Advanced H-bridge encoder board

Bidirectional 12 V brushed-DC motor driver with quadrature-encoder inputs, VNH5019A-E current sensing and a separate hardware overcurrent-cutoff path. The retained v31 study is rejected and must not be treated as a working motor controller.

Development status

Baseline documentation snapshot: 2026-10-11, before the requested connector/protection/usability revision program. New revision features require their own reviewed source and qualification evidence.

This page documents an unqualified engineering study, not a released or tested product. Saved CAD, renders and automated checks do not establish a safe assembly, compatible cable, firmware support or a usable current rating.

The retained design record states:

The latest retained study is v31, with its independent review. Fresh KiCad9.0.8 ERC, enabled geometry DRC and schematic/contract parity are zero; 76 inherited opens, four drill-to-land contacts and five ignored rule categories remain. All132 physical/engineering checklist rows are unsigned.

Board-specific qualification limits: v31 remains rejected:76 inherited opens/four drill contacts/five ignored rule categories; all132 checklist items unsigned; no fabrication/physical qualification.

Interfaces and wiring

The exact connector orientation, pin mapping and supply ownership must be taken from the selected revision’s schematic and connection specification. Do not infer wiring from the connector shape.

Power off before connecting or changing jumpers. Verify pin 1, signal direction, supply voltage and ground at both ends of every cable. A mechanically fitting connector is not proof of electrical compatibility. If a host pin mapping or current allocation remains unresolved in the design record, do not connect the board until it is resolved.

Configuration and commissioning

Use the configuration and firmware contract for the exact selected revision. Do not copy another module’s socket assignments or assume that an unused pin is available. First-article work must verify source selection, reset/unplug behavior, cable orientation and the actual load or sensor interface before normal operation.

Requested connector and usability upgrades

The following are requirements for the next design iterations; this page does not claim they are already fitted:

  • On electrically suitable three/four-pin low-voltage ports, provide compact alternative 2.54 mm header/Molex-style and keyed STEMMA-family footprints. Populate one connector option per shared position and document its pin order. Use STEMMA QT only for compatible four-wire I²C; connector appearance does not make another signal protocol I²C-compatible.
  • Render each supported connector population separately. Document clearances, cable access and the exact fitted option.
  • Use uppercase titles in a consistent Montserrat-style face, labels on both sides, visible domain boundaries, a revision-specific wiring guide and this page’s URL on the silk where readable.
  • Keep mounting-hole centers on a documented 10 mm lattice; add cable-tie holes where space and electrical clearances permit. Place status LEDs near accessible edges and give every indicator its own disable solder jumper. Provide labeled test pads and a ground observation point.
  • Review applicable DC power entries for reverse-polarity cutoff with a blinking warning, overvoltage cutoff/indication, controlled startup and electronic overcurrent protection. Indicator and protection circuits must work in the fault state without defeating isolation or safe output defaults. Thermal protection belongs only where the power/thermal analysis justifies it.
  • Electronic protection does not automatically replace a required mains/branch safety fuse. Backfeed blocking and inductive-load flyback clamps are separate design functions. Do not add identity EEPROMs, fault memory, calibration storage or paid self-test hardware under this upgrade program.

Design sources

Documentation route: smoothieware.org/extensions/advanced-h-bridge-encoder-board.

Additive design studies

The 2026-10-11 upgrade program has saved additional candidates v32, v33, v34. These studies preserve the historical design described above. Their connector, LED, mechanical and protection changes are revision-specific and remain unqualified.

See the per-board changes, failures and remaining work and mandatory family specification. Use the source hash and native check for the exact candidate being reviewed; do not infer hardware ratings from a rendered population.

Upgrade candidate readback

The three additional revisions are v32, v33, v34. They are engineering studies; saved CAD and renders do not release the hardware. The latest candidate is described below. Older baseline notes above remain historical.

advanced-h-bridge

  • Latest PCB source, SHA-256 3f95c16f9bd9d217bfe1239c777e524edf4bf9d0294c95f7b44312b1fecce490.
  • Last native check: 21 errors, including 21 open connections. This is a CAD result, not electrical, assembly or firmware qualification.
  • No alternative connector population is recorded for this physical role. Any applicable connector conversion remains an explicit design-review item.
  • normal population/render record: 6 images; source current; image hashes match; 2 unresolved models.
  • Changes, failed trials and remaining work.

Applicable protection, current-path, thermal, pinout, cable access and physical tests remain open wherever the linked board record has not verified them. A zero native-error count does not close those gates.

Current visualization package — v38, 2026-10-13

The parent-authorized recovery associates QF4/QF5 with retained exact donor model bytes and changes only their model filenames. All circuitry, footprint/paste/pad/copper/drill/mounting geometry, model rotations/scales/offsets and rules remain unchanged. Current PCB SHA-256: a4ff8563f8b3738deba7514c09e950e378e7bd49ba0200ca085a75705b9fbbc0. Current source-bound review supersedes pre-recovery renders and exports, preserved as historical provenance.

Fresh checks report zero enabled errors, opens and parity errors, 13 DRC warnings and 1 ERC warnings, identical to the pre-model-change source. All 120 model declarations resolve; six normal-population views plus a supplemental backside isometric view were inspected and 19 source-bound exports verified. The recovered bodies’ visible seating and terminal orientation are consistent with retained placements, including the servo-output zero-degree QF5 placement.

Visualization only: the exact donor has up to 0.025 mm isolated-terminal Y-centre displacement from centered 1.27 mm basic pitch. Exact drawing fidelity and physical fit are not claimed. The rendering package is complete; fabrication release, current/load/thermal/host/system safety and physical assembly qualification remain withheld. Inherited silk/library warnings remain.

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