diff --git a/README.md b/README.md index 257f4bd..fa5b96f 100644 --- a/README.md +++ b/README.md @@ -13,8 +13,10 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 5 SBC - [x] USB expansion design - [x] Case nomenclature and orientation defined - [x] Build approach: wooden case + salvaged lid canopy +- [x] Input device: ThinkPad TrackPoint keyboard +- [x] Power system: IP5389 board + 18650 cells (preliminary) - [ ] Case design (dimensions, internal layout) -- [ ] Power system (battery, charging) +- [ ] Power system board selection and testing - [ ] Bow wall design (power input, fan exhaust) - [ ] Fabrication - [ ] Software configuration @@ -54,6 +56,7 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 5 SBC - [USB Expansion](docs/usb-expansion.md) - Hub selection and port allocation - [Parts List](docs/parts-list.md) - Bill of materials with costs - [Design Decisions](docs/design-decisions.md) - Build approach, nomenclature, layout +- [Power System](docs/power-system.md) - IP5389 battery management decision ## Quick Reference @@ -69,7 +72,7 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 5 SBC - **Board:** Orange Pi 5 (RK3588S, base model, 16GB RAM) - **Storage:** MicroSD slot + USB 3.0 external - **USB:** 1× USB 3.0, 2× USB 2.0 native -- **Power:** 12V 2A barrel or USB-C PD +- **Power:** USB-C PD via IP5389 power board, 18650 cells ### Cost Estimate @@ -77,8 +80,8 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 5 SBC |----------|------| | SBC | ~$104 | | Display controller | ~$24 | -| Storage (SD + hub + enclosure) | ~$35-50 | -| Power supply | ~$10 | -| **Subtotal** | **$170-190** | +| Storage (SD + hub + enclosure) | ~$32-44 | +| Power system (board + cells + fuse + charger) | ~$32-56 | +| **Subtotal** | **$206-230** | -(Excludes case materials, battery, misc hardware) \ No newline at end of file +(Excludes case materials and misc hardware. Battery included in power system.) \ No newline at end of file diff --git a/docs/design-decisions.md b/docs/design-decisions.md index 6d480d3..4cbf9b7 100644 --- a/docs/design-decisions.md +++ b/docs/design-decisions.md @@ -36,6 +36,14 @@ User sits at the **stern**, facing the **bow**. Hinge axis runs port-to-starboar ### Bow Wall Functions -- Power input (barrel jack or USB-C PD) +- Power input (USB-C for IP5389 board charging) - Exhaust fans blowing away from user - Heat management surface + +## Power System + +IP5389 power bank board (preliminary). All-in-one: charging, BMS, USB-C PD output. See [power-system.md](power-system.md) for details. + +## Input Device + +ThinkPad TrackPoint keyboard (specific model TBD based on availability). Chosen for built-in TrackPoint pointer and 15.6" deck space compatibility. diff --git a/docs/parts-list.md b/docs/parts-list.md index bdd9792..abb55d3 100644 --- a/docs/parts-list.md +++ b/docs/parts-list.md @@ -32,8 +32,10 @@ | Item | Specification | Source | Est. Cost | Status | |------|--------------|--------|-----------|--------| -| Power supply | USB-C PD or 12V 2A | Amazon | $8-12 | To purchase | -| (Future) Battery | 10,000-20,000 mAh PD | TBD | $20-40 | Future | +| IP5389 power board | USB-C PD, 3S, bare PCB | AliExpress | $8-15 | Preliminary selection | +| 18650 cells | 3S or 3S2P, quality brand | User's pick | $12-24 | To purchase | +| 5A blade fuse + holder | Automotive | Amazon | $2 | To purchase | +| USB-C wall charger | 45W+ PD, for charging | Amazon | $10-15 | To purchase | ### Networking @@ -62,24 +64,24 @@ | MicroSD | $12 | | USB hub | $20 | | USB enclosure | $12 | -| Power supply | $10 | +| Power system (board+cells+fuse+charger) | $32-56 | | WiFi dongle | $12 | -| **Subtotal** | **$194** | +| **Subtotal** | **$206-230** | ### With Optional