HaxonWorks USB-C Module

The Challenge

Develop a module that connects to the battery module previously made and offers USB-C ports to charge numerous electronics over the USB standard at a relatively high charging rate.

Solution

• PCB Design: Sourced a 4-port USB-C PCB with 24V input, featuring two 100W bidirectional ports and two 65W unidirectional ports • Enclosure Design: Created a two-part housing for PCB, thermal pads, and interconnect in a compact form factor • Module Interface: Implemented precise 0.2mm tolerance for secure, stable connection with battery module • Mechanical Assembly: Temporary prototype assembly using basic screws, planned upgrade to threaded inserts with M2/M3 screws

Outcome

The product works, though the display of the sourced PCB failed after continous handling. Also, one of the IC's on the PCB failed causing one of the bidirectional ports to have limited charge functionality.Other customers of the PCB I sourced expressed similar problems so for future project development I will either source from a more reputable vendor or develop the PCB in-house.

Technologies Used

• SolidWorks for Mechanical Design
• 3D Modeling and Assembly
• 3D Printing for Rapid Prototyping
• Integrated Safety Systems

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