2 layers70.7 × 52.6 mm
4 layers186.9 × 129.8 mm
A 4-layer PCB-based e-bike conversion kit featuring an STM32-based VESC ESC, power management circuits, wireless throttle, GSM, GPS, and more.
- Size
- 186.9 × 129.8 mm
- Copper layers
- 4
- Thickness
- 1.6 mm
- Parts
- 179
- Nets
- 178
- Pads
- 603
- Tracks, vias
- 2,216, 219
- Pours
- 47
- Routed
- Yes
- KiCad
- KiCad 8.0 (file 20240108)
- Created
- 21 Feb 2025
- Updated
- 10 May 2025
Overview
BLDC 4 is an open-source printed circuit board by ansh1113, from the ansh1113/e-bike-conversion-kit repository on GitHub. It is a 4-layer board of 186.9 × 129.8 mm with 179 parts on 178 nets, routed with 2,216 tracks and 219 vias.
It is built around the SN65HVD232D, LM358P and MP1584EN-LF-Z, with the DRV8302, EEE1HA101UAP and XT30PW-M among its other parts. Its parts include 64 resistors, 55 capacitors, 20 connectors, 8 ICs and 8 transistors. It belongs with the robots and motor control boards and the ESP32 boards of this library.
Main components
12
SN65HVD232D
SOIC-8-40℃~+85℃ 17mA 1Mbps 3.3V CAN Transceiver SOIC-8 CAN Transceivers ROHSTexas InstrumentsCAN Transceivers
LM358P
DIP-8-1.5V~18V 0℃~+70℃ 1MHz 2 2mV 3V~36V 3nA 40mA 45nA 500uA 85dB Built-in compensation DIP-8 Operational Amplifier ROHSSlkorOperational AmplifierMP1584EN-LF-Z
SOIC-8-EP-20℃~+85℃@(TA) 1 100kHz~1.5MHz 100uA 3A 4.5V~28V 800mV~25V Adjustable Buck Buck Built-in No SOIC-8-EP DC-DC Converters ROHSMonolithic Power SystemsDC-DC ConvertersDRV8302
UncategorisedTexas Instruments
EEE1HA101UAP
SMD,D8xL10.2mm-40℃~+85℃ 10.2mm 100uF 2000hrs@85℃ 200mA@120Hz 50V 8mm Polarized ±20% SMD,D8xL10.2mm Aluminum Electrolytic Capacitors - SMD ROHSPanasonicAluminum Electrolytic Capacitors - SMD
XT30PW-M
-- Power connector / plug connector ROHSChangzhou Amass ElecUncategorisedAMDLA4020S-220MT
SMD,4x4.4mm1.2A 2.1A 22uH 320mΩ ±20% SMD,4x4.4mm Power Inductors ROHSAbraconPower Inductors
B560C-13-F-MS
SMC-65℃~+125℃ 1 Independent 175A 500uA@60V 5A 60V 850mV@5A SMC Schottky Diodes ROHSMSKSEMISchottky Diodes
IRF5305STRLPBF
D2PAK-55℃~+175℃ 1 P-Channel 1.2nF 110W 31A 4V 55V 60mΩ@10V 63nC@10V P-Channel D2PAK MOSFETs ROHSInfineon TechnologiesMOSFETs
LMJ316BB7226KLHT
120610V 22uF X7R ±10% 1206 Multilayer Ceramic Capacitors MLCC - SMD/SMT ROHSTaiyo YudenMultilayer Ceramic Capacitors MLCC - SMD/SMTMAASL105CD7105MFCA01
-UncategorisedTaiyo Yuden
SPM6530T-6R8M
SMD,7.1x6.5mm4A 4A 53.3mΩ 6.8uH ±20% SMD,7.1x6.5mm Power Inductors ROHSTDKPower Inductors
README
README.mde-Bike Conversion Kit
Overview
This project is a custom e-bike conversion kit featuring:
- STM32-based VESC ESC for motor control
- ESP32/ESP8266 for wireless control and battery monitoring
- 36V 10.4Ah Lithium Power Supply with buck circuits (36V->24V, 24V->12V, 12V->5V)
- Wireless throttle module (mode increase/decrease/start switches)
- GSM/GPS integration for tracking and security
- Battery level and mode indicator LEDs
- Electronic latch locking system
- Phone charging port
Features
- Wireless throttle control using ESP32
- Real-time battery monitoring and motor control
- GPS tracking for security
- Compact 4-layer PCB design
Installation
1. Hardware Assembly
- Mount the VESC ESC with proper cooling.
- Connect the 36V battery to the power input.
- Wire the ESP module to the ESC for PPM signal transmission.
- Connect buck converters for proper voltage regulation.