Items | Category | Cost | |----------|------| -| Base build | $194 | +| Base build | $206-230 | | Heatsink/cooling | $10 | | Panel-mount cables | $15 | -| **Total** | **$219** | +| **Total** | **$231-255** | ### Future Additions | Category | Cost | |----------|------| -| Battery pack (portable) | $20-40 | +| Battery pack (portable) | Integrated in base build | | Case materials | TBD | | Custom PCB | TBD | @@ -96,7 +98,9 @@ - MicroSD card - Powered USB hub - USB enclosure or flash drive -- Power supply +- IP5389 power board + 18650 cells +- 5A fuse + holder +- USB-C PD wall charger (45W+) - WiFi dongle --- diff --git a/docs/power-system.md b/docs/power-system.md new file mode 100644 index 0000000..9710a4f --- /dev/null +++ b/docs/power-system.md @@ -0,0 +1,79 @@ +# Power System + +## Decision: IP5389 Power Bank Board (Preliminary) + +All-in-one power management PCB. Replaces separate charger module, BMS, and boost/buck converter with a single board. + +## Why This Approach + +| Requirement | IP5389 Solution | +|------------|-----------------| +| Charge lithium cells safely | Built-in CC/CV with cell balancing | +| Battery protection | Overcharge, overdischarge, short circuit, thermal | +| Output usable voltage | USB-C PD (5V, 9V, 12V, 15V, 20V) | +| Wall power input | USB-C input from any charger | +| Charge while using | Passthrough charging | +| Repairable | Bare PCB, cells are replaceable 18650s | + +## How It Works + +``` +USB-C wall charger → IP5389 board → 18650 cells (3S or 3S2P) + ↓ (passthrough) + USB-C PD output → OPi5 (5V) + peripherals +``` + +One board, one cell pack, one output cable to the SBC. No separate modules to wire together. + +## Key Specs (varies by specific board) + +- Cell config: 3S–6S (most common: 3S or 4S) +- Output: 45W–100W USB-C PD +- Input: USB-C (bidirectional port) +- Protection: overcharge, overdischarge, short circuit, thermal +- Price: $8–15 bare PCB + +## Cell Configuration + +TBD — need to select specific board first. Likely 3S (3 cells in series) or 3S2P (6 cells, pairs in series). 3S2P with quality 3000mAh cells gives ~6000mAh at 11.1V nominal. + +## Salvaged Battery: Not Usable + +K501U battery (B31N1429, 4240mAh, 11.4V, 3S) assessed and rejected: +- Integrated BMS is paired to the laptop mainboard +- Most laptop BMS boards lock when removed from their system +- Not worth the effort to hack around +- Low capacity (4240mAh) doesn't justify the risk + +## Alternative Approaches Considered + +### Discrete Module Stack (TP5100 + 2S BMS + Buck Converter) +- Three separate modules, more wiring +- TP5100 charger (2S, 2A) + 2S 10A BMS + 5V/4A buck converter +- ~$10 in modules, works well but more complex assembly +- Backup plan if IP5389 board has issues + +### Commercial Power Bank (decased) +- Buy a power bank, remove plastic shell, integrate bare PCB + cells +- Zero design work but constrained to whatever cell layout the bank uses +- Passthrough charging not guaranteed on all models + +### UPS HAT (Waveshare / DFRobot) +- Designed for Raspberry Pi, works via USB output with OPi5 +- Premium price for unused GPIO header +- Capped at 5V output, no 12V rail without extra boost converter + +## Safety Notes + +- Always use 18650 cells with matching capacity and age in parallel pairs +- Fuse between board output and SBC (5A automotive blade fuse recommended) +- No puffy, warm-at-rest, or sub-2.5V cells — ever +- Match cell count to board specs (3S board = exactly 3S, don't mix) + +## TODO + +- [ ] Select specific IP5389 board model with verified reviews +- [ ] Confirm cell count (3S vs 3S2P) +- [ ] Verify passthrough charging on selected board +- [ ] Order board + cells +- [ ] Test charging and output before case integration