Project Description
1. Main Controller
• The board’s main controller will be a microcontroller from the Teensy 4.0 class. It must have sufficient processing speed and GPIO capacity.
2. Integrated ESC
• The board will feature a built-in ESC for driving a brushless starter motor.
• It must support a current capacity of ≥40A.
• The ESC will be powered by a 3S-4S battery. (Minimum 11.1–14.4 V, Maximum 12.6–16.8 V)
• The necessary protection and secure signal connections must be provided between the motor driver and the controller.
3. Glow Plug Output
• The board will include a power switching output for the glow plug.
• It must support a current capacity of ≥16A.
• On/Off control is sufficient.
• The glow plug will be powered by 3S or 4S voltage.
• An appropriate high-current output connector/cable connection must be provided.
• Control will be performed via the main controller.
• The GND line will be connected to the motor housing via a screw connection.
4. DC Pump Drivers
• The system includes two 5V DC brushed pumps.
• The pump driver circuits will be embedded on the board.
• Each pump will operate via a separate driver and power supply line.
• Appropriate protection circuits must be implemented to prevent interference and back-EMF effects from the brushed motors from reaching the controller.
• The connection connector must be an XT30 male type.
5. RPM Measurement – Hall Effect Sensor
• The US1881 Hall effect sensor will be used for RPM measurement.
• On the board:
o 1 embedded US1881 sensor
o ~10kΩ pull-up resistor
• The sensor must be placed on the edge/end of the board. (It will be placed on the spring located on the inner side of the board’s DXF profile.)
• The sensor output must be connected to the microcontroller’s interrupt-enabled GPIO pin.
• Since the system can measure up to 150,000 RPM, interrupt-based reading will be used.
• Additionally, for the external Hall sensor connection:
o The circuit will be pre-configured on the board
o The sensor will not be present on the board
o A 3-wire connection (VCC / GND / Signal) will be provided.
6. Thermocouple Temperature Measurement
• The board must include an embedded thermocouple reading circuit.
• The measurement range must be suitable for temperatures from room temperature up to approximately 1500°C.
• A digital thermocouple reader or a suitable analog solution may be used.
• The thermocouple connection must be provided as an external output from the board.
• A micro connector with a screw-type clamping mechanism will be mounted on the board for the connection.
• The output must be taken from the top of the board.
7. Liquid Valve Outputs
• The system contains two liquid valves that operate at 5V.
• The board must have two separate control outputs to control these valves.
• Protection must be implemented against back-EMF and interference effects that may arise from the valves.
• The valves to be used will be NC (Normally Closed) type; that is, they will be closed when power is off.
• The board will provide only the valve control outputs.
8. User Interface
The following components may be present on the board:
• 1 mini control button
• 1 7-segment display (may be omitted if there are insufficient pins)
9. Power Management
• The system will be powered by a single main power source.
• The board must include the necessary DC-DC converters.
Power requirements:
• 16V for the ESC and glow plug
• 5–12V for pumps and valves
Startup Safety:
• When the board is first powered on, the control board must be started up stably first.
• Actuators such as pumps and valves must remain de-energized initially.
• Once the controller is ready, power should be allowed to be applied to the other systems.
10. PCB Design and Electrical Safety Precautions
The following general electronic design and safety principles must be applied in board design:
• Star grounding or an appropriate grounding architecture must be used.
• Power circuits and control circuits must be separated as much as possible.
• Sufficient copper thickness and trace width must be used for high-current paths.
• Filtering and protection against EMI/interference effects that may arise from motors, pumps, and valves must be implemented.
• Where necessary:
o Flyback diodes,
o TVS diodes
o snubber circuits
o decoupling capacitors
o EMI filters
must be used.
• Analog measurement lines (sensors, etc.) must be designed to be isolated from noise.
• High-current circuits and sensitive measurement circuits must be physically separated.
• Stable regulation and filtering must be provided for power distribution.
• All necessary electrical, mechanical, and EMI protection measures must be evaluated and implemented by the designer.
11. The total current drawn from the 4S battery; current sensors capable of separately measuring the currents drawn by Pump 1 and Pump 2, the glow plug, and the ESC must be present. Additionally, the battery voltage must be measured.