From bcf87252e2ca22d996c0401620de0b88055f34d7 Mon Sep 17 00:00:00 2001 From: BarnacleBoy Date: Wed, 3 Jun 2026 03:57:03 +0000 Subject: [PATCH 1/2] =?UTF-8?q?docs:=20case-design.md=20=E2=80=94=20dimens?= =?UTF-8?q?ional=20constraints,=20component=20inventory,=20floorplan?= MIME-Version: 1.0 Content-Type: text/plain; charset=UTF-8 Content-Transfer-Encoding: 8bit --- README.md | 1 + docs/case-design.md | 125 ++++++++++++++++++++++++++++++++++++++++++++ 2 files changed, 126 insertions(+) create mode 100644 docs/case-design.md diff --git a/README.md b/README.md index fec3ac7..dc0c743 100644 --- a/README.md +++ b/README.md @@ -55,6 +55,7 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 3B SB - [Design Decisions](docs/design-decisions.md) - Build approach, nomenclature, layout - [Power System](docs/power-system.md) - IP5389 battery management decision - [Port Layout](docs/port-layout.md) - External port placement and allocation +- [Case Design](docs/case-design.md) - Dimensional constraints, component footprint, floorplan - [Initial Bring-up](docs/initial-bringup.md) - First boot and hardware validation ## Quick Reference diff --git a/docs/case-design.md b/docs/case-design.md new file mode 100644 index 0000000..36e0f74 --- /dev/null +++ b/docs/case-design.md @@ -0,0 +1,125 @@ +# Case Design + +## Form Factor + +Briefcase clamshell: + +- **Canopy** — Salvaged K501U laptop lid (display, hinge, bezel). Opens upward, hinge at the bow edge. +- **Base** — Wooden enclosure holding keyboard, SBC, power, and peripherals. + +User sits at the stern, facing the bow. See [design-decisions.md](design-decisions.md) for full nomenclature (deck/keel/bow/stern/port/starboard). + +## Dimensional Constraints + +### Canopy (Lid) + +| Dimension | Value | Source | +|-----------|-------|--------| +| Width | 39 cm | Measured, rounded up | +| Height | 26 cm | Measured, rounded up | + +The lid dimension is the *outer* shell of the K501U display assembly (plastic casing + LCD panel + bezel). The glass panel itself is smaller — these are the hinge-to-edge and side-to-side mounting boundaries. + +### Base External + +Tentative, with ~5mm per-side margin beyond the lid: + +| Dimension | Value | Notes | +|-----------|-------|-------| +| Width | 40 cm | Lid width + margins | +| Depth | 27 cm | Lid depth + margins | +| Height | TBD | Depends on component stacking | + +Base height (internal depth of the wooden box) is the critical unknown. It depends on whether all internal components fit in a single Z-slice or require multiple layers. + +## Component Footprint Inventory + +Measured and estimated dimensions for everything that goes inside the base. These are 2D floorplan sizes (width × depth); height determines minimum internal clearance. + +| Component | W × D × H | Notes | +|-----------|----------|-------| +| TrackPoint keyboard | ~32 × 11 cm × ~1 cm | Depends on specific model, typical compact USB TrackPoint KB | +| Orange Pi 3B | 8.5 × 5.6 cm × ~1.5 cm | With heatsink. Mount on standoffs | +| Display controller (eDP→HDMI) | ~7 × 5 cm × ~1.5 cm | Generic board, may vary. Near hinge | +| IP5389 power board | ~5 × 4 cm × ~0.5 cm | Thin PCB, mount near cell pack | +| 18650 cells ×6 (3S2P) | 19.5 × 3.6 cm × 1.85 cm | Each cell 18×65mm. 3 cells end-to-end = 195mm, 2 cells side-by-side = 36mm | +| USB hub PCB (decased, 10-port) | ~12 × 5 cm × ~1.5 cm | Estimate — depends on specific hub | +| HDMI A/B switch (mechanical) | ~5 × 3 × 2 cm | Passive toggle. Near hinge | +| PAM8403 audio amp | ~2.4 × 2.1 × 0.5 cm | Tiny, anywhere | +| Speakers ×2 | ~3.1 × 7 cm × ~1.5 cm | Small drivers | +| Cooling fan(s) | 4–8 cm square × ~1 cm | Size TBD based on thermal needs | +| 5A fuse + holder | ~2 × 2 × 1 cm | Inline on power rail | + +## Floorplan Strategy + +The deck surface has two fixed-location items: + +1. **Keyboard** — centered, user-facing (stern edge). ~32 cm wide leaves ~4 cm per side within a 40 cm base width for misc ports or switches. +2. **Hinge mount** — along the full bow edge, structural. + +Everything else floats between them. The major volume items: + +- **Battery pack (19.5 × 3.6 cm)** — longest rigid item other than the keyboard. Placement candidates: + - Behind the keyboard (between keyboard rear and hinge area) — requires ~20 cm of unobstructed depth behind the keyboard + - Along port or starboard side — uses the 4 cm gutter on one side + - Under the keyboard — possible if keyboard is a flat membrane type, unlikely for a mechanical + +- **OPi 3B + USB hub** — moderate footprint, flexible placement. Could sit in the area behind the keyboard alongside the battery pack. + +- **Display controller + HDMI switch** — short HDMI cable runs dictate they live near the hinge. + +### Depth Dimensions (Front-to-Back) + +``` +Bow edge (back) +│ +[hinge area — 2-3 cm] +[display controller / HDMI switch] +[battery pack and/or SBC/hub zone] +[keyboard — 11 cm] +[palm rest area — 5-8 cm] +│ +Stern edge (front) +``` + +Total: roughly 18-22 cm front-to-back for keyboard + palm rest, plus 15-20 cm behind keyboard for electronics. That fits within a ~27 cm base depth with room to spare. + +### Port-Starboard Layout (Width) + +``` +Port edge (left) Starboard edge (right) +│ │ +[2 cm gutter] [keyboard ~32 cm] [2 cm gutter] +``` + +The gutters can hold the vertical battery pack, side-mounted ports, or switch cutouts. + +## Z-Stack (Depth/Layer Planning) + +**Goal: single-slice layout** — all boards and components mounted on the same plane (the keel), with nothing stacked above or below. + +Feasibility check: +- Tallest component: speakers at ~1.5 cm, OPi with heatsink at ~1.5 cm, HDMI switch at ~2 cm +- Battery pack at 1.85 cm +- Leave ~5 mm clearance above tallest item → internal clearance of ~2.5 cm +- Wood base walls at ~1 cm each → total case height ~4.5 cm + +This keeps the case within briefcase norms (~8-13 cm is the typical range, but thinner is fine) and avoids the weight and complexity of a second deck layer. + +## Open Questions + +- [ ] Exact TrackPoint keyboard model — dimensions and mounting method +- [ ] Battery pack placement — behind keyboard vs side gutter +- [ ] Fan size and placement — SBC heatsink fan vs case fan +- [ ] Lid latch mechanism — holds canopy closed in transit +- [ ] Hinge reattachment — how to mount K501U hinge to wooden base +- [ ] Cable routing paths — power, HDMI, USB within the case +- [ ] SD card reader location — stern edge per port layout +- [ ] Kensington lock slot — stern edge +- [ ] Wood thickness and joinery method + +## Revision History + +| Date | Change | +|------|--------| +| 2026-06-03 | Initial — dimensional constraints and floorplan approach | \ No newline at end of file From 5fde053bc336cf5dd23aecc32b729681571ffb59 Mon Sep 17 00:00:00 2001 From: BarnacleBoy Date: Wed, 3 Jun 2026 05:28:49 +0000 Subject: [PATCH 2/2] update parts and power system docs with Banggood order details (board, cells, holders, amp, case, fan) --- README.md | 20 ++++++++++-------- docs/parts-list.md | 50 ++++++++++++++++++++++++-------------------- docs/power-system.md | 26 ++++++++++++++++------- 3 files changed, 57 insertions(+), 