2 layers29.2 × 16.5 mm
Current voltage sensor
MedadRufus/MastersProject
This project does data analysis of parameters from an E bike, in order to do accurate range estimations.
11 parts2MIT
2 layers90.2 × 48.3 mm
Bike logger
MedadRufus/MastersProject2This project does data analysis of parameters from an E bike, in order to do accurate range estimations.
- Size
- 90.2 × 48.3 mm
- Copper layers
- 2
- Thickness
- 1.6 mm
- Parts
- 108
- Nets
- 47
- Pads
- 335
- Tracks, vias
- 1,356, 128
- Pours
- 3
- Routed
- Yes
- KiCad
- KiCad 5 (file 20171130)
- Created
- 19 Nov 2020
- Updated
- 2 Jul 2021
Overview
Bike logger is an open-source printed circuit board by MedadRufus, from the MedadRufus/MastersProject repository on GitHub, published under the MIT licence. It is a 2-layer board of 90.2 × 48.3 mm with 108 parts on 47 nets, routed with 1,356 tracks and 128 vias.
It is built around the CP2104EK, ESP32-WROOM-32 and LSM6DS3, with the MS8607-02BA01, BAT54S and MMBT5551L among its other parts. Its parts include 26 capacitors, 25 resistors, 10 diodes, 9 connectors and 6 ICs. It belongs with the ESP32 boards of this library.
Main components
7CP2104EK
-- USB Conversion Modules ROHSSilicon LabsUSB Conversion Modules
ESP32-WROOM-32
SMD,18x25.5mm-40℃~+85℃ -98dBm 2.4GHz 2.7V~3.6V 20dBm Bluetooth4.2 ESP32-DOWDQ6 UART、SDIO、SPI、I2C、GPIO、PWM、ADC、DAC SMD,25.5x18mm WiFi Modules ROHSEspressif SystemsWiFi Modules
LSM6DS3
LGA-14(2.5x3)-40℃~+85℃ 1.71V~3.6V 8KB Accelerometer Gyroscope SPI、I2C X,Y,Z X,Y,Z ±16g ±2000dps LGA-14(2.5x3) Accelerometers ROHSSTMicroelectronicsAccelerometers
MS8607-02BA01
DFN-8(3x5)DFN-8(3x5) New Arrivals ROHSTE ConnectivityUncategorised
BAT54S
SOT-231 Pair Series Connection 1V@100mA 200mA 2uA@25V 30V 600mA SOT-23 Schottky Diodes ROHSMDDSchottky DiodesMMBT5551L
SOT-23-55℃~+150℃ 1 NPN 100nA 160V 250mV 300mW 600mA 6V 80 NPN SOT-23 Bipolar (BJT) ROHSonsemiBipolar (BJT)BAT54C
SOT-231 Pair Common Cathode 200mA 2uA@25V 30V 600mA 800mV@100mA SOT-23 Schottky Diodes ROHSNexperiaSchottky Diodes
README
README.mdMastersProject
Requirements
Design a data logger for E bikes that can record:
It needs to
- measure: battery current for output and charging(1mA precision), voltage(10mV precision), inclination of road, humidity(as proxy for rain), tempreature of battery, external temperature, e-bike velocity, accleration.
- run off the battery pack
- consume minimal power
- be sturdy enough to survive near the battery pack
- Measure the environmental values(temperature, humidity) without being affected by the system(e.g. heat from the battery)
- measure at least 2 weeks of non stop data
- option to auto upload to the cloud, when connected to wifi.
- cloud dashboard
- log data at max data rate of 1 sample per second
- Needs to handle significant noise in power supply generated by Motor
- Need to handle inductive currents from motor
- Needs isolation from motor.
The idea is to see how estimate battery discharge profiles to do accurate range and state of charge estimations.
Hardware ideas:
- Accleration/tilt from LSM9DS1. Tilt can be measured from sensor fusino on the mcu
- Processor: ESP32
- Current sensor: INA226, 500 kHz +/- 30% sample rate. Up to 36V.
- GPS: Ublox with antenna
Overall System diagram
Basic physical design
Uses of sensor variables
Software development
The following commands must be run as workarounds on the eBike Blackbox.
How to disable strapping pin function of the MTDI pin(IO12)
On the PCB, the MTDI pin, IO12, is connected to the SD card MISO pin. In order to boot up, IO12 must be held low. Otherwise, it will brownout.
Some explanation can be found on the documentation.
If driven High, flash voltage (VDD_SDIO) is 1.8V not default 3.3V. Has internal pull-down, so unconnected = Low = 3.3V. May prevent flashing and/or booting if 3.3V flash is used and this pin is pulled high, causing the flash to brownout. See the ESP32 datasheet for more details.Unfortunately, when SD card is inserted, MISO pin gets pulled up, causing continuous resets(boot loop).
