add physical case for USB hub

.gitmodules

@@ -1,3 +1,3 @@
 [submodule "library"]
 	path = library
-	url = http://git.cuvoodoo.info/qeda_library
+	url = https://git.cuvoodoo.info/kingkevin/qeda_library

.qeda.yaml

@@ -4,6 +4,35 @@ config:
     densityLevel: 'N'
     lineWidth:
       silkscreen: 0.2
+    polarityMark: none
     preferManufacturer: false
     smoothPadCorners: false
 library:
+  - connector/barrel_dc-005-2.0
+  - ic/eeprom_ft24c16a-e@p
+  - mechanical/switch_hroppart_ss12f44g5
+  - vreg/buck_xl2596@to263-5l
+  - connector/usb-a-2.0-receptacle_c42678
+  - connector/usb-b-2.0-receptacle_c46392
+  - vreg/fuse_1206sfh
+  - resistor/r0603
+  - capacitor/c0603
+  - transistor/pmos_40p05
+  - transistor/nmos_bss138
+  - diode/schottky_rb521s
+  - diode/schottky_ss34
+  - inductor/slh@1207
+  - vreg/ldo_torex_xc6206@mr
+  - ic/usbhub_microchip_usb2517
+  - diode/tvs_st_usblc6-2@sc6
+  - diode/led0805
+  - capacitor/cap_radial_10mm
+  - capacitor/cap_radial_6.3mm
+  - capacitor/cap_radial_5mm
+  - connector/header-2.54@2x3
+  - oscillator/x3225
+  - vreg/current-limit_mt9700
+  - connector/header-2.54@1x6
+  - vreg/current-limit_sy6288
+  - vreg/current-limit_tj2242
+  - vreg/current-limit_dio755x

CHANGELOG.md

@@ -0,0 +1,45 @@
+v2
+==
+
+this has major fixes for version 1:
+
+- missing crystal resistor
+- 3.3V dip using larger capacitor
+- 6-40V feedback
+- DFP over-current
+
+v1
+==
+
+this is a complete re- board layout.
+it does not fit an off-the selves enclosure anymore.
+all SMD parts are on one side to allow easier SMT assembly.
+
+fixes:
+
+- 6-40V power input activated when UFP is connected
+- use current limit on DFP (prevents USB to reset when DFP is shorted)
+- 6-40V power input capacitor now lays down
+- remove copper plane under crystal to prevent impedance error
+
+errors:
+
+- crystal still does not start
+- none of the two possible OCS inputs (Dx04 XOR Dx05) work
+- power dip causes reset when enabling all 7 DFP power outputs at once
+
+v0
+==
+
+this version has been designed to fit in a 100x60x25mm enclosure.
+this makes it very compact, and not all surface mount parts fit on one side.
+this is not too much of an issue since it's a hand soldered prototype.
+
+the prototype mostly works, with a couple of small errors:
+
+- 6-40V power input is not activated unless the hub is already powered (through USB or 5V input)
+- crystal oscillator doesn't always start. I think the underlying copper plane skewed the impedance/capacitance too much
+- USB-A footprint has inverted pinout: just solder it on the other side and don't swap the data pins in the EEPROM configuration
+- fuse on downstream port is not fast enough to prevent shorts and causes the hub to reset
+- 6-40V power input capacitor is too tall and does not fit in the case
+- one of the LEDS on port 3 is misplaced

DEVELOPMENT.md

@@ -0,0 +1,96 @@
+this will describe how to generate the output files form the sources.
+
+requirements
+============
+
+to be able to generate the outputs you need following software:
+
+- rake: the central script taking care of generating the output files (Makefile is too cumbersome to parse files)
+- [QEDA](http://qeda.org/): to generate footprints for the parts
+- [Lepton EDA](https://github.com/lepton-eda/lepton-eda): for the schematic capture
+- [pcb-rnd](http://repo.hu/projects/pcb-rnd/): for the board layout
+the output generation is automatized.
+
+compiling
+=========
+
+library
+-------
+
+almost all of the symbols and footprints used in the schematic and board layout are defined in the [QEDA](http://qeda.org/) format and generated for the CAD software.
+the `library` folder contains the QEDA parts definitions.
+
+to install QEDA using NPM from the official repository:
+~~~
+sudo npm install -g qeda
+~~~
+
+to install QEDA from the sources:
+~~~
+git clone https://github.com/qeda/qeda
+cd qeda
+npm install
+sudo npm install --global
+~~~
+
+to generate the parts:
+~~~
+rake library
+~~~
+
+this will use the parts definition (.yaml files) in the `library` to generate [gEDA gschem](http://wiki.geda-project.org/geda:gaf)/[Lepton EDA](https://github.com/lepton-eda/lepton-eda) symbols (.sym files) in the `geda/symbols` folder, and [coralEDA pcb-rnd](http://repo.hu/projects/pcb-rnd/) footprints (.lht files) in the `coraleda/subc` folder.
+
+only the QEDA parts in subfolders within `library` come from the [QEDA library](https://doc.qeda.org/library/), but the files are included in this project for simplicity and archiving purposes.
+all other parts are custom and written for this project.
+
+schematic
+---------
+
+the `.sch` file is the schematic source file.
+it has been drawn using [Lepton EDA](https://github.com/lepton-eda/lepton-eda).
+
+it uses standard symbols, and the ones in the `geda/symbols/` folder.
+most symbols are generated by QEDA as described above.
+
+to export as pdf:
+~~~
+rake print
+~~~
+
+BOM
+---
+
+to export the bill of material (as CSV):
+~~~
+rake bom
+~~~
+
+board
+-----
+
+the `.lht` file is the board layout source file.
+it has been drawn using  [coralEDA pcb-rnd](http://repo.hu/projects/pcb-rnd/).
+
+it uses the symbols from the `coraleda/subc/` folder.
+most symbols are generated by QEDA as described above.
+`oshw_logo.lht` is just the Open Source Hardware Logo.
+it been generated from https://oshwlogo.cuvoodoo.info/.
+
+to export gerber files for PCB manufacturer (and photo preview + overview document):
+~~~
+rake fabrication
+~~~
+
+flashing
+========
+
+the USB hub gets its configuration from an external EEPROM.
+running `eeprom.rb` will generate the EEPROM configuration in `eeprom.bin`.
+this must then be flashed on the board EEPROM.
+it is possible to flash it in circuit using the corresponding header, and by holding the RST signal low to prevent the USB hub from interfering with the communication.
+
+to flash it using [minipro](https://gitlab.com/DavidGriffith/minipro/):
+
+~~~
+minipro --device "AT24C16@SOIC8" --write eeprom.bin -s
+~~~

