Project Overview

The Smart Quad e-Fuse & PDU [EFDC-2X4-120] is an intelligent Power Distribution Unit that combines physical fail-safes with high-precision digital monitoring. It features 4 independent channels, each equipped with dual-fuse protection and real-time current/voltage sensing.

Technical Architecture

Power Flow: Main power enters via a high-current input terminal and is distributed across multiple output connectors for localized load management.

Precision Sensing: Each channel utilizes a 2mΩ high-side shunt resistor. The differential voltage across this shunt is captured via dedicated high-precision sense lines.

Digital Intelligence: These sense lines interface with a 4-channel power monitor IC. This provides 16-bit resolution for power, voltage, and current measurement, communicating back to the main system controller via an I2C interface.

Dual-Layer Protection: * Hardware: Redundant blade-style fuses provide a final physical safety layer for every output channel.

Transient Protection: A high-power TVS diode is integrated at each output to suppress voltage spikes and protect sensitive downstream loads from surges or inductive kickback.

Why I Decided to Make It

Standard PDUs only offer "on/off" protection. I designed the EFDC-2X4-120 because I needed a system that could "see" the power consumption of my robotics/industrial loads in real-time. By using the PAC1934, I can detect early signs of motor wear or sensor failure by monitoring current drifts before a fuse ever needs to blow.

Key Specifications

Monitoring IC: PAC1934 (16-bit, 4-Channel).

Communication: I2C Bus.

Shunt Value: 2mΩ (for minimal voltage drop and high current handling).

Protection: Dual Fuse per channel + SMCJ30A TVS Diode.

Connectors: High-current 74650073R series terminals.