EnergyMonitoringSystem

AEMS Hardware — Energy Monitoring System Board

KiCad design for the AEMS v2 data-acquisition board: a custom, multi-channel energy-monitoring front end built around the ADS131M08 ADC and the STM32H745 dual-core MCU. This is the hardware layer of the Autonomous Energy Monitoring System and is designed to be reproduced, modified, and manufactured by others.

The KiCad project root is EnergyMonitoringSystem.kicad_pro.

Board overview

The board acquires multi-channel voltage and current signals at a high, simultaneous sampling rate, digitizes them through the ADS131M08 analog front end, and hands the data to the STM32H745 for on-board logging and network streaming.

Key design features:

• ADS131M08 — 8-channel, 24-bit, simultaneous-sampling delta-sigma ADC front end.
• STM32H745 dual-core (Cortex-M7 + Cortex-M4) host MCU with eMMC and Ethernet.
• Isolated power rails feeding the analog front end and digital domains.
• Impedance-controlled, multilayer PCB (100 Ω differential / 50 Ω single-ended Ethernet, 90 Ω USB) — see the impedance and stackup exports in DesignSummary/.
• MOV-based surge protection on the measurement inputs.
• Ethernet and on-board eMMC for autonomous, network-independent logging.

The current firmware/host workflows use a 6-channel acquisition mask (0x3F) — three voltage and three current channels.

Input voltage topology: the present design is validated for its rated direct-measurement input topology. Measuring higher line-to-line service voltages (e.g. 480 V L-L) exceeds the on-board MOV continuous ratings and requires an updated MOV surge protector (upto a certain voltage level) or external potential transformer. This is consistent with the modular design intent and is tracked under FutureUpdates/.

Board Power-Up

Temporarily, due to a design issue, the board needs to be powered on as shown in the figure below. This design issue will be fixed in the next hardware version.

Project structure

hardware/
├── EnergyMonitoringSystem.kicad_pro   KiCad project
├── EnergyMonitoringSystem.kicad_sch   Root schematic
├── EnergyMonitoringSystem.kicad_pcb   PCB layout
├── *.kicad_sch                        Hierarchical sheets (see below)
├── CustomLibs/                        Project symbol/footprint libraries
│   ├── EMS.kicad_sym                  Custom symbols
│   ├── EMS.pretty/                    Custom footprints
│   └── Downloaded/                    Third-party part libs (ADS131M08, MOV, op-amps, …)
├── LTSpiceSimulation/                 Analog front-end simulations (CT op-amp, rough studies)
├── Datasheets/                        Component reference material
├── ApplicationNotes/                  ST H7 hardware development notes
├── DesignSummary/                     Stackup, impedance control, interactive BOM
├── Manufacturing/PCBWay/              Fabrication + assembly outputs (Gerbers, drill, BOM, CPL)
└── FutureUpdates/Planned/             Planned revisions (front-end isolation, etc.)

Schematic sheets

The design is hierarchical. The main functional sheets are:

Bill of materials

• Interactive BOM: open DesignSummary/ibom.html in a browser for a searchable, click-to-highlight BOM with board placement.
• Fabrication BOM / placement: Manufacturing/PCBWay/EnergyMonitoringSystem.kicad_pcb/PCBWay_bom.csv and PCBWay_positions.csv (component placement / CPL).

Manufacturing

Ready-to-fabricate outputs (generated for PCBWay) are in Manufacturing/PCBWay/ or you generated your own from the KiCAD project:

• Gerbers (F_Cu, B_Cu, In1..In6_Cu, mask, paste, silkscreen, edge cuts)
• Drill files (PTH, NPTH)
• PCBWay_bom.csv (BOM) and PCBWay_positions.csv (pick-and-place)
• PCBWay_netlist.ipc (IPC-356 netlist)
• DesignRequirements.pdf and Jump-SolderBridges.png (assembly notes)

Stackup and impedance targets are documented in DesignSummary/ (CurrentStackup.png, PCBWay Stackup.png, and the ImpedanceControl *.png exports).

To regenerate outputs, open EnergyMonitoringSystem.kicad_pcb in KiCad and re-plot Gerbers/drill and re-export the BOM/placement.

Requirements

• KiCad 7 or newer to open the project.
• Custom and downloaded libraries under CustomLibs/ are referenced via the project-local sym-lib-table / fp-lib-table, so the project should open self-contained.

Future updates

Planned hardware revisions are tracked in FutureUpdates/Planned/, including improved analog front-end isolation and higher line-to-line voltages.

License

Hardware licensing is being finalized as part of the open-hardware release; see the top-level LICENSE. Please contact the authors before redistributing the design files until the final license is committed.

For system context, firmware, and host software, see the top-level README.