README.md

@@ -1,88 +1,169 @@
-these are the hardware design files for **insert project name here**.
+the CuVoodoo USB hub is a 7-port USB 2.0 hub meant for device testing.
 
 purpose
 =======
 
+most USB hubs are super cheap and crappy, leading to poor connection and data transfer.
+there are industrial USB hubs, but they are bulky and very expensive.
+to solve this issue I decided to design my own USB hub, tailored to my needs.
+
+when developing and testing hardware, you often end with a lot of USB devices connected (serial debugger, programmer, logic analyzer, ...).
+USB allows to have up to 128 devices, but only with a maximum depth of 7.
+thus you are only allowed to have a maximum of 5 USB hubs between computer and devices, and I often have to plan my setup to not reach this limit.
+most 7-port USB hubs use two 4-port USB hub, the seconds being connected to the first.
+there are some exceptions to that, but they are rare, old, and often not advertised as such.
+this heavily limits the actual number of end devices.
+the CuVoodoo USB hub is a 7-port flat USB hub, preventing reaching this limit too fast.
+
+the upstream and downstream USB ports are individually ESD protected.
+this safety becomes important when developing, testing, and handling bare electronic devices.
+this also comes in handy when connecting circuit with different ground potentials.
+ESD protections already saved my day twice this way.
+the issue is that they can blow without you noticing, but at least they protected the device once.
+
+each output port is current limited to 500 mA.
+no USB 2.0 device should draw more that this specified limit.
+it if does, there is very probably an issue with the device.
+this protection allows to isolate the faulty device and not have it affect all other connected devices, or the hub itself.
+see `current limitation` below for more details.
+
+each downstream port is power controlled.
+this allows to remotely switch on and off individual devices.
+this is an important requirement when developing and testing devices, which require a power cycle.
+additionally, a switch next to the USB port can force the power off state.
+
+the USB hub can be self-powered (through the USB input port), externally powered by 5V, or externally powered by anything between 6 and 40V.
+this allows to use higher voltage power supplies to provide enough current to all ports.
+the 5V are not feed back to the host.
+
+each USB port comes with a high voltage output power port, connected to the high voltage input port.
+this allows to power devices which require more than 5V, with a maximum or 5A, such as 12V externally powered devices.
+these power outputs are controllable along the USB port.
+as with the 5V USB power output, this allows to remotely switch on an off individual devices.
+
+each port has status LEDs, indicating the speed and power status of the connected device.
+
+the board uses proper impedance and differential signal routing to provide clean USB signals.
+
+design choice
+=============
+
+USB 2.0
+-------
+
+this hub is only for USB 2.0 devices.
+these are by far most of the devices I develop.
+it makes it simpler and keeps the cost reasonable.
+I often even disable USB 3.0 because of the 13-device limitation of the Intel xHCI.
+when I need USB 3.0 for the very few devices, I connected them to the computer directly.
+
+USB2517
+-------
+
+I wanted to use the FE2.1 7-port USB hub chip.
+it does not need an external voltage regulator or crystal.
+it is easier to solder thanks to its TQFP package, and provides all required functionalities.
+sadly I could not find a source for the 64-pin packages, and the 48-pin variant does not provide all required functionalities.
+thus I had to fall back to the Microchip USB2517, which uses a harder to solder QFN package.
+
+power control
+-------------
+
+some USB hub chips allow to remotely control the power output on individual ports.
+this capability is here also used to control the power on the higher voltage output.
+thus you can completely power off even larger target devices.
+
+current limitation
+------------------
+
+the USB hub has current limitation on the output.
+this does limit the current to 500 mA, but only in constant current mode.
+following current limiters have been tested:
+
+- 0.5A PPTC fuse: it takes too long to trigger (> 1s), and switch off is not reliably detected
+- MT9700: it has no over-current signal
+- SY6288AAAC: the (fixed) current limit is not 0.6A, but around 1.5A
+- TJ2242GSF6: over-current is only detected after 3s (instead of specified 100us, probably caused by thermal shutdown), and it is not signaled
+- DIO7553ST6: works as expected and wished
+
+the power distribution switch detects the over-current state and asserts the fault flag after 10 ms.
+after 0.1 ms (as set in OC_TIMER, in Configuration Data Byte 2, in EEPROM) the hub will switch off power.
+this also clears the over-current state.
+after 100 ms the HUB will re-enable power.
+this loop will repeat indefinitely.
+no over-current is reported to the host in this case (when the over-current is cleared while power is off).
+it is only reported when the OCS is asserted for longer (unknown time, with OCS kept low also when powered off).
+this is a flaw of the USB2517, where the over-current is only reported if it can't control the power state.
+I did not find a configuration option for this aspect in the datasheet.
+
+LED color
+---------
+
+the USB specification, LEDs are used as port indicator (section 11.5.3)
+
+- off: powered off/disconnected
+- amber: current limitation reached
+- green: enabled or transmitting
+
+instead the following color scheme is used:
+
+- green off: power off or over-current
+- green on: power on
+- red: low speed device connected
+- blue: full speed device connected
+- purple (red+blue): high speed device connected
+- red and blue off: disconnected or in sleep
+
+power output
+------------
+
+switching the power of the USB port also switches the 6-40V forward output.
+when the 6-40V input is not connected, current/voltage feedback from the outputs is blocked.
+
 usage
 =====
 
-requirements
-============
+it mainly works like a regular USB hub, at least when it comes to the data transfer.
+just plug the device in a port.
 
