Imported from GitHub: paulmartinezcuenta/UltiCore-V1-PLC · commit eb74a70 · license MIT

Description

Custom industrial-grade PLC and logic controller engineered around the ESP32 platform.

README

UltiCore V1 - ESP32-Based Industrial PLC

UltiCore V1 is a high-reliability, industrial-grade Programmable Logic Controller (PLC) custom-designed around the ESP32-WROOM-32D architecture. Engineered for harsh electrical environments, this board features high-density optical isolation, dedicated buffered data buses, and a robust power management system.

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Advanced Hardware Architecture & Engineering

1. Dual-Bus Data Architecture & Control Logic

• Buffered Bus Isolation: Implements octal three-state buffers (74HC541TS) to split control signals into dedicated Power Data Buses and Analog Data Buses. This topology isolates the MCU pins, maximizes fan-out capability, and prevents EMI crosstalk from high-current switching sections.
• Industrial Output Stage (8-Channel Relay Matrix): Features 8 independent mechanical relays driven by robust 2N3904 BJT switching circuits. Each channel is equipped with hardwired pull-down networks for deterministic power-up states and RR1VWM6STFTR flyback suppression diodes to clamp inductive back-EMF spikes.

2. High-Density Input Conditioning & Galvanic Isolation

• Optically Isolated Digital Inputs: 8 industrial-level input channels (IN0-IN7) isolated via high-density ILD207T dual optocouplers, establishing complete galvanic separation between the 24V field domain and the 3.3V logic domain.
• Hardware Debouncing & Waveshaping: Optocoupler outputs are routed through 74HC14 Hex Schmitt-Trigger inverters to suppress mechanical switch bounce and electrical noise, delivering sharp, clean square waves to the MCU.

3. Industrial Power Supply & Protection Framework

• High-Efficiency Buck Topology: Integrates an LM2576HVS-3.3 switching regulator paired with a 100µH power inductor and a B330A Schottky diode to efficiently step down standard industrial 24VDC rails directly to a stable 3.3V rail.
• Smart Dual-Power Protection (Anti-USB & 24V Cross-Protection): Utilizes an LM358DR operational amplifier comparator circuit coupled with a PC817 optocoupler and an FQD11P06 P-Channel MOSFET. This layout actively prevents reverse-current backfeeding and hardware damage when both the high-voltage field power and USB-C programming interface are active simultaneously.
• Front-End Overcurrent & Polarity Defense: Equipped with a standard 5x20mm cartridge fuse assembly and a high-current 5S14 blocking diode for reverse-polarity protection.

4. Modern Interface & ESD Compliance

• USB-C Interface: Modern USB-C implementation driven by a CH340C USB-to-UART bridge with an integrated dual-transistor auto-reset/boot-loader circuit.
• Transient Voltage Suppression: High-speed LESD5D5.0CT1G TVS diode arrays deployed on critical USB data lines (D+/D-) for localized ESD clamping.

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Repository Structure

├── Hardware/        # KiCad schematic captures, multi-layer layout files, and structural BOM
├── Firmware/        # Modular C/C++ source code and RTOS industrial automation tasks
└── Docs/            # Hardware layout sheets, pinout mapping, and component datasheets