USB-C PD PSU

Warning

This is a WIP project. It is not yet recommended to reproduce it in its current state.

A bidirectional buck-boost DC-DC converter with the following features:

• 240W USB PD EPR (48V 5A)*
• 5-60V input
• 3.3-60V output
• 20A maximum current (theoretically, depending on the thermal solution)
• Constant-current control
• TI BQ25758A DC-DC controller
• WCH CH32X035 as the USB Type-C PD controller (hopefully*)
• Protection of CC and USB data lines up to 63V (TI TPD4S480)
• Rough mechanical compatibility with FranzImsch's parkside-adapter
• A separate-ish "HMI"/"UI" part of the PCB containing:
  • XT30 connectors for power in/output
  • 1.47" IPS display
  • Encoder + button controls
  • 1.27mm 2x06 expansion header with a few GPIOs / RS485 for potentially communicating with BMS's, etc.
  • A second CH32X035
  • Separable via rotary cutting tool (no mouse bites, because of the high current connections to the XT30 plugs and to not fall into the JLCPCB "two designs" price tier)
• 50x50mm PCB size (50x23mm without the "UI" part)

* depending on the yet-to-be-written PD firmware (and an actually functioning DC-DC converter layout :P)

You can follow the Mastodon thread for more up-to-date progress on this project.

 

Hardware

The v1.0 PCB is designed in 8 layers, but 6 would probably suffice too. Thus inner layers 3 and 4 were designed as containing only more GND / power copper pours and can probably be left out, only leading to a reduction of a combined copper thickness from 175µm to 140µm.

JLCPCB Ordering Settings

• Default, except:
• PCB Thickness: 1.0mm
• Mark on PCB: Remove Mark
• Stencil:
  • (Stencil Side: Top)
  • Customized Size: Yes - 200 x 200mm (saves on shipping cost)

References

• ESD-Paw symbol: diminDDL (Source)
• Paw-shaped Tag-Connect pawprint: Paw-Connect