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A 5-60V bidirectional buck-boost-converter, also capable of 240W USB PD EPR (48V 5A)

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LeoDJ/USB-C_PD_PSU

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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 withFranzImsch'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 secondCH32X035
    • 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 theMastodon 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


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