diff --git a/REUSE.toml b/REUSE.toml index 309f2a9..044aa7f 100644 --- a/REUSE.toml +++ b/REUSE.toml @@ -29,3 +29,8 @@ SPDX-License-Identifier = "CERN-OHL-S-2.0" [[annotations]] path = "hardware/LICENSE" SPDX-License-Identifier = "CERN-OHL-S-2.0" + +[[annotations]] +path = "hardware/boards/compact-carrier-board/**" +SPDX-FileCopyrightText = "2026 Jon Truland" +SPDX-License-Identifier = "CERN-OHL-S-2.0" diff --git a/hardware/boards/compact-carrier-board/README.md b/hardware/boards/compact-carrier-board/README.md new file mode 100644 index 0000000..c9241ef --- /dev/null +++ b/hardware/boards/compact-carrier-board/README.md @@ -0,0 +1,234 @@ +# compact-carrier-board + +Small distribution PCB that sits under the ESP32-C3-Zero where it mounts through +the desk's ESP slot, fanning its I2C/I2S/power pins out to the PCA9685, OLED, +MAX98357A amp, and servo power — instead of point-to-point wiring. + +- **Status:** in review +- **KiCad:** 10 +- **Interfaces:** ESP32-C3-Zero 2×9 socket, `J_PWR` (5V/GND + external USB + D+/D-), `J_SERVO`, `J_I2C_OLED`, `J_I2C_PCA`, `J_I2S` +- **Assumptions:** sized against the desk generated with the **PowerHD + HD-1370A** servo preset (`servos.json`) — the SG90 and FS0307 presets + produce different desk dimensions per the parametric design docs, and this + board's fit has **not** been verified against either of them. Re-check the + ESP slot dimensions in your own exported desk model before relying on this + outline if you're on a different preset. See `docs/hardware/interfaces.md` + for the canonical net map (5V/3.3V domains, GP0-GP4 assignments); this + board implements that map in copper. +- **Built:** the `carrier-fab-v3-replacement_Y5` upload was produced and + shipped by JLCPCB (not yet received). That batch carries the **mirrored + socket map this revision fixes** — see "Mirrored socket map (boards in + transit)" below for the assembly workaround. Its drilling is fine: the Y5 + drill export is a single 0.9mm tool over all 37 holes and JLC's own CAM + layer a single aperture, so the 7-undersized-hole defect of the earlier + `_Y3` upload never reached a physical board. + +## Files + +- `compact-carrier-board.kicad_pcb` — KiCad 10 board source +- `compact-carrier-board.kicad_pro` — KiCad 10 project file (no `.kicad_sch` + — this board has no schematic, laid out directly from footprints) +- `carrier-board-render.png` — 3D top render, regenerated with + `kicad-cli pcb render --side top` after the row swap and silk additions + +Gerbers, drill, BOM, and CPL are generated outputs, not source — regenerate +them from `compact-carrier-board.kicad_pcb` when ordering rather than +relying on a committed copy. `J_ESP1`/`J_ESP2` carry real `Value`/`LCSC` +fields and each footprint has a real origin at its own center, so +`kicad-cli pcb export pos` produces correct positions directly (verified: +`(13.00, -16.89)` / `(13.00, -1.65)`) — no manual patching. `J_PWR`, +`J_SERVO`, `J_I2C_OLED`, `J_I2C_PCA`, and `J_I2S` are flagged +`exclude_from_bom`/`exclude_from_pos_files` so they never appear in either +export. There's no `.kicad_sch`, so `kicad-cli` has no BOM-export +subcommand for this board (that's a schematic-only feature) — a BOM script +or fab-tool plugin reading the `.kicad_pcb`'s footprint properties directly +now gets correct `Value`/`LCSC` without hand-derivation. + +## Assembly: only the ESP header strips are populated parts + +`J_PWR`, `J_SERVO`, `J_I2C_OLED`, `J_I2C_PCA`, and `J_I2S` are bare +through-holes for direct wire connections, not connector footprints to +populate — excluded from BOM/CPL at the footprint level (see above). + +`J_ESP1`/`J_ESP2` are the one real part: **Kinghelm KH-2.54FH-1X9P-H3.5** +(LCSC/JLCPCB `C55778388`), a 2.54mm 1×9 THT female header. There's no 2×9 part +— the +ESP32-C3-Zero's socket needs **two** of these strips, one per row. The board +models this as two separate footprint objects, **`J_ESP1`** (the inner row, +nearer the wire end: 5V/GND/3V3/GPIO0-5) and **`J_ESP2`** (the outer row, +nearest the slot edge: GPIO21-GPIO6), each a real +9-pad object with its own designator — not one 2×9 footprint with a +quantity hint in prose. JLCPCB's assembly tooling (and most BOM tooling) +determines quantity by counting designators, not by parsing Comment text, so +a generated BOM lists both on one row as `"J_ESP1,J_ESP2"` (identical part, +JLC's own convention for grouping identical components) — that reads as qty +2 unambiguously. + +A generated CPL has one row per designator, `J_ESP1` and `J_ESP2`, each at +its own row's real center — (13.00, 16.89) and (13.00, 1.65) in the board's +own coordinates — read directly by `kicad-cli pcb export pos` from each +footprint's own origin, no hand-derivation needed. + +## Why this shape + +Measured directly from an exported desk part (not estimated): the ESP mounting +slot is 25.0 × 18.5mm, and three of its four sides sit only 3.0–3.6mm from +full-height enclosure walls — too tight for any connector housing. Only the +front is open. That forced the layout: + +- **26 × 44mm**, 2-layer. +- Back 18.5mm: 2×9 female socket for the ESP32-C3-Zero (2.54mm pitch, + 15.24mm row spacing — Waveshare's documented spec for the Zero board family, + confirmed within 0.04mm of a direct caliper measurement). +- Front zone: `J_PWR` (now 4-pin — 5V/GND plus the external USB D+/D-, see + below), `J_SERVO` (5V direct to PCA9685 V+, bypassing the ESP's own 3.3V + regulator), `J_I2C_OLED`, `J_I2C_PCA` (separate connectors, bus shared via + on-board copper — no external splitter cable), `J_I2S` (own on-board 5V + feed for the amp). +- Everything routes fully on-board; nothing needs an off-board jumper. + +## Pinout (rows stated in the frame that decides them) + +Row placement is the part that is easy to get backwards, so name the rule: +**the pad map, seen from the face the module plugs into, has to be the +module's component-side view.** A pin-side view is the correct drawing only +for a socket on the *opposite* face — that inversion is exactly what went +wrong in the shipped batch (below). + +Hold the C3-Zero component side up with its USB-C over this board's 5V-bus +edge (the long edge the 5V trace hugs). Then: + +- **Outer row** — `J_ESP2`, nearest the slot edge (y=14.15): + `GPIO21, GPIO20, GPIO19, GPIO18, GPIO10, GPIO9, GPIO8, GPIO7, GPIO6`. + Mechanical/no-net support **except GP19 and GP18**, the native USB pair — + see USB below. +- **Inner row** — `J_ESP1`, nearer the wire end (y=29.39): + `5V, GND, 3V3, GPIO0(SDA), GPIO1(SCL), GPIO2(BCLK), GPIO3(LRCLK), GPIO4(DIN), GPIO5` + +Pins 1 and 18 land at the 5V-bus edge in both rows, and that is what fixes +the module's USB-C to that edge. Traversing 1 to 18 reads counter-clockwise +from above, matching Waveshare's own pinout art (1-9 down the left column, +10-18 up the right, USB-C at the top). + +## USB pass-through (external jack, not the C3-Zero's own USB-C) + +Per `docs/hardware/interfaces.md`: the robot's single external USB-C (Adafruit +5993) carries both power and the ESP32's native USB D+/D- lines, so flashing +and serial CDC work through the panel-mount jack once the desk is sealed — +the C3-Zero's own onboard USB-C is left unused. No ESD or series-resistor +circuitry is specified for this link; it's a direct connection. + +| `J_PWR` pin | Net | Goes to | +| --- | --- | --- | +| 1 | GND | common ground | +| 2 | D+ | ESP32 **GPIO19** (outer-row pad, native USB DP) | +| 3 | D− | ESP32 **GPIO18** (outer-row pad, native USB DM) | +| 4 | 5V | ESP32 5V rail, PCA9685 V+ (via `J_SERVO`), MAX98357A | + +D+/D- run down the same 2.54mm grid columns as their own pads (x=20.42 and +22.96), which sits half a pitch off `J_I2C_OLED`/`J_I2C_PCA`'s grid, so they +never cross