USB-C Variable Boost Power Supply

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I am working on a project that requires strips of 12V white LEDs. This all has to run from a phone charger battery pack. The initial strip I tried using had 60 white LEDs on it. Turns out it needs 1A at 12V to run the strip of white LEDs. But this requires 4+A at 5V to be fed into a XL6019 based Boost DC-DC converter, which is something double what a USB A based phone power pack can put out and I don't yet have a USB C PD based power pack.

I thought it would be fun to finally upgrade my KiCAD from version 6 to version 7 and have a go at designing up a small PCB for this. 12 hours later and I have this experimental design:

USB-C_Variable_Power-Supply.png (163.11 KiB) Viewed 17576 times

Features:

• ESP32-C3 based MCU
• three low side MOSFET switched outputs, outputting 7V to 13V at up to 1.5A out
• XL6019 up to 5A DC-DC Boost converter (check costs and indicators each uses) A$0.95/ea and use a 47uH 5A inductor and a MBRD1045 diode
• USB C 5V at 3A input
• Switched Enable on DC-DC converter
• Green Power LEDs on USB Input, input and output switches
• Red LED on USB Input polyfuse
• yellow LED as an indicator that DC-DC converter is working
• Input and output voltage measurements
• input current measurement via 20mili ohm sense resistor and a INA180 opamp
• all voltage measurements via ADC124S101: 1) USB voltage in; 2) DC-DC voltage out; 3) board current; 4) spare
• provision for a i2C based OLED screen
• i2C based digital pot to control DC-DC converter output voltage (2.5mA max current flow via wiper!!)
• 5V i2C translator for digital Pot + ADC124 IC's.
• i2C 4 Port GPIO PCA9536 expander IC
• provide some GPIO for external uses

This PCB is now in production.