So to disable this strapping function, we need to set the efuses to disable its functionality.
So we need to install esptool. On windows 10, using conda terminal, run:
pip install esptoolThen run the following command to actually set the fuses. Set the -p argument to the port your esp32 is connected to.
python -m espefuse set_flash_voltage 3.3V -p COM6You should be done now!
References:
https://www.esp32.com/viewtopic.php?t=5970
https://forum.micropython.org/viewtopic.php?t=4387#p25381
Parts
108| Qty | Value | Footprint | References |
|---|---|---|---|
| 22 | TestPoint | TestPoint:TestPoint_Pad_1.0x1.0mm | TP1, TP10, TP11, TP12, TP16, TP17, TP18, TP19, TP22, TP23, TP24, TP25, TP27, TP28, TP29, TP30 +6 |
| 19 | 100nF | Capacitor_SMD:C_0402_1005Metric | C1, C2, C3, C6, C10, C13, C17, C18, C19, C20, C21, C22, C23, C24, C25, C26 +3 |
| 15 | R | Resistor_SMD:R_0402_1005Metric | R1, R2, R5, R6, R15, R16, R17, R18, R19, R20, R21, R22, R23, R24, R25 |
| 8 | 4.7k | Resistor_SMD:R_0402_1005Metric | R7, R8, R9, R10, R11, R12, R13, R14 |
| 8 | BAT54S | Package_TO_SOT_SMD:SOT-23 | D1, D2, D4, D5, D6, D7, D8, D9 |
| 4 | 1uF | Capacitor_SMD:C_0603_1608Metric | C5, C14, C15, C16 |
| 4 | Conn_01x04 | Connector:NS-Tech_Grove_1x04_P2mm_Vertical | J4, J5, J6, J7 |
| 4 | MountingHole_Pad | custom_footprints:MountingHole_2.7mm_M2.5_custom | H1, H2, H3, H4 |
| 4 | SW_Push_1571563-4 | custom_footprints:SW_1571563-4 | SW1, SW2, SW4, SW4_reset1 |
| 3 | Conn_01x04 | TerminalBlock_Phoenix:TerminalBlock_Phoenix_MKDS-1,5-4-5.08_1x04_P5.08mm_Horizontal | J2, J8, J9 |
| 2 | 10k | Resistor_SMD:R_0402_1005Metric | R3, R4 |
| 2 | 10uF | Capacitor_SMD:C_0603_1608Metric | C4, C11 |
| 2 | MMBT5551L | Package_TO_SOT_SMD:SOT-23 | Q1, Q2 |
| 1 | 10uF 100V | Capacitor_SMD:CP_Elec_6.3x7.7 | C12 |
| 1 | BAT54C | Package_TO_SOT_SMD:SOT-23 | D3 |
| 1 | CP2104 | Package_DFN_QFN:QFN-24-1EP_4x4mm_P0.5mm_EP2.6x2.6mm | U5 |
| 1 | ESP32-WROOM-32 | RF_Module:ESP32-WROOM-32 | U1 |
| 1 | LED | LED_SMD:LED_0402_1005Metric | D10 |
| 1 | LSM6DS3 | Package_LGA:LGA-14_3x2.5mm_P0.5mm_LayoutBorder3x4y | U4 |
| 1 | MS8607-02BA | Package_LGA:LGA-8_3x5mm_P1.25mm | U3 |
| 1 | Micro_SD_Card | Connector_Card:microSD_HC_Hirose_DM3AT-SF-PEJM5 | J1 |
| 1 | USB_B_Micro | Connector_USB:USB_Micro-B_Molex-105017-0001 | J3 |
| 1 | XC6210 | Package_TO_SOT_SMD:SOT-23-5 | U2 |
| 1 | XP_Power_STH | custom_footprints:STH0548S3V3 | U6 |
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Questions
How big is the Bike logger PCB?
It measures 90.2 × 48.3 mm and has 2 copper layers, 1.6 mm thick.
What parts does the Bike logger use?
108 parts, built around the CP2104EK, ESP32-WROOM-32, LSM6DS3 and MS8607-02BA01. 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 Bike logger KiCad files?
From the MedadRufus/MastersProject repository on GitHub, at the commit this page was made from: the board is Bike_logger/pcb/pcb.kicad_pcb. PCBKit opens the board in the browser, with nothing to install.
Can I use the Bike logger design in my own project?
Its repository publishes it under the MIT licence: you may reuse it on that licence's terms (keep the author's notice, and for a copyleft licence share your changes alike).