Battery Power Management Board Troubleshooting (BQ24170 + TPS61235)

@Mahihassi

As an accomplished Electrical Engineer specializing in embedded systems, PCB design, and product engineering, I am confident I possess the skills and expertise necessary to troubleshoot your battery power management board failures. My vast experience with a range of microcontrollers, including TI Tiva series (boasting a similar charging circuit) and my proficiency in firmware development using Embedded C/C++, will enable me to quickly get to the bottom of your TPS61235 boost output failures. I want to emphasize my knowledge and familiarity with the BQ24170 and TPS61235 chips as key differentiators for this project. Through years of developing cutting-edge firmware solutions, I've amassed a deep understanding of their intricacies. My skills in signal processing and control systems also come into play here as they enhance my ability to solve challenging, recurring issues like yours. My commitment extends beyond surface-level fixes; I offer a holistic approach that encompasses root cause analysis and long-term resolutions. Furthermore, my experience isn't limited to identifying problems; I am adept at providing full-scale product engineering solutions readying your hardware for market. Partner with me and let's ensure your dedicated battery pack works seamlessly with all design updates.

@MuhammadUzair16

Hi, I am an embedded systems engineer with over 16 years of experience developing and troubleshooting battery-powered consumer products from concept through production, including the supporting firmware where needed. I can review the complete BQ24170/TPS61235 design, PCB layout, component ratings, operating modes, and failure history to identify why the boost stage is repeatedly failing. I’ll focus on startup and load transients, switch-node layout, thermal stress, battery conditions, charger/boost interaction, protection, and component derating, then provide specific design corrections and a practical validation plan. If you can share measurements or failed-board observations alongside the design files, I can correlate them with the schematic and layout. Are failed boards available for bench testing, or should the initial diagnosis be based on your files and measurements? I’d be glad to discuss the details and help make the board production-reliable.

@amelectronics

Hi, I have experience in designing Circuits and can complete your project. I have expertise in the following: 1- Designing schematic and PCBA 2- Ordering the PCBA and getting boards manufactured. 3- Writing firmware for the PCBA to make sure everything works as expected. 4- I can also develop smartphone apps to communicate and control the hardware. If you wish we can discuss in chat. Thank you.

@tshibsamuel477

Hi there, I have carefully reviewed your BQ24170 + TPS61235 battery/boost failure issue and can help diagnose the repeated 5 V boost-stage failures from both the schematic and PCB-layout side. With nearly five years of experience in mechatronics, power electronics, PCB design, LiPo systems, DC/DC converters, and hardware debugging, I can review the complete design files, check component sizing and derating, switching-loop layout, thermal behavior, startup/inrush conditions, output loading, protection, and transient events that may be overstressing the TPS61235. I can provide a clear root-cause report with recommended schematic/layout corrections and help validate the next revision. Please send me a message with the design files, failure symptoms, and load conditions so I can start reviewing it quickly. Best regards, Samuel tshibangu

@Adeel2k14

I will personally conduct your root-cause failure analysis and help you eliminate these TPS61235 failures. As a senior electronics engineer specializing in power electronics, battery management systems, and SMPS design, I have extensive experience troubleshooting high-current synchronous boost converters and LiPo charge topologies. How I’ll diagnose the issue: - Analyze input voltage spikes, inductive ringing, and switch-node (SW) overshoot. - Review layout for ground loops, thermal dissipation, and output capacitor ESR/ESL. - Evaluate load transients, soft-start, and BQ24170 charging interactions. - Deliverables: Written failure report with corrective layout and schematic fixes. Turnaround: 4–5 days.

