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Power system docs: Banggood order details #5

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jez merged 2 commits from case-design-doc into main 2026-06-03 20:30:21 +00:00
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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
- [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
@ -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
@ -79,11 +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.)
(Excludes case materials and misc hardware. SBC cost is actual after tax/shipping.)

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docs/case-design.md Normal file
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# 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 |

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docs/parts-list.md
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@ -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)
---

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docs/power-system.md
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# 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