-to be able to generate the outputs you need following software:
+power on the Downstream Facing Ports (DFPs) is only available when the Upstream Facing Port (UFP) is connected.
 
-- rake: the central script taking care of generating the output files (Makefile is too cumbersome to parse files)
-- [QEDA](http://qeda.org/): to generate footprints for the parts
-- [Lepton EDA](https://github.com/lepton-eda/lepton-eda): for the schematic capture
-- [pcb-rnd](http://repo.hu/projects/pcb-rnd/): for the board layout
-the output generation is automatized.
+the hub can operate as bus powered (power coming from the UFP), but it would not be able to provide more than 500 mA across all DFPs.
+it is preferable to connect an external 5V power supply to be able to provide 500 mA on all DFPs.
+this will also turn the hub into self powered, not using any power from the UFP.
+alternatively, you can connect a 6 to 40V power supply on the other power input.
+the power for the hub and the 5V for the DFP will be derivate from this higher voltage supply.
+the same higher voltage will be available on the power output next to the individual DFPs.
+the hub will not switch on until the UFP USB port is connected.
 
-compiling
-=========
+a switch next to each DFP allows to turn off the power output on the USB and power ports.
+the green LED is on when power output is available.
 
-library
--------
+the power output on the USB and power ports can also be turned on/off remotely using standard USB commands.
+this power output control is implemented in [uhubctl](https://github.com/mvp/uhubctl):
 
-almost all of the symbols and footprints used in the schematic and board layout are defined in the [QEDA](http://qeda.org/) format and generated for the CAD software.
-the `library` folder contains the QEDA parts definitions.
-
-to install QEDA using NPM from the official repository:
 ~~~
-sudo npm install -g qeda
+# list controllable USB hub ports
+sudo uhubctl
+# switch of port
+uhubctl --action off --location 1-1.4 --ports 5
 ~~~
 
-to install QEDA from the sources:
+EEPROM
+======
+
+the USB2517 USB hub chip gets its configuration from an EEPROM.
+to generate the configuration:
+
 ~~~
-git clone https://github.com/qeda/qeda
-cd qeda
-npm install
-sudo npm install --global
+ruby eeprom.rb
 ~~~
 
-to generate the parts:
+this will create the `eeprom.bin` binary file.
+feel free to adjust the configuration in the generating script, such as the serial number.
+
+after having soldered all the parts on the board, connect a programmer (here a MiniPRO TL866xx) on the J4 pin header to write the AT24C02 EEPROM:
+
 ~~~
-rake library
-~~~
-
-this will use the parts definition (.yaml files) in the `library` to generate [gEDA gschem](http://wiki.geda-project.org/geda:gaf)/[Lepton EDA](https://github.com/lepton-eda/lepton-eda) symbols (.sym files) in the `geda/symbols` folder, and [coralEDA pcb-rnd](http://repo.hu/projects/pcb-rnd/) footprints (.lht files) in the `coraleda/subc` folder.
-
-only the QEDA parts in subfolders within `library` come from the [QEDA library](https://doc.qeda.org/library/), but the files are included in this project for simplicity and archiving purposes.
-all other parts are custom and written for this project.
-
-schematic
----------
-
-the `.sch` file is the schematic source file.
-it has been drawn using [Lepton EDA](https://github.com/lepton-eda/lepton-eda).
-
-it uses standard symbols, and the ones in the `geda/symbols/` folder.
-most symbols are generated by QEDA as described above.
-
-to export as pdf:
-~~~
-rake print
-~~~
-
-BOM
----
-
-to export the bill of material (as CSV):
-~~~
-rake bom
-~~~
-
-board
------
-
-the `.lht` file is the board layout source file.
-it has been drawn using  [coralEDA pcb-rnd](http://repo.hu/projects/pcb-rnd/).
-
-it uses the symbols from the `coraleda/subc/` folder.
-most symbols are generated by QEDA as described above.
-`oshw_logo.lht` is just the Open Source Hardware Logo.
-it been generated from https://oshwlogo.cuvoodoo.info/.
-
-to export gerber files for PCB manufacturer (and photo preview + overview document):
-~~~
-rake fabrication
+minipro --device "AT24C02@SOIC8" --write eeprom.bin -s
 ~~~

Rakefile

@@ -14,7 +14,9 @@ require 'csv' # to export BOM and costs
 # =================
 
 # common name used for file names
-name = "template"
+name = "usb_hub"
+# additional schematic sheets
+sheets = ["usb_hub-dfp1", "usb_hub-dfp2", "usb_hub-dfp3", "usb_hub-dfp4", "usb_hub-dfp5", "usb_hub-dfp6", "usb_hub-dfp7"]
 # project version, read from "version" file
 raise "define project version in 'version' file" unless File.exist? "version"
 version = IO.read("version").split("\n")[0]
@@ -37,8 +39,12 @@ task :default => [:print, :fabrication, :bom, :pnp]
 