@debosx

Hello! I'm a highly skilled PCB Designer with over 10 years of expertise in delivering reliable and efficient PCB designs. I specialize in creating precision designs tailored to client's needs, utilizing top-tier design tools such as Altium Designer, Autodesk Eagle, KiCad, EasyEDA, Siemens PADS, DipTrace, Allegro/OrCAD, Fritzing and Proteus. My goal is always to ensure the highest quality and performance in every project. Core Expertise : • Schematic Capture & Layout Design • Component Selection & Library Management • Reverse Engineering (PCB Replication, PCB Cloning) • Gerber, BOM, and CPL File Generation & Manufacturing Support • Design for Manufacturability (DFM) and Design for Assembly (DFA) • PCB Design & Development (Single, Double, Multi-Layer, Flexible PCBs) Industries Served : • Medical Devices • Telecommunications • Consumer Electronics • Industrial Equipment • Automotive Electronics • Safety and Security Devices Why Choose Me? • Attention to Detail and Commitment to Quality • Strong Communication Skills & Client-Centric Focus • Timely Delivery & Flexible Approach to Meet Project Requirements I would love to help you with your next PCB design project. Feel free to reach out, and let’s discuss how I can bring your ideas to life! Best Regards, Utpal

@yaroslavmark

Hi, I am a Senior Power Electronics and Embedded Systems Engineer with 10+ years of experience in battery-powered products, DC/DC converters, and PCB design, including Li-ion charging, boost regulators, power integrity, and failure analysis for industrial IoT and embedded devices. I have designed and debugged 50+ mixed-signal PCBs using Altium/KiCad, including power systems with BQ-series chargers, buck/boost converters, protection circuits, and high-current battery applications. Approach: ✅ I will review the complete schematic, PCB layout, BOM, and TPS61235 application design to identify potential issues related to switching loops, compensation, component selection, thermal stress, and transient behavior. ✅ I will analyze failure mechanisms using power measurements, oscilloscope waveform analysis, load transient testing, and comparison against TPS61235 datasheet design requirements. ✅ I will verify battery charging, boost startup, protection paths, current limits, and PCB layout improvements to determine the root cause and recommend reliable fixes. Questions: ✅ Could you provide details about the TPS61235 failure symptoms, such as output short, IC damage, overheating, or failure after specific operating conditions? ✅ What are the battery voltage range, 5V output load profile, peak current requirements, and exact failure occurrence timing? ✅ Do you have previous PCB revisions and test data showing what design changes were already implemented? Best, Yaroslav

@sakshis576

With a substantial background in Circuit Design, Electronics, and Embedded Systems, I have the expertise necessary to effectively troubleshoot and diagnose the failures you're experiencing with your power board. My familiarity with both the BQ24170 and TPS61235 components is directly relevant to your project's needs, and my proficiency in PCB Design and Layout will be invaluable in analyzing your design files to pinpoint any potential flaws. Moreover, my strong history of dealing with similar battery power management issues, which includes devising creative solutions for repeated failures in complex designs, has instilled in me a meticulous approach that promises effective results. This attention to detail has been instrumental in rectifying design shortcomings to enhance performance and efficiency.

@TingWang250617

Hi, I can help diagnose the repeated TPS61235 boost converter failures in your power board. I have experience reviewing power supply designs and troubleshooting issues related to LiPo charging, boost converters, component selection, PCB layout, thermal performance, and transient conditions. I can review your schematic, PCB layout, BOM, and previous design revisions to identify the likely root cause of the TPS61235 failures. I will also recommend the necessary design changes and tests to verify the solution. I’m comfortable working with the BQ24170 and TPS61235 and can provide a clear, practical analysis based on your existing design files. I’d be happy to review the files and discuss the failure symptoms before starting. Ting

@abdurRafiqM

HI, I am an experienced electronics and PCB Design engineer, specialised in use of ECAD software such as Altium Designer, KICAD, EasyEDA, etc. for the the design of electronics and PCB. I will design your projects to meet your Requirements and the industry standard. I do all kinds of circuits such as Power delivery circuit, Sensor Integrated Circuits, wireless control, MCUs etc. I will deliver the following. The Schematics for your Design The PCB for the design Bill of materials(If needed) Gerber, Pick and Place and other manufacturing and assembly drawings needed. Full Support and consultancy till the project is done. Kindly send me message for my previous designs and also so we can discuss further on your project I look Forward to working with you. Best Regards, Abdur-Rafiq

@shadabkhan92

As someone who has built and implemented IoT hardware with an emphasis on circuit design and embedded systems, I believe I am a perfect match for your project. I have experience working on similar projects, troubleshooting PCB-related issues, like the ones you're currently facing. With my expertise, we can quickly identify and resolve the repeated TPS61235 boost output failures that are plaguing your power board. In addition, my proficiency with Odoo ERP will give us an added advantage as we can ensure effective integration of your power management board into your existing workflows. This level of holistic integration will provide you with a robust solution, minimizing potential future risks and failures.

