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project-button-v3 — detailed specs to build a humanoid robot (with kids) | Open App Note

humanoid-robot

amyleesterling

detailed specs to build a humanoid robot (with kids)

Components (48)

Reference	Value	Description
U1	ROBOTIS U2D2 TTL interface, SKU 902-0132-000	Pin 2 VDD is intentionally omitted from the project cable. Standard fully populated cables are prohibited in the protected-branch topology.
UDRV1	Texas Instruments TPL7407LPWR channel-1 relay driver	Dedicated package for channel 1. COM is tied to the 24 V coil rail for the internal clamp; unused inputs are tied low and unused outputs are no-connect. Default-off, hot-plug/COM slew, clamp interaction with the relay module, thermal, brownout, open/short and cross-channel faults remain open.
UDRV2	Texas Instruments TPL7407LPWR channel-2 relay driver	Separate package for channel 2 to avoid one driver-package fault controlling both coils. The controller, supplies, clock and firmware remain common causes; no safety credit is claimed.
UFB1	Texas Instruments ISO1212DBQ dual 24 V input receiver	Exact dual-channel receiver candidate. Logic and field grounds both return to SAFETY_0V in this non-isolated system, so no galvanic-isolation or safety-integrity credit is claimed. Layout, thermal, EMC, fault-injection and received-part tests remain open.
CDEC1,CDRV1,CDRV2	Murata GRM21BR71H104KA01L, 100 nF 50 V X7R 0805	Exact order code frozen. Exact 0805 candidate required at UFB1 VCC1/GND1; placement within 2 mm, land pattern and received-board capacitance remain open.,Local COM bypass candidate for UDRV1. Capacitance alone does not prove TI's less-than-0.5 V/us COM slew requirement; scope hot-plug and repetitive transients in the released layout.,Local COM bypass candidate for UDRV2; the same physical slew and fault evidence remains mandatory.

humanoid-robot schematic

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humanoid-robot board

CFI1,CFI2	TDK CGA3E2X7R1H103K080AA, 10 nF 50 V X7R 0603	Exact order code frozen. Exact AEC-Q200 X7R candidate for TI Type-3 input filter. Nominal value is not credited at the 25.2 V screened rail maximum until DC-bias, tolerance, temperature and received-board capacitance are verified; locate at UFB1.,Exact order code frozen. Same exact input-filter candidate and open DC-bias/physical evidence as channel 1.

DC1	TRACO POWER TSR 1-2450, 24 V to 5 V 1 A non-isolated	Pin 1 +Vin, pin 2 common GND, pin 3 +Vout. Non-isolated by design; changing isolation requires a new driver/interface and grounding review. Published input range is 6.5-36 VDC; external capacitance is not required below 32 V, but branch protection, load budget, startup, brownout, conducted/radiated emissions and enclosure thermal tests remain open.

F24	24 V control-source branch protection	Separate protection function downstream of J24V1. Select only after source fault current, inrush, downstream conductor/connector limits, ambient, bundling, cable length, time-current coordination and jurisdiction are accepted.

FSR1,FSR2	Phoenix PT 4-HESI (5X20) item 3211861 holder with D-ST 4 item 3030420 end cover; fuse link SELECTION REQUIRED	Exact non-LED 5x20 holder and D-ST 4 item 3030420 end-cover candidates only. Fuse link, fault current, coil pickup/transient, conductor, grouping arrangement and PNOZ contact-protection coordination remain open; manufacturer maxima are not project selections.,Same exact holder/end-cover candidates and open fuse-link, grouping, coordination and physical-evidence gate as FSR1; manufacturer maxima are not project selections.

H1	IDEC HW1P-1FQD-A-24V amber diagnostic pilot light	Exact amber round flush 22 mm pilot-light complete assembly is frozen. The current IDEC page identifies a black plastic bezel, screw terminals and 24 VAC/DC illumination, but no received terminal marking, orientation, internal circuit or polarity result is recorded. TBD-HA/TBD-HB are project placeholders, not manufacturer markings. Label H1 RESET STAGE READY - DIAGNOSTIC ONLY / NO MOTION AUTHORITY. Do not call it SAFE or ARMED and assign no safety credit. Execute docs/hr-v0-h1-receiving-p0.1.md before replacing placeholders or wiring the lamp.

