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Kestrel 4in1: 6S 4-in-1 ESC running stock AM32 on four STM32G071s, with 24 CSD18540 FETs, LM5109B drivers and battery current sensing. 48 x 52 mm 6-layer KiCad 10 board, DRC clean, with gerbers, BOM, CPL and STEP.

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Kestrel 4in1: 6S 4-in-1 ESC

Four STM32G071s running stock AM32, twelve half-bridge drivers and twenty-four 60 V FETs stacked through a 48 x 52 mm board, with battery current sensing for the flight controller.

Kestrel 4in1, raytraced in KiCad

The Kestrel 4in1 is the ESC of Kestrel. Each motor has its own STM32G071 wired to AM32's HARDWARE_GROUP_G0_H pin map, the group of the Mamba F55 G071 build, so it runs a stock AM32 release: firmware/am32/README.md maps every pin and walks through the first flash. Each half bridge is stacked through the board, the high-side FET on the top face over its low side on the bottom, joined by the motor wire soldered through a plated hole.

Layers Size Footprints (LCSC parts) Nets Connections routed Routed vias ERC errors / warnings DRC errors / warnings / unconnected / parity Parts per board, 10-board build
6 48 x 52 mm 174 (148) 119 443 -> 0 open 215 0 / 4 0 / 0 / 0 / 0 $44.70

Not fabricated, assembled, powered or flown yet. Every number on this page is measured by KiCad 10.0.6 on the files in this repository (report.json, fab/erc.json, fab/drc.json) or read from the live JLC/LCSC catalogue (bom_cost.md: parts only, at a 10-board build's price tier with JLC's Extended-part fee; the bare PCB and assembly are quoted at order time). The 4 ERC warnings are KiCad's pin-type check on a pin the design ties to a rail on purpose: AM32's per-motor current input, tied to GND: the board measures battery current once, for the FC.

The whole drone: spec, build guide, BOM, measured results HeyPCB/kestrel
KiCad 10 project kicad/
Gerbers, drill, BOM, CPL, STEP, schematic PDF fab/
Firmware firmware/am32/README.md: stock AM32 (MAMBA_F55_G071), the pin map and the first flash
Renders front, back, hero, Circuit World thumbnail
Brief and generator design/

front back

What's on it

  • Motor control: 4 x STM32G071G8U6N, AM32 HARDWARE_GROUP_G0_H (the MAMBA_F55_G071 build).
  • Gate drive: 12 x LM5109B (WSON-8), 1 A peak, internal bootstrap diode, from an always-on 10 V LMR51430 rail.
  • Power stage: 24 x CSD18540Q5B (60 V, SON 5 x 6), high side on the top face over its low side on the bottom.
  • Back-EMF: 20k / 2.2k per phase against a 20k x 3 / 750 ohm virtual neutral.
  • Battery sense: 2 x 0.5 mOhm 2512 low-side shunts and an INA180A2: 12.5 mV/A on CURR (Betaflight ibata_scale 125).
  • Telemetry: all four MCUs' USART1 TX (open drain) on one TLM wire.
  • Protection: SMAJ30A on VBAT and six 10 uF / 50 V on the bus; solder a 1000 uF / 35 V low-ESR capacitor across the battery pads.
  • Harness: JST-SH 8 in the Kestrel H7's order: VBAT, GND, CURR, TLM, M1-M4.
  • Current rating: not measured. At 30 A a motor's two conducting FETs dissipate about 3.2 W before switching loss; a bench thermal run with one motor comes before the first flight (SPEC.md).

Ordering

6 layers, 1.6 mm, 2 oz outer copper recommended; parts on both faces. Upload fab/kestrel_esc_gerbers.zip, fab/kestrel_esc_bom.csv and fab/kestrel_esc_cpl_jlc.csv to JLCPCB: every part has an LCSC number. Bring-up, one board at a time, is in the hub's BUILD.md.

How it was made

Designed with the HeyPCB method on KiCad 10.0.6, headless, by the heypcb-kicad pipeline: a written brief composed from reusable circuit blocks, every pin from KiCad's own symbol library, every part bound to an LCSC number from a dated catalogue read, then ERC, a netlist round trip, locked placement, Freerouting 2.4.1, pours and stitching, silkscreen, DRC with schematic parity, DFM and a fab gate, each stage gated by a measurement. design/make_brief.py regenerates the brief (outline, part locks, net classes) from code.

Part of Kestrel, a 5-inch 6S FPV quad's electronics.

License

Hardware: CERN-OHL-S v2. KiCad's symbol, footprint and 3D libraries used in the design are CC-BY-SA 4.0 with the KiCad library exception.

About

Kestrel 4in1: 6S 4-in-1 ESC running stock AM32 on four STM32G071s, with 24 CSD18540 FETs, LM5109B drivers and battery current sensing. 48 x 52 mm 6-layer KiCad 10 board, DRC clean, with gerbers, BOM, CPL and STEP.

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