diff --git a/Small-Build.md b/Small-Build.md new file mode 100644 index 0000000..1bf9fb6 --- /dev/null +++ b/Small-Build.md @@ -0,0 +1,47 @@ +# BikeAudio — Small Build (the buildable v1 target) + +The focused, buildable unit. Beast (6/12 broadcasters) is deferred — this drops +all the hard scaling parts. See [Hardware Design v0.1] for the full picture and +the detailed [Power and Battery] / [Carrier PCB and BOM] / [Stack Connector and +Addressing] / [LED and Music Sync] pages. + +## Config +**5 boards:** 1 HUD + 1 SINK + **3 BROADCASTERS** (channels: Headset, Speaker 1, Guest). +- SINK: iPhone A2DP in -> I2S master. +- 3 BROADCASTERS: I2S -> A2DP to each speaker (I2C 0x11 / 0x10 / 0x12). +- HUD: ESP32-S3 round LCD, control over I2C. +All audio boards = ESP32-WROOM-32E (one carrier PCB, SINK vs BROADCASTER assembly). + +## Runtime target: ~8 h (start) +Load ~2.9 W @ 5 V (5 boards). At ~61% usable derate, 8 h needs ~38 Wh nameplate. + +**Battery: 2S2P 18650 (4 cells, ~50.4 Wh)** -> ~10 h with margin (comfortably clears 8 h). +- ~225 g of cells; compact. (Upgrade path to 2S3P/6 cells later for >12 h with no design change.) +- Charger: TI **BQ25887** (2S, I2C, balancing, ~2 A) over USB-C 5 V — fine at this pack size (no USB-PD needed for the small build). +- Reg: single **TPS563201 (3 A)** buck to the 5 V bus. NTC on pack -> charger (JEITA). Reverse-polarity P-FET + TVS + fuse; soft-latch power switch. + +## What the small build SIMPLIFIES (vs beast) +- **No backplane, no I2C mux** — a single vertical 5-board stack on the 26-pin 2.54 mm pass-through connector. +- **I2S:** one buffer at the SINK (e.g. 74LVC125) + 22-33 R series term, fanning to just **3** broadcaster inputs — short, easy. +- **I2C:** 100 kHz, a single **2.2-4.7 kOhm** pull-up pair on the SINK. ~5 nodes -> well under the cap budget. +- **Addressing:** **4-bit solder straps** (GPIO13/14/27/26) — only 3 broadcasters, so no auto-enumeration needed. Headset=0x11, Speaker1=0x10, Guest=0x12. +- **Power:** single 2S buck + a basic 2 A USB-C charger; no PD, no high-current multi-phase. + +## Small-build BOM (rough) +| Block | Parts | ~$ | +|---|---|---| +| 4x carrier PCB (1 sink + 3 bcast) | WROOM-32E + connectors + passives, ~$7 ea | ~28 | +| HUD | ESP32-S3-Touch-LCD-1.28 | ~15 | +| Battery | 4x INR18650-35E + 2S2P holder/weld | ~35 | +| Power electronics | BQ25887 + TPS563201 + USB-C + BMS + fuse/TVS/switch | ~20 | +| Misc | I2S buffer (74LVC125), stacking connectors, standoffs, enclosure | ~15 | +| **Total (excl. speakers)** | | **~$113** | + +## Wiring (single stack) +- **I2S:** SINK GPIO5/25/23 (BCK/WS/DATA) -> buffer -> bus -> each broadcaster GPIO19/18/22. Common GND. +- **I2C:** HUD GPIO15/16 + each board GPIO32/33 on the shared bus; one pull-up pair at the SINK. +- **Power:** 2S pack -> buck -> 5 V bus up the stack; each board's onboard LDO makes 3V3. +- **Antenna:** still mind WROOM antenna keep-out / orientation even at 4 boards (overhang + rotate). Lower risk than beast but real. + +## Next engineering step +Hand this + the detailed pages to a **KiCad layout** of the single carrier PCB (45x45 mm, 4-layer, antenna keep-out), then fab 4 + assemble. LEDs (APA102) are an optional later add per [LED and Music Sync].