Mechanical Power Module Design Spec - thepinkmile/Enigma-NG GitHub Wiki

Power Module Mechanical Design Specification

Status: Draft Project: Enigma-NG Author: Izzyonstage & GitHub Copilot Version: v1.0.0 Associated Hardware Revision: Rev A Last Updated: 2026-04-20

1. Form Factor

  • Geometry: Dedicated rectangular Power Module PCB mounted in the chassis base and docked to the Controller via the 3-way TE board-to-board connector cluster (J1/J2/J3).
  • Mounting: 4x M3 plated mounting holes bonded to chassis ground.
  • Role: Houses the system power-entry, source-selection, supercap UPS, and 3V3_ENIG generation functions; it is not a CM5 carrier board.

2. Connectivity

  • Controller Interconnect: TE 1123684-7 dock headers on the Power Module mate with the Controller Board 1-1674231-1 receptacles. J1 carries the regulated rails, J2 carries the Controller-fed VIN_POE_12V auxiliary feed, and J3 carries low-speed control / telemetry.
  • External I/O: USB-C receptacle (power only), 5-pin Molex Micro-Fit battery connector, rugged panel-mount SW1 power toggle with RGB ring LED, and separate SW2 CM5 power button. The Ethernet / PoE RJ45 entry is Controller-owned, not Power-Module-owned.
  • Service Access: External connectors and switch/button harness terminations must remain accessible from the enclosure perimeter without removing the Controller Board.

3. Thermal Management & Electrical Bonding

  • High-current area: The eFuse, dual buck regulators, OR-ing FETs, and supercap manager require copper area and via stitching per the electrical design and board layout documents.
  • Airflow: Provide free air volume above the supercap bank and the main power stage; avoid placing enclosure ribs or brackets directly over the hottest power components.
  • Chassis Bond: Mounting holes provide the primary chassis-ground bond and mechanical retention.

4. Component Clearances

  • Supercap keep-out: Reserve vertical clearance for the 8-cell 2S4P supercap block and its assembly tolerances.
  • Connector keep-out: Maintain cable bend and mating clearance around USB-C, battery connector, and the SW1/SW2 harness entry points, plus the J1/J2/J3 dock insertion volume.
  • Docked-board clearance: Preserve the TE dock mating volume and keep components clear of the J1/J2/J3 insertion / extraction envelope.

5. Assembly Guidance

  • Order of assembly: Fit the Power Module to the chassis before engaging the Controller Board onto the TE dock cluster.
  • Harnessing: Route battery, SW1, and SW2 harnesses away from the dock connectors and the supercap block to avoid service interference.
  • Cross-check: Final enclosure dimensions and exact keep-outs must remain aligned with design/Electronics/Power_Module/Board_Layout.md.

6. Cross-References

Document Description
design/Electronics/Power_Module/Design_Spec.md Electrical design specification