INJ1	HR-V0 DXL-STAR-P0.1 central branch-isolating injection board	One fixed central star board accepts three separately protected VDD/return branches, shares only DATA and common return, and leaves U2D2 pin 2 physically unrouted. Routed DXL-STAR-P0.1 source exists; exact cable lengths, terminals, enclosure, signal-integrity, thermal, continuity and no-backfeed proof remain open.

ISO1	Vishay VO618A-4X017T heartbeat optocoupler	Ordinary signal isolation only; no safety-integrity credit. Verify received identity, PCB creepage/clearance, GPIO levels, LED current, edge timing, leakage, EMC, brownout and open/short faults in the released assembly.

J24	Kycon KPJX-PM-4S panel jack candidate for GlobTek factory 4-pin locking output	GlobTek identifies YL4 as the KPPX-4P connector type and the exact PSU2 drawing assigns only pin 1 +24 V and pin 3 return/shield; pins 2 and 4 are N/C. Kycon recommends KPJX-PM-4S for KPPX plugs. GlobTek still permits a connector 'or equal', so received plug identity, keyed plug/jack view, fit, continuity and polarity remain mandatory. No N/C pin may be repurposed.

JA1	Molex 39012066 housing; 6x 444783112 HCS male contacts; 16 AWG	Mates the source's 39-01-2060-equivalent receptacle. Use six individual 16 AWG copper conductors, one per contact, and Molex tool 63819-0900. Pins 1-3 are +12 V and 4-6 are bonded 0 V. Do not hot-plug or use current sharing as a safety assumption.

JWF1,JWH1	Phoenix Contact MKDS 1/2-3,5, item 1751248	Project pin allocation is frozen for the PCB candidate. Exact relay-contact harness, conductor, marking, torque, strain relief, received orientation and application evidence remain open.,Project pin allocation is frozen for the ordinary isolated heartbeat input. GPIO source identity, cable, shielding, retention, strain relief, received orientation and EMC evidence remain open.

JWP1	Phoenix Contact MKDS 1/4-3,5, item 1751264	Project pin allocation is frozen for the PCB candidate. Manufacturer identity, 3.5 mm pitch, 1.1 mm PCB hole, conductor range and torque are controlled; branch protection, current, temperature, ferrule, harness, marking and received orientation remain open.

K1,K2	Schneider TeSys D LC1D25BD, 24 VDC coil	First redundant series contactor. Three power poles are represented in series. The 2026 catalog's LC1D25 24 V row is 32 A for one, two or three poles, but its lower-current critical-current warning applies to the 11.1 A HR-V0 screen. BD coil has built-in bidirectional peak-limiting diode; do not add assumed external suppression.,Second redundant series contactor. Same three-pole series application boundary, critical-current warning and physical evidence gate as K1.

KP1	K1 three main poles represented in series	Do not count as a second BOM device. External nets series-connect the three poles. Catalog DC evidence exists, but lower-current/critical-current application confirmation and loaded tests remain required.

KWD1,KWD2	Phoenix Contact PLC-RSC-24DC/21-21, item 2967060	First ordinary watchdog supply-gate stage. Its 11-14 NO contact is in series with KWD2 before SR1:A1 and is not in an E-stop input loop. A welded or internally bypassed contact can defeat only this diagnostic stage, not bridge S0. Ordinary relay, not force-guided and not safety-rated; no PL/SIL credit. Received terminal identity, 2.5 W steady/0.5 A 5 ms PNOZ supply-load switching, polarity, continuity, wear and fault tests remain open.,Second ordinary watchdog supply-gate stage. Its 11-14 NO contact completes SR1:A1 supply only after KWD1. A welded or internally bypassed contact can defeat the diagnostic gate but cannot bridge either S0 input contact. Exact terminals follow the official circuit diagram; PNOZ supply inrush/contact duty, received verification and common controller/supply failures remain open. No PL/SIL credit.

