Merge pull request 'Power system docs: Banggood order details' (#5) from case-design-doc into main
Reviewed-on: #5
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c6e629f908
4 changed files with 183 additions and 39 deletions
21
README.md
21
README.md
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@ -11,8 +11,8 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 3B SB
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- [x] Display identified — eDP controller board ordered ($35)
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- [x] SBC: Orange Pi 3B 8GB/256GB — purchased and delivered
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- [x] **SBC boot from eMMC — verified** (Orange Pi OS, 3-OS partition layout, multi-boot ready)
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- [ ] Display controller board — awaiting delivery (~2 weeks)
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- [ ] Power system — board selection and cell testing
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- [x] Display controller board — awaiting delivery (~2 weeks)
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- [x] Power system — Banggood board + cells + amp ordered Jun 3
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- [ ] Case fabrication
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- [ ] Full assembly and software configuration
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@ -55,6 +55,7 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 3B SB
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- [Design Decisions](docs/design-decisions.md) - Build approach, nomenclature, layout
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- [Power System](docs/power-system.md) - IP5389 battery management decision
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- [Port Layout](docs/port-layout.md) - External port placement and allocation
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- [Case Design](docs/case-design.md) - Dimensional constraints, component footprint, floorplan
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- [Initial Bring-up](docs/initial-bringup.md) - First boot and hardware validation
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## Quick Reference
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@ -79,11 +80,13 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 3B SB
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| Category | Cost |
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|----------|------|
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| SBC (w/ 256GB eMMC, WiFi+BT) | $189 |
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| Display controller | ~$24 |
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| Storage (hub + enclosure) | ~$30 |
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| Power system (board + cells + fuse + charger) | ~$44 |
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| HDMI switch + panel cables + SD reader | ~$33 |
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| **Subtotal** | **~$320** |
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|| SBC (w/ 256GB eMMC, WiFi+BT) | $189 |
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|| Display controller | ~$24 |
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|| Storage (hub + enclosure) | ~$30 |
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|| Power system (board + cells + holders + fuse) | ~$64 |
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|| PAM8403 audio amp | ~$4 |
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|| OPi 3B metal case + fan | ~$17 |
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|| HDMI switch + panel cables + SD reader | ~$33 |
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|| **Subtotal** | **~$361** |
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(Excludes case materials and misc hardware. $189 SBC cost is actual after tax/shipping.)
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(Excludes case materials and misc hardware. SBC cost is actual after tax/shipping.)
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125
docs/case-design.md
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125
docs/case-design.md
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@ -0,0 +1,125 @@
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# Case Design
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## Form Factor
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Briefcase clamshell:
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- **Canopy** — Salvaged K501U laptop lid (display, hinge, bezel). Opens upward, hinge at the bow edge.
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- **Base** — Wooden enclosure holding keyboard, SBC, power, and peripherals.
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User sits at the stern, facing the bow. See [design-decisions.md](design-decisions.md) for full nomenclature (deck/keel/bow/stern/port/starboard).
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## Dimensional Constraints
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### Canopy (Lid)
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| Dimension | Value | Source |
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|-----------|-------|--------|
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| Width | 39 cm | Measured, rounded up |
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| Height | 26 cm | Measured, rounded up |
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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.
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### Base External
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Tentative, with ~5mm per-side margin beyond the lid:
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| Dimension | Value | Notes |
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|-----------|-------|-------|
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| Width | 40 cm | Lid width + margins |
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| Depth | 27 cm | Lid depth + margins |
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| Height | TBD | Depends on component stacking |
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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.
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## Component Footprint Inventory
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Measured and estimated dimensions for everything that goes inside the base. These are 2D floorplan sizes (width × depth); height determines minimum internal clearance.
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| Component | W × D × H | Notes |
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|-----------|----------|-------|
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| TrackPoint keyboard | ~32 × 11 cm × ~1 cm | Depends on specific model, typical compact USB TrackPoint KB |
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| Orange Pi 3B | 8.5 × 5.6 cm × ~1.5 cm | With heatsink. Mount on standoffs |
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| Display controller (eDP→HDMI) | ~7 × 5 cm × ~1.5 cm | Generic board, may vary. Near hinge |
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| IP5389 power board | ~5 × 4 cm × ~0.5 cm | Thin PCB, mount near cell pack |
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| 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 |
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| USB hub PCB (decased, 10-port) | ~12 × 5 cm × ~1.5 cm | Estimate — depends on specific hub |
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| HDMI A/B switch (mechanical) | ~5 × 3 × 2 cm | Passive toggle. Near hinge |
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| PAM8403 audio amp | ~2.4 × 2.1 × 0.5 cm | Tiny, anywhere |
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| Speakers ×2 | ~3.1 × 7 cm × ~1.5 cm | Small drivers |
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| Cooling fan(s) | 4–8 cm square × ~1 cm | Size TBD based on thermal needs |
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| 5A fuse + holder | ~2 × 2 × 1 cm | Inline on power rail |
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## Floorplan Strategy
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The deck surface has two fixed-location items:
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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.
