Project Cleanup DRC
continue with project
Thought for 4 sec
I’ll review the current project state and recent work, then continue from the highest-priority unfinished item.
Worked for 10 mins 43 sec
Cleanup is complete, but the same six connections are still blocked by stitch-via/trace endpoint handling. I’m confirming the final DRC state and isolating the safest next correction.
Thought for 24 sec
Routing cleanup removed all dangling traces without disturbing placement or the 315 MHz pigtail interface.
Open items
- 6 airwires remain due to virtual stitch-via/trace endpoints.
- 1 pre-existing floating copper segment remains:
Trace 970f.
Suggested next step
- Surgically delete and rebuild the six affected trace/stitch-via structures, then rerun DRC. This may alter localized existing copper.
Rebuild routing structures
Remove floating copper
Inspect endpoint cause
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Design Notes
Authoritative Requirements
The revised compact target is authoritative: main PCB 70 × 27 mm, four layers, 1.6 mm nominal. The former 75 × 30 mm and PCB edge-launch SMA requirements are superseded.
Power Budget Status
The preliminary values are superseded by the dedicated Power Budget project file. Current design peak is 567.4 mA at 3.3 V; worst-case 3.0 V battery input is about 0.734 A at 85% efficiency. Size the complete battery path for at least 1 A peak. Full 200 mA charging plus peak system operation can require about 0.616 A from 5 V USB and therefore exceeds a standard 500 mA USB 2.0 source.
Critical Layout Constraints
- Inner1 is an uninterrupted GND plane; Inner2 is power.
- ESP32 antenna keepout applies on every layer and remains free of copper, parts, battery, cables, and mounting hardware.
- TPS63070 switch node, inductor, and input/output capacitors form a tight cluster.
- CC1101 crystal and 315 MHz matching/filter network form a tight cluster with immediate shunt-ground vias and no digital/switching routing below.
- J5 U.FL sits directly at the end of the 50 ohm RF path.
- Four mounting-hole centers require 2.5–3.0 mm minimum edge inset. The legacy locked hole objects currently need manual unlock/repositioning before fabrication.
Antenna Cable — Mechanical/DNI BOM
Not placed on the PCB: one U.FL/I-PEX MHF1 plug to SMA-female bulkhead pigtail, 50 ohm, approximately 100–150 mm, RG178 or 1.13 mm coax, supplied with SMA bulkhead nut and washer. Mount the SMA female in the enclosure top antenna opening. Secure the cable for strain relief, maintain a gentle bend radius, and do not twist or side-load PCB receptacle J5. Treat this as a required mechanical assembly BOM item, DNI from PCB pick-and-place.
Remote Harnesses
- USB J2: pin 1 VBUS, 2 GND, 3 D-, 4 D+, 5 shield/drain GND, 6 spare/NC. Use a short shielded harness or tightly twisted D+/D- pair.
- OLED J3: 1 3V3, 2 GND, 3 SDA, 4 SCL.
- Controls J4: 1 GND, 2 BOOT, 3 EN/RESET, 4 USER.
- Battery J1 remains JST-PH.
- The 2.54 mm service header and five Keystone 5018 loop test points were deleted to reduce area.
Battery ADC Scaling
GPIO4 uses 1 MOhm over 330 kOhm with 100 nF to GND. ADC voltage = VBAT × 0.24812; firmware scale factor VBAT = ADC × 4.0303. At 4.2 V cell voltage the ADC input is about 1.042 V.
Authoritative Requirements
Power Budget Status
Critical Layout Constraints
Antenna Cable — Mechanical/DNI BOM
Remote Harnesses
Battery ADC Scaling