PI1	Raspberry Pi 5 8GB unit-only high-level compute, SC1112	High-level compute and logger. The current Raspberry Pi configurator maps the 8GB unit-only selection to SC1112 through a manufacturer-generated approved-reseller link. BCM GPIO17 on physical header pin 11 is reserved for the ordinary heartbeat output; physical header pin 6 is its compute-domain return. Output must remain inactive until explicitly configured. It never owns the hardware safety function or directly restores contactors.

PSU2	GlobTek WR9QI1660YL4NKITR6B, 24 V 1.66 A 40 W, YL4/C40337 factory 4-pin locking cord	Factory-sealed Class II wall adapter with floating output and included interchangeable Q blade kit. Rev B specifies a 1200 mm UL 1185 16 AWG 1C-plus-shield output cord, YL4 four-pin locking plug, pin 1 +24 V, pin 3 return/shield, and pins 2/4 N/C. Output current limit is 110-160% with auto-recovery; full rated load is specified only through 40 C ambient and derates to 80% at 50 C. Do not connect until received identity, blade retention, plug identity, polarity, load/startup, abnormal-condition and site-use evidence are accepted.

PSU3	Raspberry Pi 27W USB-C Power Supply US Type A black, SC1158	The current Raspberry Pi configurator maps the selected US Type-A black model to SC1158 through manufacturer-generated approved-reseller links. The product brief specifies 5.1 V / 5 A and a 1.2 m captive 17 AWG cable. Received identity, site/receptacle suitability, cable and USB-C retention, load/startup/brownout, thermal behavior and physical verification remain open. Compute remains powered for diagnostics during E-stop and has no safety authority.

RHB1	Panasonic ERJ6ENF9100V, 910 Ohm 1% 0805 0.125 W	Screens approximately 1.04 mA at a project 2.6 V GPIO-high floor and 1.65 V LED maximum, and 2.53 mA at 3.3 V with 1.0 V LED minimum. The 2.6 V floor is a project screen, not a released Raspberry Pi 5 guarantee; measure the actual source across load and temperature.

RHP1	Panasonic ERJ6ENF1002V, 10.0 kOhm 1% 0805 0.125 W	The 10 kOhm pullup draws 0.33 mA at 3.3 V. Confirm logic thresholds, leakage, power sequencing, waveform rise/fall time and fault response on the released PCB.

RPD1,RPD2	Panasonic ERJ6ENF1002V, 10.0 kOhm 1% 0805	Exact order code frozen. Exact 0.125 W default-low candidate. It biases the GPIO low during high impedance; the documented VCC1 brownout region remains a fault-injection/HIL case. Firmware treats raw high as NC closed.,Exact order code frozen. Same exact default-low candidate and open physical evidence as channel 1.

RSN1,RSN2	Panasonic ERJ6ENF5620V, 562 Ohm 1% 0805	Exact order code frozen. Exact 0.125 W candidate for TI current-limit resistor between SENSE1 and IN1. Screened steady loss is 4.3 mW at 2.75 mA; layout, tolerance and fault evidence remain open.,Exact order code frozen. Same exact current-limit candidate and open physical evidence as channel 1.

RSO1,RSO2	Panasonic ERJ6ENF1001V, 1.00 kOhm 1% 0805	Exact order code frozen. Exact 0.125 W series candidate. A 3.3 V contention screen is 10.9 mW; it does not make contention safe or provide isolation.,Exact order code frozen. Same exact output-series candidate and open fault evidence as channel 1.

RTH1,RTH2	Vishay MMA02040C1001FB300, 1.00 kOhm 1% 0.4 W MELF	Exact order code frozen. Exact MELF candidate for TI Type-3 threshold/surge limiting. Screened steady loss is 7.6 mW at 2.75 mA; PCB land pattern, pulse/surge, temperature and enclosure derating still require release evidence.,Exact order code frozen. Same exact threshold/surge candidate and open physical evidence as channel 1.