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2. **Hinge mount** — along the full bow edge, structural.
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Everything else floats between them. The major volume items:
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- **Battery pack (19.5 × 3.6 cm)** — longest rigid item other than the keyboard. Placement candidates:
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- Behind the keyboard (between keyboard rear and hinge area) — requires ~20 cm of unobstructed depth behind the keyboard
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- Along port or starboard side — uses the 4 cm gutter on one side
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- Under the keyboard — possible if keyboard is a flat membrane type, unlikely for a mechanical
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- **OPi 3B + USB hub** — moderate footprint, flexible placement. Could sit in the area behind the keyboard alongside the battery pack.
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- **Display controller + HDMI switch** — short HDMI cable runs dictate they live near the hinge.
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### Depth Dimensions (Front-to-Back)
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```
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Bow edge (back)
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│
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[hinge area — 2-3 cm]
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[display controller / HDMI switch]
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[battery pack and/or SBC/hub zone]
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[keyboard — 11 cm]
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[palm rest area — 5-8 cm]
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│
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Stern edge (front)
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```
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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.
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### Port-Starboard Layout (Width)
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```
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Port edge (left) Starboard edge (right)
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│ │
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[2 cm gutter] [keyboard ~32 cm] [2 cm gutter]
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```
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The gutters can hold the vertical battery pack, side-mounted ports, or switch cutouts.
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## Z-Stack (Depth/Layer Planning)
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**Goal: single-slice layout** — all boards and components mounted on the same plane (the keel), with nothing stacked above or below.
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Feasibility check:
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- Tallest component: speakers at ~1.5 cm, OPi with heatsink at ~1.5 cm, HDMI switch at ~2 cm
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- Battery pack at 1.85 cm
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- Leave ~5 mm clearance above tallest item → internal clearance of ~2.5 cm
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- Wood base walls at ~1 cm each → total case height ~4.5 cm
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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.
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## Open Questions
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- [ ] Exact TrackPoint keyboard model — dimensions and mounting method
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- [ ] Battery pack placement — behind keyboard vs side gutter
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- [ ] Fan size and placement — SBC heatsink fan vs case fan
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- [ ] Lid latch mechanism — holds canopy closed in transit
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- [ ] Hinge reattachment — how to mount K501U hinge to wooden base
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- [ ] Cable routing paths — power, HDMI, USB within the case
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- [ ] SD card reader location — stern edge per port layout
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- [ ] Kensington lock slot — stern edge
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- [ ] Wood thickness and joinery method
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## Revision History
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| Date | Change |
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|------|--------|
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| 2026-06-03 | Initial — dimensional constraints and floorplan approach |
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@ -31,16 +31,17 @@
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| Item | Specification | Source | Est. Cost | Status |
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|------|--------------|--------|-----------|--------|
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| IP5389 power board | USB-C PD, 3S, bare PCB | AliExpress | $8-15 | Board model TBD |
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| 18650 cells (x6) | 3S2P, matched, 2500-3500mAh | Shopping | $12-30 | To purchase |
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| 5A blade fuse + holder | Automotive | Amazon | $2 | To purchase |
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|| Banggood power board | QC3.0 3S-5S 65W-100W PD, bare PCB | Banggood (ID 1990904) | $14.39 | **Purchased** — 3S-65W variant |
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|| 18650 cells (x6) | 3S2P, matched | Banggood | $48.04 | **Purchased** |
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|| Cell holders (x8) | Single 18650 slot | Banggood | $7.99 | **Purchased** (6 + 2 spares) |
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|| 5A blade fuse + holder | Automotive | — | $2 | To purchase |
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### Audio
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| Item | Specification | Source | Est. Cost | Status |
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|------|--------------|--------|-----------|--------|
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| PAM8403 amp module | 3W+3W, 5V, Class D | Amazon | $3-5 | To purchase |
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| 4Ω 3W speakers (x2) | Small drivers, ~31×70mm | Amazon | $5-10 | To purchase |
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|| PAM8403 amp module | 3W+3W, 5V, Class D, single turn knob | Banggood | $3.59 | **Purchased** |
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|| 4Ω 3W speakers (x2) | Small drivers, ~31×70mm | — | $5-10 | To purchase |
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### Networking
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@ -71,29 +72,33 @@
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| Item | Cost | Status |
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|------|------|--------|
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| Orange Pi 3B 8GB + 256GB eMMC | $189 | **Purchased** |
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| Display controller | $24 | Ordered (may be optional) |
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| **Spent so far** | **$213** | |
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|| Orange Pi 3B 8GB + 256GB eMMC | $189 | **Purchased** |
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|| Display controller | $24 | Ordered (may be optional) |
