DockOne board: request for quote

From: IEMI Labs, [email protected] · Date: 4 November 2026 · Reference: IEMI-D1-GB-A

We are asking for a turnkey quote: finish the design of our pair of guard boards, make it, assemble it, test it, and deliver boards that are ready to run. When a board arrives, we power it from a 120 V AC bench supply through an isolating transformer on guard A’s mains terminal, with guard B on the lead, put in our microSD card, and it starts our software. We do no setup, soldering or configuration.

All files are in the design pack (zip). The board, part by part: iemilabs.com/build/dockone-boards.

1. The board

Two rigid-flex boards, one in each steel dock-door guard. Guard A: an 8-layer 166 × 142 mm main board flat over the bay plate (RK3576J with a heat block to the bay plate, 4 GB LPDDR4X, 32 GB eMMC, latched microSD, PCB-mount IRM-20-5 mains supply with fuse, surge part and push-in terminal, eFuses, RS-485 and sync line chips, latched 8-pin lead header, security and ID chips, strike sensor); a front strip 166 × 190 mm behind the front face (8 call-light LEDs, sounder, Wi-Fi 6/BT module behind the antenna window, Hall tamper switch, the dock camera’s IMX415 on a 16 × 16 tab); a nose strip 62 × 200 mm behind the nose (8 call-light LEDs, the door camera’s IMX415 on a 16 × 16 tab); flexes F1 and F2. Guard B: a 4-layer 100 × 80 mm main board (latched microSD, lead header, eFuse, RS-485, 3.3 V buck, security and ID chips, strike sensor); a front strip (ESP32-S3-WROOM-1 module, IWRL6432AOP 60 GHz radar with its power and flash, SHT45, 8 call-light LEDs, sounder, Hall tamper switch); a nose strip with the OV2640 door camera on a tab and 8 call-light LEDs.

The outline, sections and placement of all 90 parts are fixed (KiCad 10 file, design rule check: 0 violations), each checked against our mechanical CAD. Please keep the outline and part positions, and tell us if anything must move.

