Wanted to add this here to keep a record of what be have talked about for power distribution changes before everything on slack disappears.
Decoupling capacitor on U5
Input Connector - a barrier block will remove the need to crimp around 28 micro-fit crimps. I think we should switch to the barrier block design.
Is R2 for current sense on the 5V output? - we already get current from the load switches.
Boost converter - why 100V capacitors? Switch to 0603 package. Does the layout guide mention anything about putting smaller capacitors closer in the chip or anything like that?
The horn only needs a 2-pin output connector. We'll use the 18AWG microfit crimps, rated for 8.5A. The horn we are planning to use only uses 4.5A. CORRECTION - it draws 7.7A, but not consistent due to the working principle of the horn.
What is the rear pi used for? - was this the pi that might have been connected to the display? (Battery Pi is connected directly to BMS Carrier)
Current limiting resistors for the LEDs on the 5V outputs should be changed to give the same current as the 12V outputs.
Why is C26 an 0805 part? - make it 0603. And fix that voltage divider to either a 100K and zener, or equal value resistors.
DRLs are going to draw 2A max, we don't need 6 wires for them. We only want 4 wires, as the left and right DRLs will go to different drivers. (This might be a good idea to keep as 6 though since if we want to use for the rear brake lights as well, there are 3 of those.
Turn signals only need 2 wires each (not 4).
Add extra mounting points to the middle of the board - we will be pushing and pulling the connectors, and don't want the board to bend. I would put one each in the following locactions: Between P10, P11 just above the connectors. Between P5, P6. Between P20 and D5. Between P3 and the inductor
Move the internal traces on the signal layer away from the controller board mounting holes, and if possible switch the controller board mounting to the standoffs that Aashmika is using on solar.
Make sure the all connectors and pinouts get labeled.
What are all the Vias for near the input connector?
Dedicated outputs for monitor, parking brake
Parking brake output should be changed to an H-bridge driver to be able to move current both ways through the parking brake for forward and reverse current. More discussions around parking brake safety and accidental actuation should be covered before fully settling on an electric parking brake.