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|| Power board (Banggood 3S-65W) | $14.39 | **Purchased** |
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|| 18650 cells (x6) + holders (x8) | $56.03 | **Purchased** |
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|| PAM8403 audio amp | $3.59 | **Purchased** |
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|| OPi 3B metal case + fan | $16.78 | **Purchased** |
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|| **Spent so far** | **$303.79** | |
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### Remaining to Purchase
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| Category | Cost |
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|----------|------|
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| Storage (USB enclosure) | ~$12 |
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| USB hub (powered 10-port) | ~$22 |
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| Power system (board+cells+fuse) | ~$32 |
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| Audio (PAM8403 amp + speakers) | ~$10 |
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| HDMI switch | ~$10 |
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| Panel-mount cables + SD reader | ~$23 |
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| **Remaining** | **~$110** |
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|| Storage (USB enclosure) | ~$12 |
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|| USB hub (powered 10-port) | ~$22 |
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|| Power (fuse + misc) | ~$2 |
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|| Speakers | ~$8 |
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|| HDMI switch | ~$10 |
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|| Panel-mount cables + SD reader | ~$23 |
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|| **Remaining** | **~$77** |
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### Total Project
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| | |
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|---|----|
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| Spent | $213 |
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| Remaining | ~$110 |
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| **Estimated total** | **~$323** |
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|| Spent | $303.79 |
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|| Remaining | ~$77 |
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|| **Estimated total** | **~$380** |
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---
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@ -101,21 +106,20 @@
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| Item | Date Ordered | Est. Arrival | Source | Tracking |
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|------|-------------|--------------|--------|----------|
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| Orange Pi 3B 8GB + 256GB eMMC | Before May 24 | Delivered | Amazon | — |
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| Display controller board | TBD | 2-4 weeks | Amazon/eBay | TBD |
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|| Orange Pi 3B 8GB + 256GB eMMC | Before May 24 | Delivered | Amazon | — |
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|| Display controller board | TBD | 2-4 weeks | Amazon/eBay | TBD |
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|| Banggood power board + cells + holders + amp + case + fan | Jun 3 | TBD | Banggood | TBD |
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## Pending Purchases
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- Powered USB hub (10-port USB 3.0)
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- USB enclosure or flash drive
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- IP5389 power board + 18650 cells
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- 5A fuse + holder
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- 4Ω 3W speakers (x2)
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- Mechanical HDMI A/B switch
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- Panel-mount cables (USB-A, USB-C, HDMI, Ethernet, audio)
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- Panel-mount SD card reader
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- Heatsink for RK3566
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- PAM8403 audio amp module
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- 4Ω 3W speakers (x2)
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---
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@ -1,8 +1,20 @@
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# Power System
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## Decision: IP5389 Power Bank Board (Preliminary)
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## Decision: Banggood QC3.0 3S Power Bank Module
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All-in-one power management PCB. Replaces separate charger module, BMS, and boost/buck converter with a single board.
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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).
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**Board:** ID 1990904, 3S-65W variant ($14.39)
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### Key Specs
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- 72×27×6mm board
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- USB-C1 (bi-dir PD input/output), USB-C2 (PD output), USB-A1, USB-A2
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- 65W max output with 3S pack
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- PD3.0/PD2.0, QC3+, QC3.0, AFC, FCP, SCP, VOOC
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- Digital tube battery indicator
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- Temperature protection
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- Passthrough charging (simultaneous charge + discharge)
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- 3S-65W (also available: 4S-100W, 5S-100W variants)
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## Why This Approach
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@ -106,10 +118,10 @@ K501U battery (B31N1429, 4240mAh, 11.4V, 3S) assessed and rejected:
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## TODO
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- [x] Cell configuration: 3S2P (6 cells, ~300g)
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- [ ] Select specific IP5389 board model with verified reviews
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- [ ] Source matched 18650 cells (Samsung 35E, LG MJ1, or equivalent)
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- [ ] Verify passthrough charging on selected board
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- [ ] Select PAM8403 audio amp module + small 4Ω speakers
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- [x] Select and order board — Banggood ID 1990904, 3S-65W
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- [x] Source matched 18650 cells — ordered via Banggood
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- [x] Select PAM8403 audio amp — ordered via Banggood
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- [ ] Verify passthrough charging on board once received
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- [ ] Select powered USB hub with 5V DC barrel input (not AC wall wart)
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- [ ] Order board + cells + amp + hub
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- [ ] Order 5A blade fuse + holder
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- [ ] Test charging and output before case integration
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