ESP32 电池切换控制
Worked for 20 mins 26 sec
针脚映射和元件布局已完成，模块排母按15.24mm中心距放置并保留USB/天线空间。当前唯一阻塞是4层叠层没有成功保存，我会再做一次针对性修复并读回确认，然后停在布局确认点。
Worked for 5 mins 50 sec
4层叠层已成功修复为Top信号、内层地、内层电源、Bottom信号；模块与逻辑区的局部拥塞也已拉开。正在做布局确认点的最终读回。
Thought for 17 sec
布局阶段已经完成并通过基础检查；我将停在走线前确认点，等待你确认模块排距与整体布局后再布线。
Thought for 16 sec
已按图片完成针脚映射和PCB布局：
- PCB：180×140mm、4层。
- ESP32排母：2×1×9、2.54mm针距、15.24mm排距。
- USB朝左侧板边，天线朝右并保留无铜区域。
- GPIO、I²C、移位寄存器和采样选择信号已固定。
- 继电器、32A端子、模拟采样及控制区已分区布局。
- 尚未走线。
**待确认：**15.24mm排距依据兼容模块常见封装推定，首板前请用卡尺测量你手中模块两排针的中心距离。确认排距及当前布局后，我再开始15A功率铜皮和控制信号走线。
确认布局并走线
先检查DRC
优化板子尺寸
生成装配预览
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Safety and FMEA
Table
| Hazard / failure | Effect | Required mitigation / verification |
|---|---|---|
| Two relays closed together | Battery-to-battery uncontrolled equalization current, fire | Hardware default-off; OE/KILL gating; one-hot firmware; break-before-make; contact feedback; test fault injection |
| ESP32 reset/brownout while shifting | Spurious relay pulse | 74HC595 OE held disabled and clear asserted by hardware until valid latched one-hot word; input defaults; KILL independent of firmware |
| Relay welded closed | Next selection parallels batteries | Per-relay contact feedback or common fault plus pre-switch voltage/current checks; refuse next close; service relay |
| Wrong relay DC rating | Contact welding/arcing | Verify ≥20A at ≥12VDC from manufacturer datasheet, not AC rating only |
| Undersized terminal/trace | Overheating/fire | ≥20A DC terminal; no 16A DB128V; thermal verification in PCB stage |
| Missing/remote fuse | Cable/fire hazard | External 20A replaceable fuse at each battery positive terminal |
| BAT_BUS dead-time resets controller | Loss of control / unsafe restart | OR-ing control supply from battery inputs; calculate and test hold-up |
| 12V applied to ESP32 | Module destruction/fire | Feed only regulated 3.3–6V to B+/B- per module page; labeled connector/net |
| ADC overvoltage/transient | Damaged ADC/MCU, wrong selection | 1% divider, series resistance, RC, 3.3V clamps; validate 20V full scale and surge |
| Current sensor saturation/polarity error | Wrong energy/control decision | ≥±20A, target ±30A; bidirectional calibration and polarity test |
| WiFi malfunction/remote command | Unsafe switching | Local invariant and KILL cannot be overridden by web request; authentication/network risk review |
| Lithium battery/BMS fault | Fire or overcharge | Each pack requires appropriate BMS; controller is not a charger; solar controller remains responsible for chemistry charging profile |
Regulatory / risk posture
Low-voltage DC but high available fault energy and WiFi radio. Final product requires applicable radio/module integration evidence, enclosure/wiring protection, fuse interrupt-rating validation, creepage/clearance appropriate to pollution environment, thermal testing at 15A, and a qualified safety review.
Regulatory / risk posture