 desc "print schematic and layout (as pdf)"
 prints = [ "#{name}.sch.pdf", "#{name}.brd.pdf", "#{name}.brd-top.svg", "#{name}.brd-bottom.svg" ]
+unless sheets.empty? then
+  prints += sheets.collect{|sheet| "#{sheet}.sch.pdf"}
+  prints << "#{name}.sch-all.pdf"
+end
 task :print => prints
-CLEAN.include([ "#{name}.versioned.sch", "#{name}.versioned.lht" ])
+CLEAN.include([ "#{name}.versioned.sch", "#{name}.versioned.lht" ] + sheets.collect{|sheet| "#{sheet}.versioned.sch"})
 CLOBBER.include(prints)
 
 desc "generate fabrication gerbers (as archive)"
@@ -89,7 +95,12 @@ end
 
 desc "generate printable version (PDF) of schematic"
 rule ".sch.pdf" => ".versioned.sch" do |t|
-  sh "lepton-cli export --color --paper iso_a4 --layout landscape --output #{t.name} #{t.source} 2> /dev/null"
+  sh "lepton-cli export --color --paper=iso_a4 --layout=landscape --output=#{t.name} #{t.source} 2> /dev/null"
+end
+
+desc "generate grouped printable version (PDF) of schematic"
+rule ".sch-all.pdf" => ["#{name}.sch.pdf"] + sheets.collect{|sheet| "#{sheet}.sch.pdf"} do |t|
+  sh "mutool merge -o #{t.name} " + t.prerequisites * " "
 end
 
 desc "generate printable version (PostScript) of board layout"
@@ -123,9 +134,9 @@ end
 desc "generate BOM file from schematic"
 rule ".bom.csv" => ".sch" do |t|
   attributes = ["device", "value", "description", "footprint", "manufacturer", "mpn", "datasheet", "lcsc", "digikey"]
-  bom_data = bom2(t.prerequisites[0],attributes)
+  bom_data = bom2(t.prerequisites[0], attributes)
   CSV.open(t.name, "wb") do |csv|
-    all_attributes = ["refdes","qty"]+attributes
+    all_attributes = ["refdes","qty"] + attributes
     csv << all_attributes
     bom_data.each do |line|
       csv << all_attributes.collect{|attribute| line[attribute]}
@@ -165,6 +176,10 @@ def bom2(schematic, attributes)
   list.gsub!(/(?!http):(?!\/\/)/, '\1":"\2') # protect the values between ':' (such as URLs)
   # parse bom2
   csv = CSV.parse(list, col_sep: ":", quote_char: '"')
+  if csv.empty? then
+    $stderr.puts "no parts found for BOM"
+    return []
+  end
   csv[1..-1].each do |row|
     line = {}
     row.each_index do |col|

