By Nicholas Burley, UTFR Electronics Lead

The University of Toronto Formula SAE Racing Team (UTFR) is continually striving for innovation and optimal performance in the challenging world of formula racing. Our vehicle's electrical system is a testament to this dedication, ensuring efficient power management and distribution to various subsystems. They will be racing in Michigan, New Hampshire, Czech and Germany in 2024. 

The UT24 Buck Converter Test Board is the centerpiece of our endeavor to refine and optimize the power regulation of our car’s low voltage system. This test board aims to scrutinize the robustness and efficacy of the buck converter, which is poised to be a pivotal part of UTFR’s Rear Controller for our 2025 vehicle.

Figure 1: Initial design of the Buck Converter Test Board, featuring its compact layout.

As with many of our high-performance boards, JLCPCB has been our partner of choice in transforming our designs into reality. With over 15 years in the industry, JLCPCB's commitment to quality and efficiency aligns perfectly with our team's ethos. Their ability to manufacture intricate designs with precision, coupled with their cost-effective solutions, makes them the top contender in PCB manufacturing.

Design & Functionality

Figure 2: A detailed schematic of the Buck Converter Test Board in Altium Designer 2022.

The primary role of the Buck Converter Test Board is to evaluate whether the converter can adequately power our car's low voltage system, which includes peripheral boards, our battery management system, multiple sensors and our Cascadia inverter. Boasting a higher amperage output and having a footprint considerably smaller than previous iterations, this buck converter promises enhanced performance without compromising space. Operating at a swift 1.455 Mhz, it is designed to efficiently regulate a 21-volt LV battery to a stable 12 volts, suitable for vehicular operations.

Altium Designer 2022, with its advanced tools and comprehensive interface, was instrumental in bringing the Buck Converter Test Board to life. The software's capabilities, from intricate schematics to detailed 3D visualization, facilitated a seamless design process. The ability to instantly integrate with JLCPCB's manufacturing standards ensured that our designs remained compliant and optimized for fabrication.

Ordering Logistics with JLCPCB

JLCPCB's streamlined ordering process complements the intricate design capabilities of Altium Designer. Here's how we seamlessly transition from design to manufacturing:

1. Generating Gerber files: Within Altium, navigate to File -> Fabrication Outputs -> Gerber Files.

Figure 3: An in-depth view of the Gerber file generation process in Altium.

1. Uploading to JLCPCB: Access the user-friendly interface on JLCPCB's platform and upload the generated Gerber files for a quick review.
2. Specifications & Review: JLCPCB's system automatically detects the board specifications, minimizing manual input and expediting the ordering process.

1. Finalizing the Order: With options to adjust parameters like silkscreen colors and layer stack-ups, one can customize the final product. Simply add to the cart, input shipping details, and proceed to payment.

Conclusion

The UT24 Buck Converter Test Board represents our unyielding quest for perfection in racecar design and functionality. Our continued collaboration with JLCPCB ensures that our designs, realized using tools like Altium Designer, get the best possible manufacturing treatment. We invite our fellow designers and enthusiasts to experience the unparalleled service of JLCPCB, which can be explored further at https://jlcpcb.com/RAT.