those connectors' pads on the way past. Since the row swap they +also pass the inner row, where the 3V3 and SDA holes occupy those two +columns, so each line takes one short lateral jog into the adjacent lane +(1.27mm off-axis, 0.42mm to the nearest pad edge) and returns — still F.Cu, +no vias. Each line measures 36.088mm and the two are exactly length-matched; +that is 16mm longer than before the swap, which is electrically unremarkable +at full-speed 12 Mbps. + +## Mirrored socket map (boards in transit) + +That artwork is preserved as its own board, [`compact-carrier-board-pinside`](../compact-carrier-board-pinside/README.md), +so the build the in-transit batch needs stays orderable and documented rather than +living only in this section's prose. + +**The shipped boards (`carrier-fab-v3-replacement_Y5`) have the two socket +rows the wrong way round.** Their pad map is the C3-Zero seen from its *pin +side*, which is the correct drawing only for a socket on the opposite face; +as fabricated, a component-side-up module does not mate. + +Caught by handedness, which no rotation can change: on the module +(component side, USB-C up) pins 1-9 run DOWN the left column and 10-18 UP +the right, so 1 to 18 is counter-clockwise; on those boards `J_ESP1` 1 to 9 +runs left-to-right along the outer row and `J_ESP2` 10 to 18 right-to-left +along the inner row, i.e. clockwise. + +**This revision fixes the source** — rows swapped in copper, nothing moved +mechanically. **For the boards in transit, fix it at assembly:** solder both +female strips to the **pour face** (B.Cu) and run that face up. From the +pour face you see the mirror of the F.Cu artwork, which is the +component-side map, so the module mates. What that build costs: the module's +own USB-C ends up over the long edge facing the opposite wall from this +revision's intent (unused either way — the Adafruit 5993 jack carries power +and CDC), the silkscreen ends up underneath so mark pin 1 before assembly, +and the wire-end connector positions mirror left-right, so the runs to the +PCA9685 / OLED / amp swap sides. + +## Fab notes + +- `kicad-cli pcb drc --severity-all` (KiCad 10.0.6, run *without* + `--refill-zones` so it judges the on-disk fill) reports **0 violations and + 0 unconnected items** — and that statement now means something. The + project's DRC floors used to be `min_clearance` 0.0, `min_silk_clearance` + 0.0, `min_text_height` 0.8 and `min_text_thickness` 0.08, so DRC could not + have failed on clearance, silk overlap or undersized text however bad they + got. They are now 0.2 / 0.15 / 1.0 / 0.15, matching JLCPCB's floors and + its standard-font minimum. Schematic parity is not checked and cannot be — + there is no `.kicad_sch` for this board, and `--schematic-parity` answers + "Schematic parity tests require a fully annotated schematic". +- **Every pad on the board is named on silk.** The socket rows carry + `GP21`-`GP6` (outer) and `5V, GND, 3V3, GP0`-`GP5` (inner) with a `USB` + arrow pointing at the 5V-bus edge; each wire-end connector carries its own + pin names (`3V3/SDA/SCL/GND` on both I2C headers, `5V/BCLK/LRC/DIN/GND` on + `J_I2S`, `GND/D+/D-/5V` on `J_PWR`, `5V/GND` on `J_SERVO`). 48 silk items, + all 1.0mm height / 0.15mm stroke. Placement is checked geometrically, not + by DRC — 0 silk-to-silk overlaps, 0.421mm minimum silk-to-pad, 0.383mm + minimum silk-to-edge. Before this the board carried nothing but seven + reference designators, which is why a mirrored pad map was invisible both + in the render and on the bare board. +- The seven reference designators were 0.8mm high with a 0.12mm stroke, + under JLCPCB's standard-font minimum and passing DRC only because + `min_text_thickness` was 0.08. All seven are now 1.0mm / 0.15mm. + `J_I2C_PCA`, `J_PWR` and `J_SERVO` moved to clear the new pin-name bands, + and every label is