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Charger

Open-source distributed USB-C charging system for FPV battery packs, part of the incutec OpenDrone line. Two boards share one charge, sense and balance core built around the TI BQ25758 buck-boost charge controller: the Charger node (hardware/), a headless 2-6S charging node, and the Manager (hardware-manager/), a 2-8S hub with display and encoder UI. Designed in KiCad (Charger node in KiCad 10 format, Manager in KiCad 9) for JLCPCB assembly.

Specifications, block-by-block part choices, power tree and cell sense/balance detail: hardware/docs/DESIGN.md.

Status

Prototype pending. Neither board has been fabricated. The Charger node has a schematic and a PCB with footprints placed but nothing routed; the Manager is schematic only. Both boards currently fail the schematic review and are not ready for fabrication. Defect list, layout state and readiness verdict: hardware/docs/SCHEMATIC_REVIEW.md.

Repository layout

Path Contents
hardware/ Charger node KiCad 10 project: schematics, PCB, libs/ (libraries)
hardware/docs/ Design documentation (DESIGN.md, SCHEMATIC_REVIEW.md)
hardware-manager/ Manager KiCad 9 project: schematics, libs/ (no PCB yet)
libs/KiCad-Library Shared Incutec symbol/footprint/3D library (git submodule)

datasheets/ directories are gitignored; datasheets are fetched on demand and do not ship with the repo.

Design entry points

  • Charger node root schematic: hardware/Charger.kicad_sch (main sheet hardware/main.kicad_sch plus 6 instances of hardware/cell.kicad_sch)
  • Charger node board: hardware/Charger.kicad_pcb (footprints placed, no outline, unrouted)
  • Manager root schematic: hardware-manager/Manager.kicad_sch (main sheet hardware-manager/main.kicad_sch plus 8 instances of hardware-manager/cell.kicad_sch)

Which symbol and footprint libraries the projects use: DESIGN.md, Libraries.

Build and export

git clone --recursive https://github.com/OpenDrone-hw/Charger.git

Open hardware/Charger.kicad_pro or hardware-manager/Manager.kicad_pro in KiCad 10. Production exports (gerbers, BOM, CPL) are generated with the KiCad Fabrication Toolkit plugin; none exist yet. Headless checks use kicad-cli:

kicad-cli sch erc --exit-code-violations hardware/Charger.kicad_sch
kicad-cli sch erc --exit-code-violations hardware-manager/Manager.kicad_sch
kicad-cli pcb drc --exit-code-violations hardware/Charger.kicad_pcb

The pcb drc run is not a meaningful check yet: the Charger node board has no outline and no routing, so it passes without proving anything.

Manufacturing

Target fab is JLCPCB assembly with LCSC parts, exported with the Fabrication Toolkit into hardware/production/ (gitignored). No production exports have been generated and nothing has been fabricated.

Contributing

See CONTRIBUTING.md.

License

Hardware licensed under CERN-OHL-S-2.0. See LICENSE. Not USB-IF certified; intended for DIY and open-source use.

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OpenDrone LiPo charger, work in progress

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