case/case_bottom_3d-print.scad

@@ -0,0 +1,187 @@
+$fn=30;
+
+BOARD_WIDTH=96.5;
+BOARD_HEIGHT=96.0;
+BOARD_THICKNESS=1.6;
+HOLE_NW_X=4.0;
+HOLE_NW_Y=4.0;
+HOLE_NE_X=92.5;
+HOLE_NE_Y=4.0;
+HOLE_SW_X=4.0;
+HOLE_SW_Y=92.0;
+HOLE_SE_X=92.5;
+HOLE_SE_Y=92.0;
+
+WALL_SPACE=1.0;
+WALL_THICKNESS=2.0;
+HOLE_HEIGHT=15.0; // USB A is 14.5
+
+module pillar() {
+  translate([0,0,HOLE_HEIGHT/2]) {
+    difference() {
+      cylinder(h=HOLE_HEIGHT, d=6, center=true);
+      cylinder(h=HOLE_HEIGHT, d=3.5, center=true);
+    }
+  }
+}
+
+mirror([1,0,0]) { // we used bottom view
+
+// bottom plate
+cube([BOARD_WIDTH+2*WALL_SPACE+2*WALL_THICKNESS, BOARD_HEIGHT+2*WALL_SPACE+2*WALL_THICKNESS, WALL_THICKNESS]);
+
+// screw mounts
+translate([WALL_THICKNESS+WALL_SPACE+HOLE_NW_X,WALL_THICKNESS+WALL_SPACE+HOLE_NW_Y,WALL_THICKNESS]) {
+  pillar();
+}
+translate([WALL_THICKNESS+WALL_SPACE+HOLE_NE_X,WALL_THICKNESS+WALL_SPACE+HOLE_NE_Y,WALL_THICKNESS]) {
+  pillar();
+}
+translate([WALL_THICKNESS+WALL_SPACE+HOLE_SW_X,WALL_THICKNESS+WALL_SPACE+HOLE_SW_Y,WALL_THICKNESS]) {
+  pillar();
+}
+translate([WALL_THICKNESS+WALL_SPACE+HOLE_SE_X,WALL_THICKNESS+WALL_SPACE+HOLE_SE_Y,WALL_THICKNESS]) {
+  pillar();
+}
+
+// side
+MARGIN=1.0;
+USB_B_WIDTH=12.0+MARGIN;
+USB_B_HEIGHT=11.0+MARGIN;
+USB_A_WIDTH=7.0+MARGIN;
+USB_A_HEIGHT=14.5+MARGIN;
+BARREL_WIDTH=9.0+MARGIN;
+BARREL_HEIGHT=11.3+MARGIN;
+INDUCTOR_HEIGHT=7.5;
+
+// side north
+difference() {
+  cube([BOARD_WIDTH+2*WALL_SPACE+2*WALL_THICKNESS, WALL_THICKNESS, WALL_THICKNESS+HOLE_HEIGHT+BOARD_THICKNESS+INDUCTOR_HEIGHT]);
+  // DFP 7 USB A
+  translate([WALL_THICKNESS+WALL_SPACE+12.5-USB_A_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-USB_A_HEIGHT]) {
+    cube([USB_A_WIDTH,WALL_THICKNESS,USB_A_HEIGHT]);
+  }
+  // DFP 7 BARREL
+  translate([WALL_THICKNESS+WALL_SPACE+28-BARREL_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+    cube([BARREL_WIDTH,WALL_THICKNESS,BARREL_HEIGHT]);
+  }
+  // DFP 6 USB A
+  translate([WALL_THICKNESS+WALL_SPACE+40.5-USB_A_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-USB_A_HEIGHT]) {
+    cube([USB_A_WIDTH,WALL_THICKNESS,USB_A_HEIGHT]);
+  }
+  // DFP 6 BARREL
+  translate([WALL_THICKNESS+WALL_SPACE+56-BARREL_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+    cube([BARREL_WIDTH,WALL_THICKNESS,BARREL_HEIGHT]);
+  }
+  // DFP 5 USB A
+  translate([WALL_THICKNESS+WALL_SPACE+68.5-USB_A_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-USB_A_HEIGHT]) {
+    cube([USB_A_WIDTH,WALL_THICKNESS,USB_A_HEIGHT]);
+  }
+  // DFP 5 BARREL
+  translate([WALL_THICKNESS+WALL_SPACE+84-BARREL_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+    cube([BARREL_WIDTH,WALL_THICKNESS,BARREL_HEIGHT]);
+  }
+}
+
+// side west
+difference() {
+  cube([WALL_THICKNESS, BOARD_HEIGHT+2*WALL_SPACE+2*WALL_THICKNESS, WALL_THICKNESS+HOLE_HEIGHT+BOARD_THICKNESS+INDUCTOR_HEIGHT]);
+  // USB B
+  translate([0,WALL_THICKNESS+WALL_SPACE+48-USB_B_WIDTH/2,WALL_THICKNESS+HOLE_HEIGHT-USB_B_HEIGHT]) {
+    cube([WALL_THICKNESS,USB_B_WIDTH,USB_B_HEIGHT]);
+  }
+  // 5V BARREL
+  translate([0,WALL_THICKNESS+WALL_SPACE+33-BARREL_WIDTH/2,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+    cube([WALL_THICKNESS,BARREL_WIDTH,BARREL_HEIGHT]);
+  }
+  // 12V BARREL
+  translate([0,WALL_THICKNESS+WALL_SPACE+63-BARREL_WIDTH/2,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+    cube([WALL_THICKNESS,BARREL_WIDTH,BARREL_HEIGHT]);
+  }
+}
+
+// side south
+translate([0,BOARD_HEIGHT+WALL_THICKNESS+2*WALL_SPACE,0]) {
+  difference() {
+    cube([BOARD_WIDTH+2*WALL_SPACE+2*WALL_THICKNESS, WALL_THICKNESS, WALL_THICKNESS+HOLE_HEIGHT+BOARD_THICKNESS+INDUCTOR_HEIGHT]);
+    // DFP 1 USB A
+    translate([WALL_THICKNESS+WALL_SPACE+27.5-USB_A_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-USB_A_HEIGHT]) {
+      cube([USB_A_WIDTH,WALL_THICKNESS,USB_A_HEIGHT]);
+  }
+    // DFP 1 BARREL
+    translate([WALL_THICKNESS+WALL_SPACE+12-BARREL_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+      cube([BARREL_WIDTH,WALL_THICKNESS,BARREL_HEIGHT]);
+    }
+    // DFP 2 USB A
+    translate([WALL_THICKNESS+WALL_SPACE+55.5-USB_A_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-USB_A_HEIGHT]) {
+      cube([USB_A_WIDTH,WALL_THICKNESS,USB_A_HEIGHT]);
+    }
+    // DFP 2 BARREL
+    translate([WALL_THICKNESS+WALL_SPACE+40-BARREL_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+      cube([BARREL_WIDTH,WALL_THICKNESS,BARREL_HEIGHT]);
+    }
+    // DFP 3 USB A
+    translate([WALL_THICKNESS+WALL_SPACE+83.5-USB_A_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-USB_A_HEIGHT]) {
+      cube([USB_A_WIDTH,WALL_THICKNESS,USB_A_HEIGHT]);
+    }
+    // DFP 3 BARREL
+    translate([WALL_THICKNESS+WALL_SPACE+68-BARREL_WIDTH/2,0,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+      cube([BARREL_WIDTH,WALL_THICKNESS,BARREL_HEIGHT]);
+    }
+  }
+}
+
+// side east
+translate([BOARD_WIDTH+WALL_THICKNESS+2*WALL_SPACE,0,0]) {
+  difference() {
+    cube([WALL_THICKNESS, BOARD_HEIGHT+2*WALL_SPACE+2*WALL_THICKNESS, WALL_THICKNESS+HOLE_HEIGHT+BOARD_THICKNESS+INDUCTOR_HEIGHT]);
+    // DFP 4 USB A
+    translate([0,WALL_THICKNESS+WALL_SPACE+40.5-USB_A_WIDTH/2,WALL_THICKNESS+HOLE_HEIGHT-USB_A_HEIGHT]) {
+      cube([WALL_THICKNESS,USB_A_WIDTH,USB_A_HEIGHT]);
+    }
+    // DFP 4 BARREL
+    translate([0,WALL_THICKNESS+WALL_SPACE+56-BARREL_WIDTH/2,WALL_THICKNESS+HOLE_HEIGHT-BARREL_HEIGHT]) {
+      cube([WALL_THICKNESS,BARREL_WIDTH,BARREL_HEIGHT]);
+    }
+  }
+}
+
+// top plate
+SWITCH_WIDTH=3.0+0.5;
+SWITCH_LENGTH=6.0+0.5;
+
+translate([0,0,WALL_THICKNESS+HOLE_HEIGHT+BOARD_THICKNESS+INDUCTOR_HEIGHT]) {
+  difference() {
+    cube([BOARD_WIDTH+2*WALL_SPACE+2*WALL_THICKNESS, BOARD_HEIGHT+2*WALL_SPACE+2*WALL_THICKNESS, WALL_THICKNESS]);
+    // DFP 7
+    translate([WALL_THICKNESS+WALL_SPACE+20.0, WALL_THICKNESS+WALL_SPACE+6.7,WALL_THICKNESS/2]) {
+      cube([SWITCH_WIDTH, SWITCH_LENGTH, WALL_THICKNESS], center=true);
+    }
+    // DFP 6
+    translate([WALL_THICKNESS+WALL_SPACE+48.0, WALL_THICKNESS+WALL_SPACE+6.7,WALL_THICKNESS/2]) {
+      cube([SWITCH_WIDTH, SWITCH_LENGTH, WALL_THICKNESS], center=true);
+    }
+    // DFP 5
+    translate([WALL_THICKNESS+WALL_SPACE+76.0, WALL_THICKNESS+WALL_SPACE+6.7,WALL_THICKNESS/2]) {
+      cube([SWITCH_WIDTH, SWITCH_LENGTH, WALL_THICKNESS], center=true);
+    }
+    // DFP 4
+    translate([WALL_THICKNESS+WALL_SPACE+89.7, WALL_THICKNESS+WALL_SPACE+48.0,WALL_THICKNESS/2]) {
+      cube([SWITCH_LENGTH, SWITCH_WIDTH, WALL_THICKNESS], center=true);
+    }
+    // DFP 3
+    translate([WALL_THICKNESS+WALL_SPACE+76.0, WALL_THICKNESS+WALL_SPACE+89.3,WALL_THICKNESS/2]) {
+      cube([SWITCH_WIDTH, SWITCH_LENGTH, WALL_THICKNESS], center=true);
+    }
+    // DFP 2
+    translate([WALL_THICKNESS+WALL_SPACE+48.0, WALL_THICKNESS+WALL_SPACE+89.3,WALL_THICKNESS/2]) {
+      cube([SWITCH_WIDTH, SWITCH_LENGTH, WALL_THICKNESS], center=true);
+    }
+    // DFP 1
+    translate([WALL_THICKNESS+WALL_SPACE+20.0, WALL_THICKNESS+WALL_SPACE+89.3,WALL_THICKNESS/2]) {
+      cube([SWITCH_WIDTH, SWITCH_LENGTH, WALL_THICKNESS], center=true);
+    }
+  }
+}
+
+}

