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Manufacturing
There are a number of different possible methods to generate a hardware implementation of the reference design, either through a set of modules and through-hole components (simpler for building with limited resources), or a surface-mount board from a variety of manufacturers.
The prototype development board assumes that the ESP32 development module (or a close equivalent) is used to drive the system, with the SD card provided through a simple SPI-based module, which are widely available through Amazon among other locations.
The remaining parts can be readily ordered from DigiKey, Mouser, and other locations, depending on your place in the world. The Bill of Materials is:
| Number | Part | Order Code (Mouser) | Notes |
|---|---|---|---|
| 4 | H11L1 | 512-H11L1M | Logic output optoisolator |
| 1 | MCP2562 | 579-MCP2562-E/P | CAN bus transceiver |
| 3 | 5mm LED | 941-C503BRANCZ0C0AA1 | Any colour can be used; R/G/B is typical (code is for red) |
| 1 | RFM-0505S | 919-RFM-0505S | Isolating DC-DC Converter |
| 1 | SN65C1168 | 595-SN65C1168NSR | RS-422 2x2 transceiver |
| 7 | 100nF | 594-K104M15X7RF53H5 | Ceramic decoupling capacitor |
| 1 | Screw Terminal | 651-1725737 | Header for RS-422 connection |
| 3 | 220Ω | 756-MFR4-220RFI | LED pull-up resistors R10-12 |
| 4 | 10kΩ | 660-MFS1/2DCT52R1002 | Pull-ups R1-2, 5-6 |
| 2 | 1.2kΩ | 660-MFS1/2DCT52R1201 | Pull-ups R3-4 |
| 2 | 560Ω | 594-SFR16S0005600FR5 | Pull-ups R7-8 |
| 1 | 120Ω | 594-SFR25H1201%TR | CAN bus terminator |
| 1 | Socket | 523-HPC-05PMMPSF8001 | NMEA2000 compatible socket |
A series of pin-headers will also be required (e.g., Mouser 649-1012937893602BLF).
Given the KiCAD schematic and PCB layout files, a variety of manufacturers could be used to produce and assemble a surface mount PCB. The WIBL prototypes have been manufactured with JLCPCB, and appropriately formatted Bill of Material and CPL (pick and place) files are available for this service from the project's website. During the development period, which coincided with the COVID-19 pandemic, supply-chain issues frequently meant that particular components could not be reliably sourced, and multiple substitutions had to be made, often from order to order. Close inspection of the BOM for a given version of the board will often, therefore, demonstrate small differences from the main schematic.
During initial development, JLCPCB did not offer a through-hole assembly mechanism, and therefore the DC-DC isolating converter, super-capactior, the NMEA2000 connector, and pin-headers could not be assembled directly at the fab; these were added by hand after delivery. In addition, the RS-422 transceiver was not available from LCSC, the preferred supply house for JLCPCB assembly, and was added after delivery. However (2023-03) a through-hole assembly service is now available, and some parts may now be available for use directly through LCSC. Therefore, some adjustment of the canonical BOM may be required for an individual order.