39 deletions(-) diff --git a/README.md b/README.md index dc0c743..2cedd7c 100644 --- a/README.md +++ b/README.md @@ -11,8 +11,8 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 3B SB - [x] Display identified — eDP controller board ordered ($35) - [x] SBC: Orange Pi 3B 8GB/256GB — purchased and delivered - [x] **SBC boot from eMMC — verified** (Orange Pi OS, 3-OS partition layout, multi-boot ready) -- [ ] Display controller board — awaiting delivery (~2 weeks) -- [ ] Power system — board selection and cell testing +- [x] Display controller board — awaiting delivery (~2 weeks) +- [x] Power system — Banggood board + cells + amp ordered Jun 3 - [ ] Case fabrication - [ ] Full assembly and software configuration @@ -80,11 +80,13 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 3B SB | Category | Cost | |----------|------| -| SBC (w/ 256GB eMMC, WiFi+BT) | $189 | -| Display controller | ~$24 | -| Storage (hub + enclosure) | ~$30 | -| Power system (board + cells + fuse + charger) | ~$44 | -| HDMI switch + panel cables + SD reader | ~$33 | -| **Subtotal** | **~$320** | +|| SBC (w/ 256GB eMMC, WiFi+BT) | $189 | +|| Display controller | ~$24 | +|| Storage (hub + enclosure) | ~$30 | +|| Power system (board + cells + holders + fuse) | ~$64 | +|| PAM8403 audio amp | ~$4 | +|| OPi 3B metal case + fan | ~$17 | +|| HDMI switch + panel cables + SD reader | ~$33 | +|| **Subtotal** | **~$361** | -(Excludes case materials and misc hardware. $189 SBC cost is actual after tax/shipping.) \ No newline at end of file +(Excludes case materials and misc hardware. SBC cost is actual after tax/shipping.) \ No newline at end of file diff --git a/docs/parts-list.md b/docs/parts-list.md index 96a5e51..d85d191 100644 --- a/docs/parts-list.md +++ b/docs/parts-list.md @@ -31,16 +31,17 @@ | Item | Specification | Source | Est. Cost | Status | |------|--------------|--------|-----------|--------| -| IP5389 power board | USB-C PD, 3S, bare PCB | AliExpress | $8-15 | Board model TBD | -| 18650 cells (x6) | 3S2P, matched, 2500-3500mAh | Shopping | $12-30 | To purchase | -| 5A blade fuse + holder | Automotive | Amazon | $2 | To purchase | +|| Banggood power board | QC3.0 3S-5S 65W-100W PD, bare PCB | Banggood (ID 1990904) | $14.39 | **Purchased** — 3S-65W variant | +|| 18650 cells (x6) | 3S2P, matched | Banggood | $48.04 | **Purchased** | +|| Cell holders (x8) | Single 18650 slot | Banggood | $7.99 | **Purchased** (6 + 2 spares) | +|| 5A blade fuse + holder | Automotive | — | $2 | To purchase | ### Audio | Item | Specification | Source | Est. Cost | Status | |------|--------------|--------|-----------|--------| -| PAM8403 amp module | 3W+3W, 5V, Class D | Amazon | $3-5 | To purchase | -| 4Ω 3W speakers (x2) | Small drivers, ~31×70mm | Amazon | $5-10 | To purchase | +|| PAM8403 amp module | 3W+3W, 5V, Class D, single turn knob | Banggood | $3.59 | **Purchased** | +|| 4Ω 3W speakers (x2) | Small drivers, ~31×70mm | — | $5-10 | To purchase | ### Networking @@ -71,29 +72,33 @@ | Item | Cost | Status | |------|------|--------| -| Orange Pi 3B 8GB + 256GB eMMC | $189 | **Purchased** | -| Display controller | $24 | Ordered (may be optional) | -| **Spent so far** | **$213** | | +|| Orange Pi 3B 8GB + 256GB eMMC | $189 | **Purchased** | +|| Display controller | $24 | Ordered (may be optional) | +|| Power board (Banggood 3S-65W) | $14.39 | **Purchased** | +|| 18650 cells (x6) + holders (x8) | $56.03 | **Purchased** | +|| PAM8403 audio amp | $3.59 | **Purchased** | +|| OPi 3B metal case + fan | $16.78 | **Purchased** | +|| **Spent so