case/case_top_laser-cut.svg

@@ -0,0 +1,45 @@
+<?xml version="1.0" encoding="UTF-8" standalone="no"?>
+<svg
+   width="103mm"
+   height="102mm"
+   viewBox="-103 -102 103 102"
+   version="1.1"
+   id="svg4172"
+   sodipodi:docname="top_plate.svg"
+   inkscape:version="1.2.1 (9c6d41e410, 2022-07-14, custom)"
+   xmlns:inkscape="http://www.inkscape.org/namespaces/inkscape"
+   xmlns:sodipodi="http://sodipodi.sourceforge.net/DTD/sodipodi-0.dtd"
+   xmlns="http://www.w3.org/2000/svg"
+   xmlns:svg="http://www.w3.org/2000/svg">
+  <defs
+     id="defs4176" />
+  <sodipodi:namedview
+     id="namedview4174"
+     pagecolor="#ffffff"
+     bordercolor="#666666"
+     borderopacity="1.0"
+     inkscape:showpageshadow="2"
+     inkscape:pageopacity="0.0"
+     inkscape:pagecheckerboard="0"
+     inkscape:deskcolor="#d1d1d1"
+     inkscape:document-units="mm"
+     showgrid="false"
+     inkscape:zoom="1.0246119"
+     inkscape:cx="362.08831"
+     inkscape:cy="323.04914"
+     inkscape:window-width="1916"
+     inkscape:window-height="1041"
+     inkscape:window-x="0"
+     inkscape:window-y="37"
+     inkscape:window-maximized="1"
+     inkscape:current-layer="svg4172" />
+  <title
+     id="title4168">OpenSCAD Model</title>
+  <path
+     d=" M 0,-102 L -102.5,-102 L -102.5,-0 L 0,-0 z M -24.75,-89.05 L -24.75,-95.55 L -21.25,-95.55 L -21.25,-89.05 z M -52.75,-89.05 L -52.75,-95.55 L -49.25,-95.55 L -49.25,-89.05 z M -80.75,-89.05 L -80.75,-95.55 L -77.25,-95.55 L -77.25,-89.05 z M -95.95,-49.25 L -95.95,-52.75 L -89.45,-52.75 L -89.45,-49.25 z M -24.75,-6.45 L -24.75,-12.95 L -21.25,-12.95 L -21.25,-6.45 z M -52.75,-6.45 L -52.75,-12.95 L -49.25,-12.95 L -49.25,-6.45 z M -80.75,-6.45 L -80.75,-12.95 L -77.25,-12.95 L -77.25,-6.45 z "
+     stroke="black"
+     fill="lightgray"
+     stroke-width="0.5"
+     id="path4170"
+     style="stroke:#ff0000;fill:none" />
+</svg>

