Brief introduction:

The device is designed to achieve 750~1.2KW cluster charger fast charging output, and most of the same type of products on the market do not support fast charging or most do not support single-port fast charging. If you need to charge multiple devices that support fast charging at the same time, using traditional power sources in parallel will cause low charging efficiency, especially if the device itself supports fast charging, but the cluster power supply does not support fast charging. This equipment has a total of 18 output channels, 6 ports 120W + 12 ports 30W Type-c measured single port power 30W, effective output theoretical power 540W limit power 1.2KW.

Basic parameters:

Input power supply: 220V - 5A

Output power supply: 45W channel, measured power 30W, 5~12V (USB tester + electronic load testing)

The 120W channel actually measures 30W 5~12V (USB tester + electronic load testing, full power output requires the device to support maximum power fast charging)

No-load power consumption: 1.3W (18 units)

Minimum power consumption with load: 1.3W

Maximum power with load is 1.2KW

Fast charge protocol support: 45W port: Supports DCP protocol (Apple and BC1.2)

Support Qualcomm QC2.0, QC3.0 and QC3+

Support Huawei fast charging protocol FCP

Support Samsung fast charging protocol AFC (MAX 12V)

Support UFCS output fast charging protocol

Support Type-C output and USB PD2.0/PD3.0 (PPS) protocol

120W port: Supports PD3.1/PPS/EPR28V fast charging output via USB-C port

Integrate BC1.2 and APPLE protocols

Integrated QC2.0/QC3.0/QC3+/QC4+/QC5 output fast charging protocol

Integrated FCP and HSCP output fast charging protocol

Integrated AFC output fast charging protocol

Integrated MTK output fast charging protocol

Integrated UFCS output fast charging protocol

Open source license: CC-BY-NC-SA-4.0

Circuit system architecture diagram

Main control shunt board:

Main control scheme STC8H1K08 (QFN-20)

Voltage and current parameter sampling INA226 (ISO1540 data isolation)

120W unit board: IP6557. The units can be freely combined according to the actual needs.

Instructions for indicator lights: Each small board has a power indicator light, which lights up by default after power on. The fast charging indicator light is recognized as the fast charging mode when the power output voltage is >5V, and the fast charging indicator light is on. The fault indicator light is always on after the fuse is blown, indicating that the unit is damaged.
PCB:
Transfer shunt plate: Note that if high current is used, SMT bus tapeout must be attached to increase the circuit current carrying capacity. Do not use stacked solder instead of the bus tapeout.

Program logic diagram:

Main program logic:

Some experiences during debugging:

During the initial program testing of INA226, a problem was found: the sampling data only showed voltage but no current. The voltage data was normal, but the current data could not be measured. After further testing, it was found that INA226 must be re - initialized if it is powered off and then powered on again. Strangely enough, if it is not initialized, only the current cannot be measured, while the voltage measurement remains normal.

Unit display function (for OLED display)

The rest are all normal functions and subroutines

Housing, Assembly Model Description:

Preview Image

Internal structure perspective view

Heat sink punching

Material accessories:

https://item.taobao.com/item.htm?id=750586300583&pisk=gKZQOHgQCBAQpcoJF2XwfbNj2Zi5OOSV2LM8n8KeeDnKP3eUGY-rzwDWVfwAKX7l-7a_w50E9burVYNqsJ-PKJW5V8ex90zETYFaN5YUTulz_gw0G2-UeuJ3SSyvYk7n43inq0CVgiS4LJmo2hQEA7RnBvkR4vHpJDm9gX9FkiS4KR9EptyO0u8twRMHy3F-JV3tEfHpp0HdCVHqe0KKyHL96fct2HKKphIt3xAJwbFJ6hHohQL-90e9XvDo2YF-wVBsEfHK20HAfGMNUXwCLEenB1xHX-l623EsB_c4dttEhuHB_jwI1sUQAvOmMJh623hERW9UCJ5BmRo3BSM4TGKQG-qg1AFAV1iuszF-F5IDaD44to0_IZKTdDGtkxEOenhzAPyx1m9RvRiIOqEEli6YMRw8uVZNHimIvXUrx8JfTRZQTJq_ULLtADzslkiAmBhz7-ZSFuflfSw0j5MTMg1d4RtqGiB9Pj9BVAGVCOTkrHUU_bMcNbMqJADwgO66Oc3KIAGVCOTkr2HiQiB1CBiO.&spm=tbpc.boughtlist.suborder_itemtitle.1.77f52e8dgS34OB

Tao Baolink

Taobao link

Taobao Link

TaoBao Link

TaoBao link

Screws and nuts:

M2*10 X4 Countersunk Screws

M2*15 X22 countersunk head screw

M3*6 X4 Countersunk Screws

M2*5 hot melt countersunk hole nut X26

M3*6 hot melt countersunk hole nut X4

Testing and Assembly:

Fast charging test: protocol support

Decoy pressure test:

Finished product display:

Conclusion:

Circuit, program and modeling are all open source

Secondary development can freely combine units to achieve more ports and greater power