2 layers129.9 × 63.6 mm
Traeger rev 2.3.0.kicad pro
jazzmonger/Traeger-PID-Controller
Traeger Smoker/Grill Controller based on an
45 parts36
2 layers124 × 112 mm
VentSense Stage2
Aryan-swag/VentSenseVentSense: 2-of-3 gas/temperature/voltage early warning and per-cell isolation for small Li-ion packs. Vishwakarma Awards 2026-27 Stage 2 (VK26-IITH-SE-0279)
- Size
- 124 × 112 mm
- Copper layers
- 2
- Thickness
- 1.6 mm
- Parts
- 93
- Nets
- 114
- Pads
- 312
- Tracks, vias
- 0, 0
- Pours
- 1
- Routed
- Yes
- KiCad
- KiCad 10.0 (file 20260206)
- Created
- 24 Oct 2026
- Updated
- 25 Oct 2026
Overview
VentSense Stage2 is an open-source printed circuit board by Aryan-swag, from the Aryan-swag/VentSense repository on GitHub. It is a 2-layer board of 124 × 112 mm with 93 parts on 114 nets.
It is built around the ESP32-DEVKITC-32E, MAX6675ISA+ and BC547. Its parts include 48 resistors, 24 ICs, 12 diodes, 5 capacitors and 2 switches. It belongs with the power boards and the ESP32 boards of this library.
Main components
3README
README.mdVentSense — Multimodal Early Vent-Gas & Thermal Runaway Isolation System
Vishwakarma Awards 2026-27 | Stage 2: Design Specification Repository
Application Unique ID: VK26-IITH-SE-0279
1. Executive Summary & Core Innovation
VentSense is a multimodal battery safety and per-cell fault-isolation system for 4S1P INR18650-25R lithium-ion packs. It correlates early electrolyte vent-gas signatures (CO via MQ-7, H2 via MQ-8), per-cell wall temperature (DS18B20 1-Wire array), and calibrated cell voltages (ADS1115 16-bit I2C ADCs, 0.75 mV resolution) within a 60-120 s sliding voting window. Upon confirming a dual-modality fault, the ESP32 controller de-energizes a dedicated fail-secure SPDT relay in < 1.0 s.
2. Stage 2 Audit Quick-Links (For Jury Verification)
| Deliverable / Artifact | Verification Metric / Status | Repository Path |
|---|---|---|
| Native KiCad 10 Schematics (5 Sheets) | 123 symbols, 100% footprint-mapped | kicad/VentSense_Stage2/ |
| Electrical Rules Check (ERC) Log | 0 Errors, 0 Warnings | exports/VS_ERC.rpt |
| Full Schematic PDF & PNG Renders | High-res PDF and per-sheet PNGs | exports/VS_schematic.pdf |
| 2-Layer Controller Carrier PCB Layout | 124 x 112 mm FR4 carrier (93 on-board parts) | kicad/VentSense_Stage2/VentSense_Stage2.kicad_pcb |
| Design Rules Check (DRC) Log | 0 DRC Violations, 0 Unconnected Pads | exports/VS_DRC.rpt |
| Auto-Routed Production PCB & Gerbers | 899 routed copper segments, 20 vias | hardware/pcb_production/VentSense_Carrier_Gerbers_v1.0.zip |
| Unpacked Gerber & Drill Layers | RS-274X Gerbers + Excellon PTH/NPTH drills | hardware/pcb_production/gerbers/ |
| Itemized Bill of Materials (BOM) | 73 Core lines + 25 Spares (100% domestic) | bom/ |
3. Five-Sheet Hierarchical Architecture
- Sheet 1 (
VentSense_Stage2.kicad_sch): Top-level interconnect for power rails (+12V, +5V, +3V3, GND), I2C, SPI, 1-Wire, and relay control. - Sheet 2 (
Power_Protection.kicad_sch): 12V 5A input, IRF4905 reverse-polarity protection, 5A/3A fuses, 2-NC E-Stop, XL4015 5A buck, TC4427 gate driver, IRLZ44N switches, and KSD301 thermal cutoff. - Sheet 3 (
Battery_Switching.kicad_sch): 4S1P INR18650-25R string, 4x SPDT fail-secure bypass relays, pack disconnect relay, Bourns MF-R250 PTCs, and 100k/20k 1% dividers. - Sheet 4 (
Sensing_Array.kicad_sch): 3x ADS1115 16-bit ADCs (0x48, 0x49, 0x4B), INA219 current monitor (0x40), 4x DS18B20 probes, BME280 (0x76), and MAX6675 thermocouple verifier. - Sheet 5 (
MCU_And_UI.kicad_sch): ESP32-DevKitC-32E, DS3231 RTC (0x68), SSD1306 OLED (0x3C), 2x PCF8574 LED expanders (0x20, 0x21), BC547 buzzer driver, and microSD SPI logger.