2. Parts

Ref	Part	Where
U1	Rockchip RK3576J (industrial, −40 to 85 °C), 8 cores, 6 TOPS NPU, 16 MP ISP; heat block down to the steel bay plate	main
HS1	Aluminium block 24 × 24 × 10.4 with 1 mm gap pads, from the RK3576J to the 5 mm steel bay plate welded into the guard (the guard is the heat sink)	main
U2	LPDDR4X 32 Gbit ×32 (4 GB), 200-ball FBGA	main
U11	eMMC 5.1 32 GB industrial, 153-ball FBGA (shipped empty, so the card always starts first; our loader on the card reads the card first; keeps clip store)	main
C1	RK3576J decoupling field (behind the chip)	main
U3	Rockchip RK806S-5 power chip and inductors: RK3576J core, NPU, GPU, logic, DDR and 1.8/3.3 V from the 5 V rail	main
Y1	24 MHz MEMS oscillator (SiTime SiT8008 class)	main
Y2	32.768 kHz MEMS oscillator (SiTime SiT1533 class)	main
U8	Microchip ATECC608B security chip, UDFN-8: signs every call, the trailer log and the evening summary	main
U9	ID EEPROM 2 kbit (product, guard A, board version, serial, calibration)	main
U6	ST LSM6DSOX motion chip, LGA-14: forklift strikes on the guard, the cap lifted	main
J1	microSD socket with a hinged, latched lid (Amphenol 101-00660 class), fitted on every board: our software starts from the card; reached by lifting the cap	main
U91	microSD ESD and filter array, 6 lines (TPD6F003-class), with 22 Ω series resistors on CLK, CMD and D0–D3 and the card-detect line	main
U90	microSD card power switch (TPS22917-class load switch, 3.3 V, driven by the card power-enable pin) with a 10 kΩ discharge resistor: a stuck card can be power-cycled	main
U40	Mean Well IRM-20-5 PCB-mount 5 V 4 A supply (encapsulated, IEC/UL 62368-1, class II), on the dock door’s own 120 V circuit	main
J10	WAGO 2604-3103 push-in PCB terminal block, 3-pole 5 mm (L, N, earth to the guard), wires clamped, no plug; behind the conduit entry	main
F1	T2A fuse (Littelfuse 0443 class, SMD) and a 150 V MOV before the supply	main
U42	TI TPS25947 class eFuse (4 A, reverse block) + TVS on the 5 V rail; second eFuse (1 A) on the lead to guard B	main
J3	Molex Micro-Fit 3.0 43045-0802 8-pin vertical header, positive latch, keyed (5 V ×2, GND ×3, RS-485 A/B, frame sync); the lead runs in the door header conduit	main
U43	TI THVD1450 RS-485 transceiver (10 Mbps, ±18 kV) and a sync line driver with TVS	main
TP1	Factory pads: USB 2.0, debug serial, boot, rails, current sense	main
D1	RGB LED with driver, 5050 (WS2812B class), behind the front slot: green door free, amber trailer, red stop	front
D2	RGB LED with driver, 5050 (WS2812B class), behind the front slot: green door free, amber trailer, red stop	front
D3	RGB LED with driver, 5050 (WS2812B class), behind the front slot: green door free, amber trailer, red stop	front
D4	RGB LED with driver, 5050 (WS2812B class), behind the front slot: green door free, amber trailer, red stop	front
D5	RGB LED with driver, 5050 (WS2812B class), behind the front slot: green door free, amber trailer, red stop	front
D6	RGB LED with driver, 5050 (WS2812B class), behind the front slot: green door free, amber trailer, red stop	front
D7	RGB LED with driver, 5050 (WS2812B class), behind the front slot: green door free, amber trailer, red stop	front
D8	RGB LED with driver, 5050 (WS2812B class), behind the front slot: green door free, amber trailer, red stop	front
LG1	Clear PC light bar 52 × 6 from the LEDs to the front slot, frosted face	front
SP1	CUI CMT-1603 class magnetic sounder, 85 dB at 10 cm, behind the tone holes	front
GK1	Foam sound gasket ring from the sounder to the tone holes	front
U5	AMPAK AP6275S Wi-Fi 6 + Bluetooth 5 module (certified, RK3576 SDK default), chip antenna at its top edge behind the antenna window	front
U21	Dock camera LDOs 2.9 / 1.8 / 1.1 V and its 37.125 MHz MEMS oscillator	front
U7	TI DRV5032FB Hall switch at the strip’s top edge: the magnet in the cap holds it; lifting the cap is logged and signed	front
U36	Level shifter for the call-light data lines (3.3 to 5 V)	front
D9	RGB LED with driver, 5050 (WS2812B class), behind the nose slot: seen from the trailer and across the door	nose
D10	RGB LED with driver, 5050 (WS2812B class), behind the nose slot: seen from the trailer and across the door	nose
D11	RGB LED with driver, 5050 (WS2812B class), behind the nose slot: seen from the trailer and across the door	nose
D12	RGB LED with driver, 5050 (WS2812B class), behind the nose slot: seen from the trailer and across the door	nose
D13	RGB LED with driver, 5050 (WS2812B class), behind the nose slot: seen from the trailer and across the door	nose
D14	RGB LED with driver, 5050 (WS2812B class), behind the nose slot: seen from the trailer and across the door	nose
D15	RGB LED with driver, 5050 (WS2812B class), behind the nose slot: seen from the trailer and across the door	nose
