[COMPLETED] Project Quiver PT2 Power PCB V1

Arrow Project Quiver Power PCB V1

This thread will keep track of the first iteration of a custom power PCB for Project Quiver PT2. I will start with gathering the system requirements. For this I will look at Quiver PT1 and keep a record of the most important features and conditions.

Input taken from memory, the Quiver V1 Harnessing Grant and the CAD assembly
https://arrowdao.notion.site/Project-Quiver-V1-Harnessing-Grant-134dfaee0db4808a8ad1d0583b67fba4

https://cad.onshape.com/documents/526aa8e34cdbf52093ac7d44/w/950eade83ff0db5ba253f5c2/e/b6fc5f4bc508ba430992e73e

System Requirements

  • General size: 200x120mm (to fit in a similar space as the PT1 PCB)

  • Layout:

    • One side of the PCB lies on the edge and carries the connectors
    • The motor connectors are orientated inwards to the center or to the sides
    • The main power terminals also lie on the edge that faces inwards
  • Power Distribution:

    • High power distribution from Battery to Motors
      • Includes Fuse solid state relais and precharge
    • Power distribution to:
      • Payload (Brush Bullet Dispenser, power requirements unknown(10W, 12V), GPIO pin from FC will activate 12V supply)
      • Radar Altimeter (2W; 5V or 12V)
      • Flight controller pixhawk 6X (2.5W; 5V)
      • Flight controller peripherals 6X (maximum possilbe 7.5W, 5V)
      • SIYI HM30 transmitter (5W, 12V)
      • SIYI A8 camera and gimbal (5W, 12V)

    = ~22W on the 12V bus and ~10W on the 5V bus

  • Signals:

    • The PCB will also offer CAN Bus connections to devices:
      • Motors/ESCs
      • Battery
      • Brush bullet dispenser
      • Radar altimeter
      • Flight controller
    • The PCB will not include connections for devices that are directly connected to the FC

Hardware on the PCB

  • XT60PW connector for each motor
  • 5 Pos. signal connector for each Motor/ESC
  • MATEKSYS FCHUB 12S V2 for power conversion 12V and 5V and current measurement
  • Screw terminals for the battery connection
  • Precharge resistors
  • Fuses for 12V and 5V
  • One large sealed connector for most connections

Proposed Layout

  • Fuse and solid state relais will be outside of the PCB casing.
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Comments from the call today about the PCB:

  • Additional connector for the brush bullet to carry 12V, 5V, and GPIO signal
  • XT30 power connection for SIYI Air Unit
  • Clarification on if precharge control will happen via CAN or GPIO from Pixhawk

Questions:

  • How are you planning on controlling the brush bullet? In PT1 we are adding a relay in the dispenser to control the motor.
  • During the call I think you mentioned that the SSR and fuses will be external? Will they sit on a separate PCB? Are the fuses for the ESCs or the SSR?

Thank you!

Do you think splitting the one big connector into smaller connectors for each component/system and locating them according to their locations on the aircraft? i.e. locating the pixhawk connector on right/left side, altimeter on the other side, camera through the camera location, attachment interface connector at the back and so on.
@Julius @errrks.eth

I think its better to leave the connectors on one side of the PCB for now. However, I will divide the large plug into smaller ones.

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This is the last update before V1 of the Quiver PDB will be finished. Last week we discussed some changes to the initial layout such as:

  • Moving the flight controller and payload connectors to the back of the PCB. They will face inside of the drone, to reduce cable length
  • Moving the motor connections to the left and right side of the PCB
  • Adding a XT30 connector for the SIYI HM30 power supply

This is the circuit diagram of the PCB (I have added some notes for clarification, please check):

The PCB is not yet fully routed, but i added the high current lines to make it more visible how the main power is distributed. This is the top view on the PCB:


Bottom (the traces are reinforced with copper to carry higher currents):

Onshape link to 3D model of this version:

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Thank you, Julius! This looks great and will be a much needed update for Quiver. I have reviewed the schematic and can’t think of any concerns or questions. The notes are very helpful.

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Great Stuff, All looks good schematic wise, only comment would be when routing the PCB, dont skimp on distances between tracks at different potentials, and track widths, if possible consider adding a couple extra layers to separate HV and LV tracks.

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The work on the PCB is completed.
Submission to the GBC (Sorry I missed the inital timeline for February 10 2025)

The digital files include:

  • Complete Kicad project
  • 3D step file (one reduced version, one full version with routing)
  • BOM
  • Manufacturing files prepared for JLCPCB
  • Pictures

All files can be downloaded from this link:
https://drive.google.com/drive/folders/16L5hBI6shYaOVsX0JZiCZbpuma5p8X1x?usp=sharing

Top render

Bottom render

Routing view

Final schematic:

Online view and download form Fusion 360:

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I have a concern about the PDB voltage limit, the official document from Mateksys says the FCHUB 12S V2 PDB holds 8~60 voltage, but the main bus voltage from our fully charged Tattu 3.5 LiHV battery is 60.9.
Is that save for this design?

I don’t think thats an issue. If you run it on 70V then you might see a failure sooner (for example on a capacitor), but 0.9V more is to be neglected. Also it will only operate over 60V for <1% of its life. As soon as you run the motors the voltage will drop below 60V in seconds.

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Grant completion accepted by GBC. Github link: project-quiver/task-grant-bounty/pt2/electronics/0001-PDB_V1 at main · Arrow-air/project-quiver · GitHub

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