Parts
93| Qty | Value | Footprint | References |
|---|---|---|---|
| 12 | 330 | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R36, R37, R38, R39, R40, R41, R42, R43, R44, R45, R46, R47 |
| 8 | 15k | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R17, R19, R21, R23, R25, R27, R29, R31 |
| 8 | 22k | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R18, R20, R22, R24, R26, R28, R30, R32 |
| 4 | 100k | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R2, R3, R6, R7 |
| 4 | 100k 1% | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R9, R12, R14, R16 |
| 4 | 100nF | Capacitor_THT:C_Disc_D5.0mm_W2.5mm_P2.50mm | C7, C8, C9, C10 |
| 4 | 20k 1% | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R10, R11, R13, R15 |
| 2 | 10 | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R4, R5 |
| 2 | 10k | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R49, R50 |
| 2 | 4.7k | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R34, R35 |
| 1 | 1k | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R48 |
| 1 | 1uF | Capacitor_THT:C_Disc_D5.0mm_W2.5mm_P2.50mm | C3 |
| 1 | 4.7 kΩ | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R33 |
| 1 | 5V active buzzer | Buzzer_Beeper:Buzzer_12x9.5RM7.6 | BZ1 |
| 1 | ADS1115 #1 0x48 (CO) | Connector_PinSocket_2.54mm:PinSocket_1x10_P2.54mm_Vertical | U4 |
| 1 | ADS1115 #2 0x49 (H2) | Connector_PinSocket_2.54mm:PinSocket_1x10_P2.54mm_Vertical | U5 |
| 1 | ADS1115 #3 0x4B (cells) | Connector_PinSocket_2.54mm:PinSocket_1x10_P2.54mm_Vertical | U6 |
| 1 | Acknowledge | VentSense_Footprints:SW_Push_6mm_THT | SW1 |
| 1 | BC547 | Package_TO_SOT_THT:TO-92_Inline | Q4 |
| 1 | BME280 0x76 | Connector_PinSocket_2.54mm:PinSocket_1x04_P2.54mm_Vertical | U22 |
| 1 | DS18B20 cell 1 | Connector_JST:JST_XH_B3B-XH-A_1x03_P2.50mm_Vertical | U15 |
| 1 | DS18B20 cell 2 | Connector_JST:JST_XH_B3B-XH-A_1x03_P2.50mm_Vertical | U16 |
| 1 | DS18B20 cell 3 | Connector_JST:JST_XH_B3B-XH-A_1x03_P2.50mm_Vertical | U17 |
| 1 | DS18B20 cell 4 | Connector_JST:JST_XH_B3B-XH-A_1x03_P2.50mm_Vertical | U18 |
| 1 | DS3231 RTC 0x68 | Connector_PinSocket_2.54mm:PinSocket_1x06_P2.54mm_Vertical | U21 |
| 1 | ESP32-DevKitC-32E | VentSense_Footprints:ESP32-DevKitC-32E_2x19_P2.54mm_W25.4mm | U19 |
| 1 | MAX6675 | Connector_PinSocket_2.54mm:PinSocket_1x07_P2.54mm_Vertical | U26 |
| 1 | MQ-7 seg 1 | Connector_JST:JST_XH_B4B-XH-A_1x04_P2.50mm_Vertical | U7 |