D16	RGB LED with driver, 5050 (WS2812B class), behind the nose slot: seen from the trailer and across the door	nose
LG2	Clear PC light bar 6 × 52 from the LEDs to the nose slot	nose
U31	Door camera LDOs 2.9 / 1.8 / 1.1 V and its 37.125 MHz MEMS oscillator	nose
U106	ST LSM6DSOX motion chip, LGA-14: forklift strikes on guard B, the cap lifted	main
U108	Microchip ATECC608B security chip: signs guard B’s frames and readings	main
U109	ID EEPROM 2 kbit (product, guard B, board version, serial, calibration)	main
J101	microSD socket with a hinged, latched lid (Amphenol 101-00660 class), fitted on every board: guard B’s software and clip store on the card	main
U93	microSD ESD and filter array, 6 lines (TPD6F003-class), with 22 Ω series resistors on CLK, CMD and D0–D3 and the card-detect line	main
U92	microSD card power switch (TPS22917-class load switch, 3.3 V, driven by the card power-enable pin) with a 10 kΩ discharge resistor: a stuck card can be power-cycled	main
J103	Molex Micro-Fit 3.0 43045-0802 8-pin vertical header, positive latch, keyed: the same pin-out as guard A	main
U142	TI TPS25947 class eFuse (1 A, reverse block) + TVS on the 5 V from the lead	main
U143	TI THVD1450 RS-485 transceiver and the sync line receiver with TVS	main
U103	TI TPS62A02 class 3.3 V 2 A buck for the module, radar and camera	main
TP101	Factory pads: USB (ESP32-S3), debug serial, boot, rails, current sense	main
D101	RGB LED with driver, 5050 (WS2812B class), behind the front slot	front
D102	RGB LED with driver, 5050 (WS2812B class), behind the front slot	front
D103	RGB LED with driver, 5050 (WS2812B class), behind the front slot	front
D104	RGB LED with driver, 5050 (WS2812B class), behind the front slot	front
D105	RGB LED with driver, 5050 (WS2812B class), behind the front slot	front
D106	RGB LED with driver, 5050 (WS2812B class), behind the front slot	front
D107	RGB LED with driver, 5050 (WS2812B class), behind the front slot	front
D108	RGB LED with driver, 5050 (WS2812B class), behind the front slot	front
LG101	Clear PC light bar 52 × 6 from the LEDs to the front slot	front
SP101	CUI CMT-1603 class magnetic sounder, 85 dB at 10 cm, behind the tone holes	front
GK101	Foam sound gasket ring from the sounder to the tone holes	front
U110	TI IWRL6432AOP 60 GHz radar, antennas in package (±70° azimuth, ±40° elevation): forklifts and people coming to the door, their speed	front
U111	Radar rails (TI LP87745 class), 40 MHz MEMS oscillator (SiTime SiT8008 class) and 2 MB QSPI flash	front
U112	Sensirion SHT45 temperature and humidity chip on a slotted tongue behind the vents (frost, sweating loads, an open door in winter)	front
U101	Espressif ESP32-S3-WROOM-1-N16R8: ESP32-S3, 16 MB flash, 8 MB PSRAM (camera frames), PCB antenna up behind the antenna window, FCC/CE certified; castellated, soldered	front
U107	TI DRV5032FB Hall switch at the strip’s top edge, under the cap magnet	front
U136	Level shifter for the call-light data lines	front
D109	RGB LED with driver, 5050 (WS2812B class), behind the nose slot	nose
D110	RGB LED with driver, 5050 (WS2812B class), behind the nose slot	nose
D111	RGB LED with driver, 5050 (WS2812B class), behind the nose slot	nose
D112	RGB LED with driver, 5050 (WS2812B class), behind the nose slot	nose
D113	RGB LED with driver, 5050 (WS2812B class), behind the nose slot	nose
D114	RGB LED with driver, 5050 (WS2812B class), behind the nose slot	nose
D115	RGB LED with driver, 5050 (WS2812B class), behind the nose slot	nose
D116	RGB LED with driver, 5050 (WS2812B class), behind the nose slot	nose
LG102	Clear PC light bar 6 × 52 from the LEDs to the nose slot	nose
U121	Door camera LDOs 2.8 / 1.3 V and its 24 MHz MEMS oscillator	nose
U30	Sony IMX415-AAQR-C 8 MP colour camera chip (C1, 3840 × 2160), turned 35° out to the trailer and 15° down	tab
LH2	M12 lens holder with a 60 × 91.5° lens over the camera chip, its front 0.3 mm off the inside of the guard wall at the closest corner, the lens barrel 8.1 mm on through the hole to just inside the face	tab
U20	Sony IMX415-AAQR-C 8 MP colour camera chip (C1), turned 30° to the door and 15° down over the dock floor	tab
LH1	M12 lens holder with a 70 × 43° lens over the camera chip, its front 0.3 mm off the inside of the guard wall at the closest corner, the lens barrel 7.6 mm on through the hole to just inside the face	tab
U120	OmniVision OV2640 2 MP camera chip (chip-scale package), turned 35° out to the trailer and 15° down: stereo with guard A	tab
LH101	M7 lens holder with a 60 × 75.2° lens over the camera chip, its front 0.3 mm off the inside of the guard wall at the closest corner, the lens barrel 7.3 mm on through the hole to just inside the face	tab