far** | **$303.79** | | ### Remaining to Purchase | Category | Cost | |----------|------| -| Storage (USB enclosure) | ~$12 | -| USB hub (powered 10-port) | ~$22 | -| Power system (board+cells+fuse) | ~$32 | -| Audio (PAM8403 amp + speakers) | ~$10 | -| HDMI switch | ~$10 | -| Panel-mount cables + SD reader | ~$23 | -| **Remaining** | **~$110** | +|| Storage (USB enclosure) | ~$12 | +|| USB hub (powered 10-port) | ~$22 | +|| Power (fuse + misc) | ~$2 | +|| Speakers | ~$8 | +|| HDMI switch | ~$10 | +|| Panel-mount cables + SD reader | ~$23 | +|| **Remaining** | **~$77** | ### Total Project | | | |---|----| -| Spent | $213 | -| Remaining | ~$110 | -| **Estimated total** | **~$323** | +|| Spent | $303.79 | +|| Remaining | ~$77 | +|| **Estimated total** | **~$380** | --- @@ -101,21 +106,20 @@ | Item | Date Ordered | Est. Arrival | Source | Tracking | |------|-------------|--------------|--------|----------| -| Orange Pi 3B 8GB + 256GB eMMC | Before May 24 | Delivered | Amazon | — | -| Display controller board | TBD | 2-4 weeks | Amazon/eBay | TBD | +|| Orange Pi 3B 8GB + 256GB eMMC | Before May 24 | Delivered | Amazon | — | +|| Display controller board | TBD | 2-4 weeks | Amazon/eBay | TBD | +|| Banggood power board + cells + holders + amp + case + fan | Jun 3 | TBD | Banggood | TBD | ## Pending Purchases - Powered USB hub (10-port USB 3.0) - USB enclosure or flash drive -- IP5389 power board + 18650 cells - 5A fuse + holder +- 4Ω 3W speakers (x2) - Mechanical HDMI A/B switch - Panel-mount cables (USB-A, USB-C, HDMI, Ethernet, audio) - Panel-mount SD card reader - Heatsink for RK3566 -- PAM8403 audio amp module -- 4Ω 3W speakers (x2) --- diff --git a/docs/power-system.md b/docs/power-system.md index f7bd5c2..b09f31d 100644 --- a/docs/power-system.md +++ b/docs/power-system.md @@ -1,8 +1,20 @@ # Power System -## Decision: IP5389 Power Bank Board (Preliminary) +## Decision: Banggood QC3.0 3S Power Bank Module -All-in-one power management PCB. Replaces separate charger module, BMS, and boost/buck converter with a single board. +All-in-one power management PCB ordered from Banggood. Replaces separate charger module, BMS, and boost/buck converter with a single board. Uses Injoinic IP5389-family chip (likely IP5389H variant based on feature set: bi-dir PD, 3S-5S, digital display, 65-100W). + +**Board:** ID 1990904, 3S-65W variant ($14.39) + +### Key Specs +- 72×27×6mm board +- USB-C1 (bi-dir PD input/output), USB-C2 (PD output), USB-A1, USB-A2 +- 65W max output with 3S pack +- PD3.0/PD2.0, QC3+, QC3.0, AFC, FCP, SCP, VOOC +- Digital tube battery indicator +- Temperature protection +- Passthrough charging (simultaneous charge + discharge) +- 3S-65W (also available: 4S-100W, 5S-100W variants) ## Why This Approach @@ -106,10 +118,10 @@ K501U battery (B31N1429, 4240mAh, 11.4V, 3S) assessed and rejected: ## TODO - [x] Cell configuration: 3S2P (6 cells, ~300g) -- [ ] Select specific IP5389 board model with verified reviews -- [ ] Source matched 18650 cells (Samsung 35E, LG MJ1, or equivalent) -- [ ] Verify passthrough charging on selected board -- [ ] Select PAM8403 audio amp module + small 4Ω speakers +- [x] Select and order board — Banggood ID 1990904, 3S-65W +- [x] Source matched 18650 cells — ordered via Banggood +- [x] Select PAM8403 audio amp — ordered via Banggood +- [ ] Verify passthrough charging on board once received - [ ] Select powered USB hub with 5V DC barrel input (not AC wall wart) -- [ ] Order board + cells + amp + hub +- [ ] Order 5A blade fuse + holder - [ ] Test charging and output before case integration