techmannih/nema34-mounted-stepper-controller
A 48 V USB‑C PD 3.1 EPR NEMA‑34 stepper controller PCB combining STM32/TMC5160 control, external MOSFET motor bridges, protected power and regenerative braking, USB data, telemetry, diagnostics, status LEDs, and buzzer alarms.
- Version
- 0.3.92
- License
- unset
- Stars
- 1
engineering/filled-copper-review.json
{
"status": "analytical-screen-only-hardware-qualification-pending",
"baseline_commit": "d28bcf61d0d0479ad3a44b3ad14bfbf5b858c435",
"board": "dist/manufacturing/kicad-project/pd1180-epr-r0.3.kicad_pcb",
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"change": "Reran all six motor-current paths at both mesh sizes on the encoder top-capacitor revision. No powered or thermal qualification implied.",
"before": [
{
"net": "MOTOR_A1",
"from": "Q7:9",
"to": "R115:1",
"grid_mm": 0.075,
"nodes": 24480,
"resistance_mohm_20c": 20.9415,
"voltage_drop_mv_at_5_5a": 115.178,
"loss_w_at_5_5a": 0.6335,
"source_nodes": 2928,
"destination_nodes": 368,
"components": 1,
"board_sha256": "ed81f2ec88d66d8bcc982ccb56d393fb08e92f256c9a55982854857234df7dad",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_A1",
"from": "Q7:9",
"to": "R115:1",
"grid_mm": 0.05,
"nodes": 55196,
"resistance_mohm_20c": 21.2778,
"voltage_drop_mv_at_5_5a": 117.028,
"loss_w_at_5_5a": 0.6437,
"source_nodes": 6552,
"destination_nodes": 840,
"components": 1,
"board_sha256": "ed81f2ec88d66d8bcc982ccb56d393fb08e92f256c9a55982854857234df7dad",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
}
],
"after": [
{
"net": "MOTOR_A1",
"from": "Q7:9",
"to": "R115:1",
"grid_mm": 0.075,
"nodes": 47680,
"resistance_mohm_20c": 2.8393,
"voltage_drop_mv_at_5_5a": 15.616,
"loss_w_at_5_5a": 0.0859,
"source_nodes": 2928,
"destination_nodes": 368,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_A1",
"from": "Q7:9",
"to": "R115:1",
"grid_mm": 0.05,
"nodes": 107249,
"resistance_mohm_20c": 2.8313,
"voltage_drop_mv_at_5_5a": 15.572,
"loss_w_at_5_5a": 0.0856,
"source_nodes": 6552,
"destination_nodes": 840,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
}
],
"final_mesh_difference_percent": 0.2825557164553388,
"analytical_model_tests": {
"rectangular_sheet_expected_mohm": 4.860038095238096,
"coarse_mohm": 5.0446,
"fine_mohm": 4.9873,
"barrel_expected_mohm": 1.371915609452138,
"barrel_mohm": 1.3719,
"passed": true
},
"model_source_sha256": {
"scripts/export-filled-power-copper.py": "293474ca65798cf99077d80e26a465e90792d0f5127b459e1aaeb5a2c474c76b",
"scripts/screen-filled-power-copper.py": "3f6adf115d9f99cdaada7050a539459491608d11b3c011e6ebba54791c8a750b",
"scripts/test-filled-power-copper.py": "2be758ad54dabc7013fef0f844a65a991c01af8df011103a5231dc8e282212ef"
},
"reproduction": {
"dependencies": "numpy==2.0.2 scipy==1.13.1 shapely==2.0.7",
"export": "KiCad Python: scripts/export-filled-power-copper.py <board.kicad_pcb> <filled-copper.json>",
"solve": "python scripts/screen-filled-power-copper.py <filled-copper.json> MOTOR_A1 0.05 Q7:9 R115:1",
"model_tests": "python scripts/test-filled-power-copper.py",
"baseline_board": "git show d28bcf61d0d0479ad3a44b3ad14bfbf5b858c435:dist/manufacturing/kicad-project/pd1180-epr-r0.3.kicad_pcb"
},
"qualification": "No temperature-rise, PWM-current or 5.5 A continuous-current qualification is claimed.",
"reviewed_at": "2026-10-15T22:43:28.191169+00:00",
"motor_output_paths": [
{
"net": "MOTOR_A1_OUT",
"from": "R115:2",
"to": "J2:1",
"grid_mm": 0.075,
"nodes": 16853,
"resistance_mohm_20c": 4.8955,
"voltage_drop_mv_at_5_5a": 26.925,
"loss_w_at_5_5a": 0.1481,
"source_nodes": 368,
"destination_nodes": 4488,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_A1_OUT",
"from": "R115:2",
"to": "J2:1",
"grid_mm": 0.05,
"nodes": 37703,
"resistance_mohm_20c": 4.9184,
"voltage_drop_mv_at_5_5a": 27.051,
"loss_w_at_5_5a": 0.1488,