@PathumSudarshana

Hi, I can help diagnose the repeated TPS61235 boost failures. I’ll review your schematics, PCB layout, BOM, and revision history, focusing on the TPS61235, BQ24170, power paths, transients, component selection, and layout. I’ll work to identify the actual root cause and recommend practical fixes to make the design reliable. I’m ready to review the design files and failure data.

@ssumitkumar7800

Hi, Repeated TPS61235 failures after multiple design revisions usually point to an underlying power-path, transient, layout, thermal, component-selection, or startup/load interaction rather than simply a bad IC. I can review the complete design and work systematically toward the actual failure mechanism rather than just suggesting another board revision. I would start by reviewing: BQ24170 charging and battery power path TPS61235 boost configuration and operating conditions Input/output capacitor selection and ratings Inductor, diode/rectification path, and current capability PCB layout, grounding, return paths, and high-current loops Battery voltage range and transient conditions Startup behavior and load characteristics Protection circuitry and possible over-voltage/current events Thermal conditions and component derating Changes between your previous board revisions I’d compare the design revisions to identify what changed and whether those changes could have introduced a failure condition, then develop a focused test/diagnostic plan to validate the suspected root cause. If you provide the schematics, PCB files, BOM, datasheets, and details of how/when the TPS61235 fails, I can start with a design review and narrow down the most likely causes before recommending hardware changes. Best, Sumit

@bohdan38

My extensive experience in embedded hardware and firmware development, with a deep understanding of power systems and battery-powered electronics, makes me the ideal choice to tackle the issues you're facing. I have worked on numerous projects similar to yours, and my clients have always appreciated my ability to quickly identify and resolve complex hardware problems. In previous roles, I have successfully designed and troubleshooted systems employing various battery charging ICs and boost converters such as the BQ24170 and TPS61235. My familiarity with these components will allow me to efficiently dig into your design files and identify potential areas of concern. Additionally, my proficiency in tools like oscilloscopes, logic analyzers, spectrum analyzers, and JTAG/SWD tools will prove highly valuable in the debugging process. I truly thrive when faced with challenges like identifying repeated failures in electrical systems. With every hurdle encountered during my career, I've learned something new and developed better problem-solving skills. I assure you that I'll bring not just my technical expertise but also a passionate curiosity to thoroughly uncover the root causes of these failures for you. I look forward to working together to create a more reliable battery pack for your product.

@shenglin0617

Hello, I have read your problem description. I am a Chinese embedded hardware engineer with 8 years of power electronics design and failure analysis experience. I have worked with TI charger and boost ICs including BQ24170 and TPS61235, so I know their typical failure modes well. Repeated TPS61235 failure after multiple design updates usually points to a few things I will check first: input capacitor placement and loop stability, output overvoltage stress during load disconnect, thermal stress at the boost switch node, and inrush current when the battery is first connected. I will also check the PCB layout around the TPS61235 switching loop, because a bad loop causes ringing that kills the IC over time even if the schematic looks correct. I need your design files: schematic PDF, PCB layout, BOM with actual part numbers, and any test data or photos of failed boards. I will review the design, identify the most likely failure mechanism, and give you a clear report with root cause analysis and specific fixes. If needed I can also modify the design and provide updated files. I can start immediately. I have done similar failure investigations for battery powered products and found issues like missing snubbers, wrong capacitor derating, and layout-induced ringing. Looking forward to helping you solve this. Best regards, ShengLin Gu.