- Attach LEDs, GSM/GPS module, and gyro sensor.
- Install wireless throttle module on the handlebar.
2. Software Setup
- Install VESC Tool for ESC configuration.
- Flash the ESP firmware using Arduino IDE.
- Configure PPM values for different speed modes.
Firmware Installation
1. Flashing VESC Firmware
- Download and install VESC Tool.
- Connect STM32 to your PC via USB.
- Select the correct firmware version and upload.
2. Flashing ESP Firmware
- Install Arduino IDE with ESP32/ESP8266 support.
- Install necessary libraries (
WiFi,TinyGPS++,Adafruit_GFXetc.). - Compile and upload
Firmware/hook_receiver/hook_receiver.ino.
Parts
179| Qty | Value | Footprint | References |
|---|---|---|---|
| 17 | 2.2u | CRF1:SMD-0603_c | C10, C11, C12, C13, C14, C16, C17, C18, C20, C23, C24, C26, C31, C35, C41, C401 +1 |
| 9 | 2k2 | CRF1:SMD-0603_r | R4, R5, R11, R12, R13, R22, R24, R27, R33 |
| 8 | 10u,50V | CRF1:SMD-1206 | C1, C8, C9, C39, C40, C43, C44, C49 |
| 7 | 10k | CRF1:SMD-0603_r | R2, R7, R8, R9, R10, R20, R402 |
| 7 | 2K | Resistor_SMD:R_1210_3225Metric | R39, R40, R41, R44, R45, R47, R52 |
| 7 | 39k | CRF1:SMD-0603_r | R3, R23, R26, R30, R32, R36, R46 |
| 6 | 100R | CRF1:SMD-0603_r | R37, R38, R48, R49, R50, R51 |
| 6 | 4R7 | CRF1:SMD-0603_r | R28, R29, R34, R35, R42, R43 |
| 6 | IRFS7530 | CRF1:D2PAK-7-GDS | Q1, Q2, Q3, Q4, Q5, Q6 |
| 4 | 100n | CRF1:SMD-0603_c | C2, C3, C27, C32 |
| 4 | 43650-0402 | Connector_JST:JST_EH_B4B-EH-A_1x04_P2.50mm_Vertical | J3, J6, J12, J13 |
| 4 | 4n7 | CRF1:SMD-0603_c | C4, C5, C6, C7 |
| 3 | 220n | CRF1:SMD-0603_c | C28, C29, C30 |
| 3 | EEE1HA101UAP | Capacitor_SMD:CAP_EEE1HA101UAP | C42, C50, C53 |
| 3 | KAM21BR71H104JT | Capacitor_SMD:C_0805_2012Metric | C47, C48, C55 |
| 3 | MountingHole | MountingHole:MountingHole_3.2mm_M3 | H3, H3, H3 |
| 3 | XT30PW-M | Connector_JST:JST_EH_B2B-EH-A_1x02_P2.50mm_Vertical | J1, J2, J4 |
| 2 | 100u | w_smd_cap:c_tant_B | C25, C33 |
| 2 | 15p | CRF1:SMD-0603_c | C15, C38 |
| 2 | 2-1445098-2 | Connector_AMASS:AMASS_XT30U-F_1x02_P5.0mm_Vertical | J7, J10 |
| 2 | 2.2kΩ | Resistor_SMD:R_1210_3225Metric | R56, R59 |
| 2 | 2.2n | CRF1:SMD-0603_c | C34, C36 |
| 2 | 22R | CRF1:SMD-0603_r | R103, R104 |
| 2 | 2k | Resistor_SMD:R_1210_3225Metric | R16, R31 |
| 2 | 3403.0176.24 | Fuse:Fuse_Schurter_UMT250 | F1, F2 |
| 2 | LM22678TJ-ADJ/NOPB | regulator:LM22678TJ-ADJNOPB | U7, U9 |
| 2 | SHUNT | CRF1:WSLP2726 | R53, R54 |
| 2 | XT30PW-M | Connector_AMASS:AMASS_XT30U-F_1x02_P5.0mm_Vertical | J11, J14 |
| 1 | |||
| 1 | 0R | CRF1:SMD-0603_r | R6 |
| 1 | 120p | CRF1:SMD-0603_c | C19 |
| 1 | 15k | CRF1:SMD-0603_r | R19 |
| 1 | 15u, 100v | w_smd_cap:c_2220 | C51 |
| 1 | 15u,100V | w_smd_cap:c_2220 | C37 |
| 1 | 171971-0005 | Connector_JST:JST_EH_B5B-EH-A_1x05_P2.50mm_Vertical | J5 |
| 1 | 18.2kΩ | Resistor_SMD:R_1210_3225Metric | R55 |