| 1 | MQ-7 seg 2 | Connector_JST:JST_XH_B4B-XH-A_1x04_P2.50mm_Vertical | U8 |
| 1 | MQ-7 seg 3 | Connector_JST:JST_XH_B4B-XH-A_1x04_P2.50mm_Vertical | U9 |
| 1 | MQ-7 seg 4 | Connector_JST:JST_XH_B4B-XH-A_1x04_P2.50mm_Vertical | U10 |
| 1 | MQ-8 seg 1 | Connector_JST:JST_XH_B4B-XH-A_1x04_P2.50mm_Vertical | U11 |
| 1 | MQ-8 seg 2 | Connector_JST:JST_XH_B4B-XH-A_1x04_P2.50mm_Vertical | U12 |
| 1 | MQ-8 seg 3 | Connector_JST:JST_XH_B4B-XH-A_1x04_P2.50mm_Vertical | U13 |
| 1 | MQ-8 seg 4 | Connector_JST:JST_XH_B4B-XH-A_1x04_P2.50mm_Vertical | U14 |
| 1 | OLED 0x3C | Connector_PinSocket_2.54mm:PinSocket_1x04_P2.54mm_Vertical | U20 |
| 1 | PCF8574 #1 0x20 | Connector_PinSocket_2.54mm:PinSocket_1x13_P2.54mm_Vertical | U23 |
| 1 | PCF8574 #2 0x21 | Connector_PinSocket_2.54mm:PinSocket_1x13_P2.54mm_Vertical | U24 |
| 1 | Reset | VentSense_Footprints:SW_Push_6mm_THT | SW2 |
| 1 | Seg 1 Green | LED_THT:LED_D3.0mm | D4 |
| 1 | Seg 1 Red | LED_THT:LED_D3.0mm | D2 |
| 1 | Seg 1 Yellow | LED_THT:LED_D3.0mm | D3 |
| 1 | Seg 2 Green | LED_THT:LED_D3.0mm | D7 |
| 1 | Seg 2 Red | LED_THT:LED_D3.0mm | D6 |
| 1 | Seg 2 Yellow | LED_THT:LED_D3.0mm | D5 |
| 1 | Seg 3 Green | LED_THT:LED_D3.0mm | D10 |
| 1 | Seg 3 Red | LED_THT:LED_D3.0mm | D8 |
| 1 | Seg 3 Yellow | LED_THT:LED_D3.0mm | D9 |
| 1 | Seg 4 Green | LED_THT:LED_D3.0mm | D13 |
| 1 | Seg 4 Red | LED_THT:LED_D3.0mm | D11 |
| 1 | Seg 4 Yellow | LED_THT:LED_D3.0mm | D12 |
| 1 | TC4427 (DIP-8) | Package_DIP:DIP-8_W7.62mm | U1 |
| 1 | microSD | Connector_PinSocket_2.54mm:PinSocket_1x06_P2.54mm_Vertical | U25 |
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Questions
How big is the VentSense Stage2 PCB?
It measures 124 × 112 mm and has 2 copper layers, 1.6 mm thick.
What parts does the VentSense Stage2 use?
93 parts, built around the ESP32-DEVKITC-32E, MAX6675ISA+ and BC547. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.
Where can I download the VentSense Stage2 KiCad files?
From the Aryan-swag/VentSense repository on GitHub, at the commit this page was made from: the board is kicad/VentSense_Stage2/VentSense_Stage2.kicad_pcb and its schematic kicad/VentSense_Stage2/MCU_IO.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the VentSense Stage2 design in my own project?
Its repository states no licence, so its author keeps all rights: ask Aryan-swag before reusing the design.