Each part’s size, side and position is in dockone-board-parts.csv in the pack. Ask before you substitute a part.

3. Scope of work

1. Schematic from Rockchip’s RK3576 reference design and Espressif’s ESP32-S3 hardware design guide and our block list. We review it before layout.
2. Layout in our outline and placement: the RK3576 memory and power routing, impedance-controlled MIPI and USB, and RF for every antenna keep-out. Lay the fast lines on a solid ground plane (inner layer 1, supply on inner layer 2; on a 2-layer section the whole bottom is ground under the module), with one via beside each ground and supply pad and no vias in pads unless you quote filled and capped vias (IPC-4761 type VII); no copper or vias in the antenna keep-out on any layer, none under the card socket; route the impedance lines first (camera MIPI pairs 100 Ω differential, USB 90 Ω, antenna 50 Ω) and add an impedance test coupon. Include the stack-up proposal and DFM, and a rigid-flex drawing (bend lines, stiffeners, coverlay).
3. Fabrication of the rigid-flex board.
4. Sourcing of all parts.
5. Assembly, both sides, with X-ray inspection of the ball-grid parts. Conformal coating (IPC-CC-830), with the sensors, sockets, connectors and antennas masked.
6. Board support package: U-Boot and a Linux device tree for this layout from Rockchip’s RK3576 SDK, with a real-time (PREEMPT_RT) kernel and the cameras’ frame-sync inputs. A Rockchip SDK image must start from the microSD card. Camera drivers: door camera a IMX415 at 2160 × 3840, 5 fps; door camera a (gap) IMX415 at 2160 × 3840, 5 fps; dock camera a IMX415 at 3840 × 2160, 2 fps; door camera b OV2640 at 1200 × 1600, 5 fps. Flash our ESP32-S3 image (we send it). We add our own software on top.
7. Test of every board to the acceptance list in §5, with a test report per serial number.
8. Deliverables: KiCad (or Altium) source, Gerbers, drill, pick-and-place, BOM, stack-up, test procedure and reports, and the BSP source.

4. “Ready to run” on delivery

This is the most important part of the job:

• Every board arrives assembled, programmed and tested.
• We put our microSD card in (J1, a hinged, latched socket) and power it, and it starts. No soldering, no jumpers, no settings, no flashing.
• The ID EEPROM is written with the serial number and board revision.
• The security chip is provisioned per the steps we will send.

5. Acceptance tests (each board, with report)

1. Current-limited first power-on: no short, idle current within the agreed limit.
2. Rails: every power rail within ±3 %.
3. Boot: starts the Rockchip SDK image from the microSD card to a shell over the debug UART; the eMMC is detected and can be written.
4. Door camera A: IMX415 streams 2160 × 3840 at 5 fps with no lost frames over 10 minutes, and a frame of a test chart is saved; the frame-sync input triggers frames.
5. Door camera A (gap): IMX415 streams 2160 × 3840 at 5 fps with no lost frames over 10 minutes, and a frame of a test chart is saved; the frame-sync input triggers frames.
6. Dock camera A: IMX415 streams 3840 × 2160 at 2 fps with no lost frames over 10 minutes, and a frame of a test chart is saved; the frame-sync input triggers frames.
7. Door camera B: OV2640 streams 1200 × 1600 at 5 fps with no lost frames over 10 minutes, and a frame of a test chart is saved; the frame-sync input triggers frames.
8. Radios: U101 (Espressif ESP32-S3-WROOM-1-N16R8): each joins or answers a test station.
9. Sensors and outputs, each read or driven in turn: U91, U93 (microSD ESD and filter array), D1–D116 (RGB LED with driver), U7, U107 (TI DRV5032FB Hall switch at the strip’s top edge), U103 (TI TPS62A02 class 3.3 V 2 A buck for the module), U110 (TI IWRL6432AOP 60 GHz radar), U111 (Radar rails), U112 (Sensirion SHT45 temperature and humidity chip on a slotted tongue behind the vents).
10. Power: the draw at idle and at full load from a 120 V AC bench supply through an isolating transformer on guard A’s mains terminal, with guard B on the lead, against our estimate.
11. Heat: the RK3576J temperature after 1 hour at full load in a 35 °C room, against our estimate.

6. Quantities and timing

Item	Quantity
Rev A boards	5 and 20: please quote both
Budget prices	for 100 and 1,000 boards
Quote wanted	within two weeks of this request
Boards wanted	please give your lead times for design, fabrication and assembly

7. Our design review

Before we order, every board-level number is checked against its target: 24 pass, 3 fixed by the review, 12 to prove on rev A, 0 fail. The full review is on the board page and in the pack. Rev A must let us measure:

• AI engine time per frame
• Power cut
• Card grade
• Wi-Fi from inside a steel guard
• Guard B’s radio (BLE back-up link)
• Fast lines on a solid ground plane
• Board inside the product CAD, every part checked in 3D
• Camera tabs on their brackets
• Mains on the board
• Cap tamper sensor
• Forklift strike on the guard
• Flex lengths

8. The design pack

Download the design pack (zip): this request, the KiCad 10 board, a 3D model (STEP), side A and side B drawings (PDF), the parts list, placement, the board outline and drawing layers as Gerbers, and the design review.

Questions: [email protected]