coraleda/subc/CAPC1608X92N.lht

@@ -0,0 +1,307 @@
+# subcircuit generated using QEDA
+li:pcb-rnd-subcircuit-v6 {
+ ha:subc.1 {
+  uid = CAPC1608X92N............
+  ha:attributes {
+   footprint = CAPC1608X92N
+  }
+  ha:data {
+   li:padstack_prototypes {
+    ha:ps_proto_v6.2 {
+     htop = 0
+     hbottom = 0
+     hdia = 0
+     hplated = 0
+     li:shape {
+      ha:ps_shape_v4 {
+       clearance = 0.200mm
+       li:ps_poly {
+        -0.625mm
+        -0.550mm
+        0.625mm
+        -0.550mm
+        0.625mm
+        0.550mm
+        -0.625mm
+        0.550mm
+       }
+       ha:layer_mask {
+        top = 1
+        copper = 1
+       }
+       ha:combining {
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0
+       li:ps_poly {
+        -0.675mm
+        -0.600mm
+        0.675mm
+        -0.600mm
+        0.675mm
+        0.600mm
+        -0.675mm
+        0.600mm
+       }
+       ha:layer_mask {
+        top = 1
+        mask = 1
+       }
+       ha:combining {
+        sub = 1
+        auto = 1
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0
+       li:ps_poly {
+        -0.625mm
+        -0.550mm
+        0.625mm
+        -0.550mm
+        0.625mm
+        0.550mm
+        -0.625mm
+        0.550mm
+       }
+       ha:layer_mask {
+        top = 1
+        paste = 1
+       }
+       ha:combining {
+        auto = 1
+       }
+      }
+     }
+    }
+   }
+   li:objects {
+    ha:padstack_ref.23 {
+     proto = 2
+     rot = 0
+     x = 0.000mm
+     y = -0.750mm
+     ha:attributes {
+      term = 1
+      name = 1
+     }
+     clearance = 0.200mm
+     ha:flags {
+      clearline = 1
+     }
+    }
+    ha:padstack_ref.24 {
+     proto = 2
+     rot = 0
+     x = 0.000mm
+     y = 0.750mm
+     ha:attributes {
+      term = 2
+      name = 2
+     }
+     clearance = 0.200mm
+     ha:flags {
+      clearline = 1
+     }
+    }
+   }
+   li:layers {
+    ha:subc-aux {
+     lid = 0
+     ha:type {
+      top = 1
+      misc = 1
+      virtual = 1
+     }
+     li:objects {
+      ha:line.25 {
+       clearance = 0
+       thickness = 0.1mm
+       ha:attributes {
+        subc-role = origin
+       }
+       x1 = 0.000mm
+       x2 = 0.000mm
+       y1 = 0.000mm
+       y2 = 0.000mm
+      }
+      ha:line.26 {
+       clearance = 0
+       thickness = 0.1mm
+       ha:attributes {
+        subc-role = x
+       }
+       x1 = 0.000mm
+       x2 = 1.000mm
+       y1 = 0.000mm
+       y2 = 0.000mm
+      }
+      ha:line.27 {
+       clearance = 0
+       thickness = 0.1mm
+       ha:attributes {
+        subc-role = y
+       }
+       x1 = 0.000mm
+       x2 = 0.000mm
+       y1 = 0.000mm
+       y2 = 1.000mm
+      }
+      ha:line.28 {
+       clearance = 0
+       thickness = 0.1mm
+       ha:attributes {
+        subc-role = pnp-origin
+       }
+       x1 = 0.000mm
+       x2 = 0.000mm
+       y1 = 0.000mm
+       y2 = 0.000mm
+      }
+     }
+    }
+    ha:top-silkscreen {
+     lid = 1
+     ha:type {
+      top = 1
+      silk = 1
+     }
+     li:objects {
+      ha:text.29 {
+       x = 0.000mm
+       y = 0.000mm
+       rot = 0
+       scale = 100
+       string = %a.parent.refdes%
+       fid = 0
+       ha:flags {
+         floater = 1
+         dyntext = 1
+       }
+      }
+      ha:line.30 {
+       x1 = -0.925mm
+       y1 = -0.900mm
+       x2 = -0.925mm
+       y2 = 0.900mm
+       thickness = 0.200mm
+       clearance = 0
+      }
+      ha:line.31 {
+       x1 = 0.925mm
+       y1 = -0.900mm
+       x2 = 0.925mm
+       y2 = 0.900mm
+       thickness = 0.200mm
+       clearance = 0
+      }
+     }
+    }
+    ha:top-assembly {
+     lid = 2
+     ha:type {
+      top = 1
+      doc = 1
+     }
+     purpose = assy
+     li:objects {
+      ha:arc.32 {
+       x = 0.000mm
+       y = 0.000mm
+       width = 0.500mm
+       height = 0.500mm
+       thickness = 0.100mm
+       astart = 0
+       adelta = 360
+       clearance = 0
+      }
+      ha:line.33 {
+       x1 = -0.700mm
+       y1 = 0.000mm
+       x2 = 0.700mm
+       y2 = 0.000mm
+       thickness = 0.100mm
+       clearance = 0
+      }
+      ha:line.34 {
+       x1 = 0.000mm
+       y1 = -0.700mm
+       x2 = 0.000mm
+       y2 = 0.700mm
+       thickness = 0.100mm
+       clearance = 0
+      }
+      ha:text.35 {
+       x = 0.000mm
+       y = 0.000mm
+       rot = 90
+       scale = 53
+       string = CAPC1608X92N
+       fid = 0
+       ha:flags {
+         floater = 1
+       }
+      }
+      ha:line.36 {
+       x1 = -0.400mm
+       y1 = -0.800mm
+       x2 = 0.400mm
+       y2 = -0.800mm
+       thickness = 0.100mm
+       clearance = 0
+      }
+      ha:line.37 {
+       x1 = 0.400mm
+       y1 = -0.800mm
+       x2 = 0.400mm
+       y2 = 0.800mm
+       thickness = 0.100mm
+       clearance = 0
+      }
+      ha:line.38 {
+       x1 = 0.400mm
+       y1 = 0.800mm
+       x2 = -0.400mm
+       y2 = 0.800mm
+       thickness = 0.100mm
+       clearance = 0
+      }
+      ha:line.39 {
+       x1 = -0.400mm
+       y1 = 0.800mm
+       x2 = -0.400mm
+       y2 = -0.800mm
+       thickness = 0.100mm
+       clearance = 0
+      }
+     }
+    }
+    ha:top-courtyard {
+     lid = 3
+     ha:type {
+      top = 1
+      doc = 1
+     }
+     purpose = ko.courtyard
+     li:objects {
+      ha:polygon.40 {
+       li:geometry {
+        ta:contour {
+         { -0.875mm; -1.550mm }
+         { -0.875mm; -1.050mm }
+         { -0.875mm; 1.050mm }
+         { -0.875mm; 1.550mm }
+         { 0.875mm; 1.550mm }
+         { 0.875mm; 1.050mm }
+         { 0.875mm; -1.050mm }
+         { 0.875mm; -1.550mm }
+        }
+       }
+      }
+     }
+    }
+   }
+  }
+ }
+}