"source_nodes": 840,
"destination_nodes": 9800,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_A2",
"from": "Q9:9",
"to": "J2:2",
"grid_mm": 0.075,
"nodes": 35706,
"resistance_mohm_20c": 10.8228,
"voltage_drop_mv_at_5_5a": 59.526,
"loss_w_at_5_5a": 0.3274,
"source_nodes": 2928,
"destination_nodes": 3476,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_A2",
"from": "Q9:9",
"to": "J2:2",
"grid_mm": 0.05,
"nodes": 80212,
"resistance_mohm_20c": 10.7007,
"voltage_drop_mv_at_5_5a": 58.854,
"loss_w_at_5_5a": 0.3237,
"source_nodes": 6552,
"destination_nodes": 7816,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_B1_OUT",
"from": "R116:2",
"to": "J2:3",
"grid_mm": 0.075,
"nodes": 14438,
"resistance_mohm_20c": 6.4583,
"voltage_drop_mv_at_5_5a": 35.521,
"loss_w_at_5_5a": 0.1954,
"source_nodes": 368,
"destination_nodes": 3464,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_B1_OUT",
"from": "R116:2",
"to": "J2:3",
"grid_mm": 0.05,
"nodes": 32546,
"resistance_mohm_20c": 6.4229,
"voltage_drop_mv_at_5_5a": 35.326,
"loss_w_at_5_5a": 0.1943,
"source_nodes": 840,
"destination_nodes": 7808,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_B2",
"from": "Q13:9",
"to": "J2:4",
"grid_mm": 0.075,
"nodes": 34271,
"resistance_mohm_20c": 7.1754,
"voltage_drop_mv_at_5_5a": 39.465,
"loss_w_at_5_5a": 0.2171,
"source_nodes": 2928,
"destination_nodes": 3468,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_B2",
"from": "Q13:9",
"to": "J2:4",
"grid_mm": 0.05,
"nodes": 76976,
"resistance_mohm_20c": 7.1207,
"voltage_drop_mv_at_5_5a": 39.164,
"loss_w_at_5_5a": 0.2154,
"source_nodes": 6552,
"destination_nodes": 7816,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
}
],
"reviewed_from_commit": "71c2efc3350f365382dd32ec3a0e6ecfd0fd9e17",
"reviewed_source_entry_sha256": "51fae7ba95264851e1ccc3f17c060cd151ebb6e01e5452a80e31cf61ec6a67b7",
"mounting_eco_baseline": {
"net": "MOTOR_A1",
"from": "Q7:9",
"to": "R115:1",
"grid_mm": 0.05,
"nodes": 96815,
"resistance_mohm_20c": 3.2946,
"voltage_drop_mv_at_5_5a": 18.12,
"loss_w_at_5_5a": 0.0997,
"source_nodes": 6552,
"destination_nodes": 840,
"components": 1,
"board_sha256": "0c1dbe10d257462dc62c383588286ed5d06c9d1228f8f9cae0ef2c6974ffc430",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
"b1_drain_to_shunt": [
{
"net": "MOTOR_B1",
"from": "Q11:9",
"to": "R116:1",
"grid_mm": 0.075,
"nodes": 27382,
"resistance_mohm_20c": 6.5046,
"voltage_drop_mv_at_5_5a": 35.775,
"loss_w_at_5_5a": 0.1968,
"source_nodes": 2928,
"destination_nodes": 368,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
},
{
"net": "MOTOR_B1",
"from": "Q11:9",
"to": "R116:1",
"grid_mm": 0.05,
"nodes": 61480,
"resistance_mohm_20c": 6.4825,
"voltage_drop_mv_at_5_5a": 35.654,
"loss_w_at_5_5a": 0.1961,
"source_nodes": 6552,
"destination_nodes": 840,
"components": 1,
"board_sha256": "4e53cf5210003b327a1b4cd49f3c5c81ff3a0f5f44277b71c384c29bc95a5cb3",
"method": "9-point DC sheet-conductance screening; 35 um copper at 20 C, 20 um via plating, 1.6 mm equally spaced stack",
"limitations": [
"Grid approximation; validate mesh convergence and native connectivity separately",
"Ideal terminal contacts; via contacts approximate, copper thickness and barrel plating are assumptions",
"Excludes connector/contact, shunt and transistor resistance, AC/PWM/proximity effects and temperature feedback",
"DC 5.5 A comparison is not a duty-cycle, temperature-rise or current-rating qualification"
]
}
],
"current_export_sha256": "b059d3dd1d28aa3dbef09236ad7fb8c88739d7c45fadea26e2b097caa814ae2c",
"mesh_convergence_percent": {
"MOTOR_A1": 0.2825557164553388,
"MOTOR_B1": 0.3409178557655227,
"MOTOR_A1_OUT": 0.4655985686402066,
"MOTOR_A2": 1.1410468474025197,
"MOTOR_B1_OUT": 0.5511529060081909,
"MOTOR_B2": 0.7681829033662354
}
}
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