PCB Design with ESP32 and LiFePO₄ Backup

This project involves designing a robust, production-ready PCB integrating an ESP32 module with a wide input power range of 5V to 60V and a single-cell LiFePO₄ battery-based UPS system, intended for reliable operation in electrically noisy and vibration-prone environments. The power architecture must prioritize external DC input as the primary source, seamlessly switch to battery backup without reboot and support USB Type-C as a programming/debugging-only power source without any conflict or backfeeding between sources. The design should include comprehensive protection mechanisms such as reverse polarity protection (preferably MOSFET-based), surge and transient protection (TVS), and fuse/PTC safety. Efficient power conversion is required using a buck converter for stepping down to 5V followed by low-noise regulation to 3.3V for the ESP32. The LiFePO₄ charging system must use a dedicated charger IC with appropriate voltage and current settings along with full battery protection features. The ESP32 section should follow best practices including proper decoupling, reset and boot circuitry, and strict antenna layout guidelines with no copper or ground under the antenna region. The board must include an internal USB Type-C interface with a USB-to-UART bridge and auto-programming capability, ensuring reliable firmware flashing and debugging. User interface elements include a high-loudness buzzer (≥85–95 dB) driven via a transistor or MOSFET, a single high-brightness RGB LED visible through the enclosure, an externally accessible power button aligned with the enclosure, and an internally accessible reset button for recovery and programming. Additionally, a reserved, electrically clean expansion area must be provided with access to 3.3V, ground and multiple GPIOs, ensuring no interference from high-current or switching circuits. The PCB should preferably be a 4-layer design with a solid ground plane, proper segregation of power, MCU, and expansion sections, and EMI-conscious routing practices such as minimizing loop areas and ensuring clean return paths. Mechanical considerations include a compact rectangular form factor, four mounting holes, and edge-aligned connectors and indicators for enclosure integration. The final design must emphasize robustness, safety, thermal reliability, and use of widely available components, delivering complete KiCad design files, BOM, Gerbers, and documentation suitable for production use.

ID do Projeto: 40315963