PowerPCB

High-Reliability Power Distribution & Telemetry Module (PDB-Rev1)

A compact, multi-rail Power Distribution and Telemetry Board designed for embedded avionics, robotics, and high-power actuation systems. Built with active protection circuits, precision current sensing, and brownout mitigation.

Features & System Architecture

• Wide Input Range ($V_{\text{IN}}$): Optimized for 2S–4S LiPo batteries ($7.4\text{ V} - 16.8\text{ V}$).

• Step-Down SMPS: Texas Instruments TPS54531 DC-DC Buck Converter

  • Regulated Output: $5.0\text{ V} \text{ / } 5\text{ A}$ continuous output rail.

  • Switching Frequency: $570\text{ kHz}$ for reduced ripple and compact inductor footprint.

• Precision Telemetry: INA226 High-Side Power & Current Monitor

  • Architecture: 4-terminal Kelvin sensing topology to eliminate trace resistance errors.

  • Bus Voltage: Up to $36\text{ V}$ real-time bus voltage monitoring.

  • Interface: Standard $I^2\text{C}$ interface with dedicated pull-ups to $3.3\text{ V}$ logic.

• High-Current Actuation Stage:

  • Switching: Low-$R_{\text{DS(on)}}$ AOD4184A N-Channel MOSFET stage (up to $40\text{ V}$ rating).

  • Protection: In-line gate damping, fail-safe pull-down network, and transient clamping.

Power Integrity & Protection Systems

• Active Reverse Polarity Protection: High-side P-Channel MOSFET topology providing near-zero voltage drop compared to traditional Schottky diodes.

• Transient Voltage Suppression: Dedicated TVS network clamping inductive spikes from high-power loads and motor switching.

• Brownout & Voltage Sag Mitigation: Integrated power-steering Schottky barrier and high-capacity bulk reservoir on the logic rail, preventing MCU brownouts and reset cycles during heavy current draw.

Hardware & Tools

• EDA / Layout: KiCad

• Verification: Digital Storage Oscilloscope, Digital Multimeter, Benchtop DC Power Supply