@Santoshchaulaga

Hello, I am Santosh Chaulagain, a professional Electrical Engineer and PCB Designer with over 7 years of experience in schematic design, PCB layout, and embedded systems, including ESP32, IoT devices, analog and digital circuits. I have successfully completed multiple projects for clients worldwide, delivering reliable and manufacturable designs. I have carefully reviewed your project requirements and I am confident that I can provide a high-quality solution tailored to your needs. My expertise includes PCB design using industry standards, component selection, BOM preparation, Gerber generation, and design optimization for cost and performance. I always ensure that my designs are fabrication-ready and tested for reliability. I focus on clear communication, timely delivery, and customer satisfaction. I am happy to discuss your project in detail and provide revisions until the final result meets your expectations. Looking forward to working with you. Best regards, Santosh C. Electrical Engineer | PCB Designer | ESP32 & IoT Specialist

@Aaleen110

The repeated failures of the TPS61235 boost output, despite multiple design updates, point to a subtle interaction issue, likely in the charging stage or power sequencing before the boost converter activates. I'd start by simulating the BQ24170 charging profile in LTspice, checking for any unexpected voltage spikes or current surges that could stress the TPS61235 during its enable transition. Then I'd examine the PCB layout for impedance mismatches on the input and output power traces of the TPS61235, also looking closely at the component placement for the BQ24170's output capacitors and the TPS61235's input capacitors, making sure they are as close to the IC pins as possible. I'd also build up a test board with select components and use an oscilloscope to capture the exact voltage and current waveforms at the input and output of the TPS61235 during charge and discharge cycles, also checking the enable pin signal for any ringing. The brief mentions multiple design updates but doesn't specify if the component selection for the BQ24170 or TPS61235 has changed or if it's just the surrounding circuitry. I'll assume component selection has remained consistent and the updates are layout or passive component changes until told otherwise. The design files are available, so I'd expect to receive schematics, PCB layout files in Altium Designer, and any relevant bill of materials. 8 reviews on here, everything delivered on time and on the agreed price so far, plus Preferred Freelancer status. What is the specific failure mode observed for the TPS61235: is it a hard failure, or does it exhibit intermittent output voltage drops? Send over the design files so I can begin the schematic review.

@nubelo_VzWb6Th2

Hello, I am a Master of Electronic Engineering with extensive experience in PCB Design and Power Electronics. I have carefully analyzed your requirement regarding the failures in the TPS61235 boost stage and the BQ24170 charging circuit. Diagnosing failures in high-current switching regulators like these requires a deep dive into specific technical areas: 1. PCB Layout Audit: Checking for proper grounding (PGND/AGND separation) and minimizing parasitic inductance in switching loops. 2. Inductor Saturation: Verifying if the peak current is exceeding the inductor's saturation rating during transients or heavy loads. 3. Input/Output Capacitance: Ensuring Low-ESR ceramic capacitors are correctly placed to manage high-frequency ripple and voltage spikes. 4. Inrush Current & Startup: Evaluating if the startup sequence or soft-start timing is causing overstress and damaging the ICs. I will provide a comprehensive technical report identifying the root cause and the corrected design files (Altium/KiCad) to ensure long-term reliability and efficiency. My academic background and hands-on experience with Texas Instruments power management ICs make me the ideal candidate for this troubleshooting task. I am available to start immediately and review your schematics today. Best regards, MSc. Luis Alberto Salas.

@Mani16052026

I’m a strong fit for this project because I have hands-on experience in embedded electronics, power supply design, PCB troubleshooting, and root-cause analysis of hardware failures. For your BQ24170 + TPS61235 battery power management board, I would not simply replace the failed TPS61235. I would systematically investigate the complete power path and identify the actual reason for the repeated failures, including: BQ24170 charging and power-path behaviour TPS61235 VIN/VOUT/SW transients and overshoot Inductor selection and saturation Battery voltage and load-current conditions Startup and load-transient behaviour PCB layout and high-current return paths Power-source transitions and possible reverse current into the 5V rail Differences between previous and latest board revisions I can review your schematic, PCB layout, BOM and previous design revisions, correlate them with the failure symptoms, and recommend practical hardware modifications to eliminate the root cause. My background in embedded systems and electronics product development allows me to look at the problem from both the circuit and system level rather than treating the boost converter in isolation. I can start by reviewing the design files and failure history, then provide a structured troubleshooting plan and clear recommendations for the next hardware revision.