
"Post-fuse rail dividers"
"PV presence sense"
"EXT presence sense"
"Temperature sensor"
"Test points VBAT IBAT rails"
"Logic control"
"N-MOSFET relay drivers"
"Flyback diodes"
"Arduino node_5V pin"
"Arduino GND"
"Arduino ADC VBAT"
"Arduino ADC IBAT"
"Arduino ADC rails"
"Arduino digital OV fault"
"Arduino digital UV fault"
"Buzzer fault annunciation"
"Optional fault LEDs"

Pricing & Availability

Distributor

Qty 1

Arrow

$2.67–$4.79

Digi-Key

$3.91–$8.48

LCSC

$6.87–$8.87

Mouser

$8.26–$8.77

TME

$3.64

Verical

$3.31–$7.54

Controls