coraleda/subc/CAPPRD200W45D500H700N.lht

@@ -0,0 +1,428 @@
+# subcircuit generated using QEDA
+li:pcb-rnd-subcircuit-v6 {
+ ha:subc.1 {
+  uid = CAPPRD200W45D500H700N...
+  ha:attributes {
+   footprint = CAPPRD200W45D500H700N
+  }
+  ha:data {
+   li:padstack_prototypes {
+    ha:ps_proto_v6.2 {
+     htop = 0
+     hbottom = 0
+     hdia = 0.650mm
+     hplated = 1
+     li:shape {
+      ha:ps_shape_v4 {
+       clearance = 0.200mm
+       li:ps_poly {
+        -0.525mm
+        -0.525mm
+        0.525mm
+        -0.525mm
+        0.525mm
+        0.525mm
+        -0.525mm
+        0.525mm
+       }
+       ha:layer_mask {
+        top = 1
+        copper = 1
+       }
+       ha:combining {
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0
+       li:ps_poly {
+        -0.575mm
+        -0.575mm
+        0.575mm
+        -0.575mm
+        0.575mm
+        0.575mm
+        -0.575mm
+        0.575mm
+       }
+       ha:layer_mask {
+        top = 1
+        mask = 1
+       }
+       ha:combining {
+        sub = 1
+        auto = 1
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0.200mm
+       li:ps_poly {
+        -0.525mm
+        -0.525mm
+        0.525mm
+        -0.525mm
+        0.525mm
+        0.525mm
+        -0.525mm
+        0.525mm
+       }
+       ha:layer_mask {
+        intern = 1
+        copper = 1
+       }
+       ha:combining {
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0.200mm
+       li:ps_poly {
+        -0.525mm
+        -0.525mm
+        0.525mm
+        -0.525mm
+        0.525mm
+        0.525mm
+        -0.525mm
+        0.525mm
+       }
+       ha:layer_mask {
+        bottom = 1
+        copper = 1
+       }
+       ha:combining {
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0
+       li:ps_poly {
+        -0.575mm
+        -0.575mm
+        0.575mm
+        -0.575mm
+        0.575mm
+        0.575mm
+        -0.575mm
+        0.575mm
+       }
+       ha:layer_mask {
+        bottom = 1
+        mask = 1
+       }
+       ha:combining {
+        sub = 1
+        auto = 1
+       }
+      }
+     }
+    }
+    ha:ps_proto_v6.3 {
+     htop = 0
+     hbottom = 0
+     hdia = 0.650mm
+     hplated = 1
+     li:shape {
+      ha:ps_shape_v4 {
+       clearance = 0.200mm
+       ha:ps_circ {
+        x = 0
+        y = 0
+        dia = 1.050mm
+       }
+       ha:layer_mask {
+        top = 1
+        copper = 1
+       }
+       ha:combining {
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0
+       ha:ps_circ {
+        x = 0
+        y = 0
+        dia = 1.100mm
+       }
+       ha:layer_mask {
+        top = 1
+        mask = 1
+       }
+       ha:combining {
+        sub = 1
+        auto = 1
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0.200mm
+       ha:ps_circ {
+        x = 0
+        y = 0
+        dia = 1.050mm
+       }
+       ha:layer_mask {
+        intern = 1
+        copper = 1
+       }
+       ha:combining {
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0.200mm
+       ha:ps_circ {
+        x = 0
+        y = 0
+        dia = 1.050mm
+       }
+       ha:layer_mask {
+        bottom = 1
+        copper = 1
+       }
+       ha:combining {
+       }
+      }
+      ha:ps_shape_v4 {
+       clearance = 0
+       ha:ps_circ {
+        x = 0
+        y = 0
+        dia = 1.100mm
+       }
+       ha:layer_mask {
+        bottom = 1
+        mask = 1
+       }
+       ha:combining {
+        sub = 1
+        auto = 1
+       }
+      }
+     }
+    }
+   }
+   li:objects {
+    ha:padstack_ref.17 {
+     proto = 2
+     rot = 0
+     x = 0.000mm
+     y = -1.000mm
+     ha:attributes {
+      term = 1
+      name = 1
+     }
+     clearance = 0.200mm
+     ha:flags {
+      clearline = 1
+     }
+    }
+    ha:padstack_ref.18 {
+     proto = 3
+     rot = 0
+     x = 0.000mm
+     y = 1.000mm
+     ha:attributes {
+      term = 2
+      name = 2
+     }
+     clearance = 0.200mm
+     ha:flags {
+      clearline = 1
+     }
+    }
+   }
+   li:layers {
+    ha:subc-aux {
+     lid = 0
+     ha:type {
+      top = 1
+      misc = 1
+      virtual = 1
+     }
+     li:objects {
+      ha:line.19 {
+       clearance = 0
+       thickness = 0.1mm
+       ha:attributes {
+        subc-role = origin
+       }
+       x1 = 0.000mm
+       x2 = 0.000mm
+       y1 = 0.000mm
+       y2 = 0.000mm
+      }
+      ha:line.20 {
+       clearance = 0
+       thickness = 0.1mm