re-checked against the 0.30mm edge margin — three of + them sit at exactly that margin, so the larger text boxes were nudged back + inside rather than allowed to overhang. +- GND pour clearance raised 0.20 → 0.25mm — the zone's local clearance and + the Default netclass together — and refilled. At 0.20 the fill sat at + exactly JLCPCB's floor with nothing left for their etch tolerance; the + nearest track-based constraint is 0.42mm, so the extra 0.05mm costs no + geometry. +- 4 reference designators (`J_ESP1`, `J_ESP2`, `J_I2C_OLED`, `J_I2C_PCA`) + were printing 0.2–0.6mm past the board's left edge — visually confirmed, + not just a DRC technicality. Each footprint's own text bounding box (not + an estimate) was used to shift the label right just enough to sit at a + 0.3mm margin from the edge; the render below reflects the fix. +- GND zone (B.Cu) outline is inset 0.5mm from the board edge, not 1mm as in + earlier revisions — the 1mm inset put pads near the top edge (e.g. `J_ESP1` + pin 2, GND) close enough to the zone's own boundary that a fresh zone + refill could fail to route a thermal-relief connection to them, especially + after the `J_ESP2` drill fix changed nearby pad geometry. Swept the inset + from 1.0mm down to 0.3mm in 8 steps against the drill-fixed board, each + with a fresh `kicad-cli pcb drc --refill-zones`: 1.0mm and 0.8mm both + reproducibly fail with 1 unconnected pad; every value from 0.6mm down to + 0.3mm passes with 0. 0.5mm sits in the middle of that verified-safe range + — well clear of the failure boundary and with real margin above JLCPCB's + ~0.2–0.3mm copper-to-edge floor. +- Tightest feature: 0.15mm copper (GND pour minimum thickness). Comfortably + inside JLCPCB's 0.127mm floor; sits exactly at PCBWave's 0.15mm floor (their + recommended safe minimum is 0.20mm) — check their DFM report before ordering + if using PCBWave. +- Connectors are plain 2.54mm through-hole pads (pin headers + jumpers), not + JST — real JST-PH footprint dimensions weren't verified at design time. +- 5V trace sized per IPC-2221 (2A, 1oz copper, 10°C rise → ≈0.78mm minimum). + The whole net is now 1.0mm over its 44.9mm length, with **no pinch points + left**: the row swap moved the 5V pad off the outer row onto the inner one, + 15.24mm closer to its loads, which removed the squeeze past the mechanical + pad row that previously forced two short 0.6mm sections. + Any track change requires refilling the GND zone, and the refill must be + done via KiCad itself (GUI Fill All Zones + save, or the + `pcbnew.ZONE_FILLER` Python API) and re-verified with `kicad-cli pcb drc` + run *without* `--refill-zones` — that flag only recomputes the fill + in-memory for the check, it does not persist to the file, so a stale + on-disk fill can pass DRC while still being wrong in the Gerbers. This bit + us once already in this revision's history. diff --git a/hardware/boards/compact-carrier-board/carrier-board-render.png b/hardware/boards/compact-carrier-board/carrier-board-render.png new file mode 100644 index 0000000..1cd553f Binary files /dev/null and b/hardware/boards/compact-carrier-board/carrier-board-render.png differ diff --git a/hardware/boards/compact-carrier-board/compact-carrier-board.kicad_pcb b/hardware/boards/compact-carrier-board/compact-carrier-board.kicad_pcb new file mode 100644 index 0000000..cd830a7 --- /dev/null +++ b/hardware/boards/compact-carrier-board/compact-carrier-board.kicad_pcb @@ -0,0 +1,2021 @@ +(kicad_pcb + (version 20260206) + (generator "pcbnew") + (generator_version "10.0") + (general + (thickness 1.6) + (legacy_teardrops no) + ) + (paper "A4") + (layers + (0 "F.Cu" signal) + (2 "B.Cu" signal) + (9 "F.Adhes" user "F.Adhesive") + (11 "B.Adhes" user "B.Adhesive") + (13 "F.Paste" user) + (15 "B.Paste" user) + (5 "F.SilkS" user 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