Analog Power Monitoring PCB

Featured Project

A 2-layer KiCad board and simulation workflow for protected DC input monitoring, analog front-end scaling, and robust MCU ADC reconstruction.

Designed a 2-layer KiCad power monitoring PCB that accepts an external DC supply, protects the input, and converts voltage/current into MCU-readable ADC signals.
Implemented a 5 A fused input path with TVS protection, a 10 mOhm shunt resistor, and wide power routing for current flow from input to output.
Built separate sensing paths for voltage measurement using a 56 kOhm / 10 kOhm divider and current measurement using shunt-based sensing with analog conditioning.
Integrated MCU/debug headers, RC filtering, decoupling capacitors, top/bottom copper routing, and GND planes; completed ERC/DRC cleanup with 0 electrical errors and 0 unconnected items.

Modeled 861 operating points across 0-20 V and 0-5 A, producing transfer curves, ADC response plots, and a power map for the full practical range.
Verified a voltage divider ratio of 0.1515 V/V, allowing input voltage measurement up to 21.78 V before a 3.3 V ADC saturates.
Verified current-sense scaling of 0.5 V/A, with a theoretical ADC limit of 6.6 A and a practical fuse-limited range of 5 A.
Simulated a 0-100 W operating envelope with 12-bit ADC reconstruction errors of approximately 0.0086% voltage, 0.0255% current, and 0.0273% power.

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