RW1,RW2	Vishay CRCW12102K70FKEA, 2.70 kOhm 1% 0.5 W 1210	Exact order code frozen. Exact 0.5 W candidate for the parallel wetting load. Worst screened steady loss is 0.238 W, 47.6% of the 70 C rating; PCB/enclosure temperature, pulse and fault derating remain open.,Exact order code frozen. Same exact wetting-load candidate and open physical evidence as channel 1.

S0	IDEC XW1E-BV402M-R dual-NC E-stop candidate	Candidate is documented as 40 mm mushroom, turn/pull reset, 2NC, screw terminal and terminal cover. With TOP up in the manufacturer bottom view, project channel 1 is the right NC pair marked 1-2 and channel 2 is the left NC pair marked 1-2. R-/L- prefixes are project-unique KiCad designators, not extra manufacturer markings. Verify orientation, markings and both positively opening NC channels on the received device before wiring.

S1	IDEC HW1B-M1F10-B black momentary 1NO RESET	Exact black flush momentary 1NO screw-terminal complete assembly is frozen for RESET. IDEC states that old and redesigned HW assemblies can ship under the same complete order code during the transition that began 2026-06-15, and the live product-page BOM returned no component detail on 2026-08-07. Do not copy legacy or push-in terminal numbers. The panel shall carry the explicit RESET legend and remain outside the swept envelope. Record the received design, underside orientation, molded terminal marks and released/pressed continuity before replacing either TBD terminal.

S2	IDEC HW1B-M1F10-G green momentary 1NO ARM	Exact green flush momentary 1NO screw-terminal complete assembly is frozen for ARM, distinct from black RESET. IDEC states that old and redesigned HW assemblies can ship under the same complete order code during the transition that began 2026-06-15, and the live product-page BOM returned no component detail on 2026-08-07. Do not copy legacy or push-in terminal numbers. Record the received design, underside orientation, molded terminal marks and released/pressed continuity before replacing either TBD terminal. The panel shall carry the explicit ARM legend; ARM must actuate and release after every safety dropout.

SD1	Littelfuse 75920-01 70 V DC SPST master disconnect candidate	Exact active catalog candidate only: through-panel 75920-01 with yellow knob, OFF-position padlock feature and two identical 3/8-24 studs. Littelfuse permits high-side use, but published current-cycle ratings depend on 4/0 cable and are not project conductor or fault-duty proof. Source/load stud assignment, lug stack, touch protection, panel location, load-break rule, zero-energy verification, human factors and qualified Boston application review remain open. SD1 is not the E-stop and has no functional-safety credit.

SR1,SRA1	Pilz PNOZ s4 24 VDC 3 n/o 1 n/c, order 750104	Final ARM and external-device-monitoring relay. Mode: short-cross detection plus monitored start on falling edge; seal and inspect selector with power removed.,First-stage E-stop eligibility relay. Mode: short-cross detection plus monitored start on falling edge; seal and inspect selector with power removed.

TP1-TP16	Harwin S1751-46R SMT test point	Dedicated clip/probe point. Confirm probe compatibility, installed access, clearance, marking, retention and no-short test method on the assembled guarded board.

WDCTRL1	Raspberry Pi Pico 1, order SC0915 / RP2040	Monotonic heartbeat monitor. Physical GPIO candidates are frozen for review; platform startup, external bias, compilation, HIL and shared failures remain open and receive no safety credit.

XT1	Phoenix PT 2,5 six-position terminal group: 5x 3209510 gray, 1x 3209523 blue, 1x 3030417 end cover, 2x 3022218 end brackets, 1x 0828734 marker sheet	Exact six-position family and position-to-net allocation are frozen with no bridges. PT 2,5 item 3209510 and blue item 3209523 each provide two push-in connections and 5.2 mm width; D-ST 2,5 item 3030417 is the open-side end cover; two CLIPFIX 35 item 3022218 end brackets retain the group; UCT-TM 5 item 0828734 supplies 5.2 mm markers. Conductor order code, ferrule/direct-wire method, protection, current/temperature coordination, received compatibility, strip length, installed retention, marking and point-to-point evidence remain open.