| 1 | 18k | CRF1:SMD-0603_r | R17 |
| 1 | 1K | Resistor_SMD:R_1210_3225Metric | R15 |
| 1 | 1M | CRF1:SMD-0603_r | R25 |
| 1 | 1k | Resistor_SMD:R_1210_3225Metric | R14 |
| 1 | 210kΩ | Resistor_SMD:R_1210_3225Metric | R57 |
| 1 | 220k | CRF1:SMD-0603_r | R21 |
| 1 | 22n | CRF1:SMD-0603_c | C22 |
| 1 | 22u | w_smd_inductors:inductor_smd_8x5mm | L1 |
| 1 | 39kΩ | Resistor_SMD:R_1210_3225Metric | R60 |
| 1 | 3k3 | CRF1:SMD-0603_r | R18 |
| 1 | 40.2kΩ | Resistor_SMD:R_1210_3225Metric | R58 |
| 1 | 6.8n | CRF1:SMD-0603_c | C21 |
| 1 | 8MHz 10ppm | CRF1:Crystal_5x3mm | X2 |
| 1 | AMDLA4020S-220MT | Inductor_SMD:IND_AMDLA4020S-220MT | L2 |
| 1 | B560C-13-F | Diode_SMD:B560C-13-F | D6 |
| 1 | CANBUS | JST conn:b4b-ph-kl | P101 |
| 1 | DIODESCH | Diodes_SMD:SMA_Handsoldering | D4 |
| 1 | DRV8302 | CRF1:TSSOP-56-PP | U3 |
| 1 | ESP32-DEVKIT-V1 | Module:MODULE_ESP32_DEVKIT_V1 | U4 |
| 1 | GREEN | LEDs:LED-0603 | D1 |
| 1 | HALL/Encoder | CRF1:MICRO_JST_6 | P1 |
| 1 | IN+ | CRF1:1PAD_4x5mm | P4 |
| 1 | IN- | CRF1:1PAD_4x5mm | P5 |
| 1 | IRF5305STRLPBF | IRF530:TRANS_IRF3205S | Q8 |
| 1 | LED | LEDs:LED-0603 | D3 |
| 1 | LM358P | Package_DIP:DIP-8_W7.62mm_Socket | U6 |
| 1 | LMJ316BB7226KLHT | Capacitor_SMD:C_1206_3216Metric | C46 |
| 1 | MAASL105CD7105MFCA01 | Capacitor_SMD:C_0402_1005Metric | C54 |
| 1 | MINI-USB-SHIELD-32005-201 | CRF1:USB-UX60R-MB-5ST | X1 |
| 1 | MOTOR1 | CRF1:1PAD_4x5mm | P6 |
| 1 | MOTOR2 | CRF1:1PAD_4x5mm | P7 |
| 1 | MOTOR3 | CRF1:1PAD_4x5mm | P9 |
| 1 | MP1584EN-LF-Z | regulator:MP1584(1) | U8 |
| 1 | NI | CRF1:SMD-0603_r | R401 |
| 1 | NTC 10k | CRF1:SMD-0603_r | R1 |
| 1 | Optoisolator1 | Package_DIP:DIP-4_W7.62mm_Socket | U5 |
| 1 | PWR_COMM | CRF1:b7b-ph-kl | P3 |
| 1 | RED | LEDs:LED-0603 | D2 |
| 1 | SERVO | CRF1:pinhead-1X03 | K1 |
| 1 | SN65HVD232 | CRF1:SOIC-8-W | U401 |
| 1 | SPM6530T-6R8M | Inductor_SMD:IND_SPM6530T-6R8M-HZ | L4 |
| 1 | SRN6045TA-220M | Inductor_SMD:IND_SRN6045TA-220M | L3 |
| 1 | SS34 | Diode_SMD:DIO_SS34 | D7 |
| 1 | STB75NF75T4 | STB75NF75T4:VREG_L7805ACD2T | Q7 |
The 174 most common of 179 parts.
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Questions
How big is the BLDC 4 PCB?
It measures 186.9 × 129.8 mm and has 4 copper layers, 1.6 mm thick.
What parts does the BLDC 4 use?
179 parts, built around the SN65HVD232D, LM358P, MP1584EN-LF-Z and DRV8302. 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 BLDC 4 KiCad files?
From the ansh1113/e-bike-conversion-kit repository on GitHub, at the commit this page was made from: the board is Hardware/PCB Files/BLDC_4.kicad_pcb and its schematic Hardware/PCB Files/BLDC_4.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the BLDC 4 design in my own project?
Its repository states no licence, so its author keeps all rights: ask ansh1113 before reusing the design.