USB-C 12-Channel Servo Controller

12-channel USB-C servo controller, Pololu Maestro compatible, with an MCP server so AI agents (Claude, etc.) can drive servos. $18 on Tindie · product page.

_{▶ 2-minute video: wiring, current monitoring, GUI and the controller driving a real MG995}

Open-source alternative to the Pololu Mini Maestro 12 that speaks the Maestro serial protocols, so Maestro libraries work unchanged — plus USB-C, servo-rail current and voltage sensing, on-board scripts. Built for JLCPCB turnkey assembly, ≈ $4.43 per board at 100 units against $29.95 for the Maestro.

MCU	WCH CH32V203C8T6, RISC-V 96 MHz, LQFP-48
Channels	12 hardware PWM, 50 Hz, 0.5 µs; travel limits per channel (64–4080 µs, 500–2500 default); analog input on 0–7
Host interface	USB-C, CDC serial (no driver); ASCII protocol and the Pololu Maestro Compact / Pololu / Mini SSC protocols
Servo power	separate rail on a 5.08 mm screw terminal, 5–13.2 V full function, ~5 A total
Sensing	rail current (5 mΩ + INA180A2) and voltage (÷4), overcurrent / LiPo undervoltage cut-off
PCB	66 × 38 mm, 2 layers, all parts top side, 4 × M3
Status	first board verified on hardware 2026-09-28 — selftest.py --rail --move 58/58; channels 1–11 not yet driven with a real servo

Document	For
USER.md	using the board: wiring, power, tools, command reference, flashing
tools/README.md	host tools: library, CLI, GUI, scripts, MCP server, release builds
this file	design: why each choice, BOM and cost, limitations, what is left before fab

---

AI agents (MCP server)

tools/servo_mcp.py is an MCP server that lets an AI agent move servos, run poses and sequences, and read rail current/voltage, with guardrails: per-channel limits, ramped moves, overcurrent stop. pip install -r tools/requirements.txt, then:

Claude Code

claude mcp add servo -- python /path/to/UsbServoController/tools/servo_mcp.py

Claude Desktop (claude_desktop_config.json)

{
  "mcpServers": {
    "servo": {
      "command": "python",
      "args": ["/path/to/UsbServoController/tools/servo_mcp.py"]
    }
  }
}

Add "--port", "COM5" to pick a port, or "--mock" to try it without hardware. Close the GUI first: only one program can hold the serial port.

The server is also on PyPI, so any MCP client can run it without cloning the repo: command uvx, args ["ucan-servo-mcp"] (plus --config path/to/servogui.json to use the limits, poses and sequences saved by the GUI).

---

1. Quick start

pip install -r tools/requirements.txt
python tools/servogui.py              # GUI (or --mock with no hardware)
python tools/servoctl.py set 0 1500   # CLI
cd embedded-ch32 && make flash        # build + flash over USB, ~3 s, no jumper

Downloads: firmware images and the prebuilt GUI for Windows and Linux are on the Releases page. To build the GUI yourself: python tools/build_release.py → tools/dist/.

---

2. Why the CH32V203C8T6

The hard requirement was a USB bootloader in ROM, so a blank chip can be flashed over USB-C with no programmer. That rules out the STM32F103 the design started on (USART-only bootloader). Of LQFP-48 parts that have one and are stocked at JLCPCB:

Candidate	USB boot on blank chip	Stock	$@100
CH32V203C8T6 (chosen)	✅	8,643	0.877
CH32X035C8T6 / CH32F203C8T6	✅	~500	0.72 / 1.02
AT32F415CBT7	✅	10,518	1.319
STM32F072C8T6	✅	2,945	2.495

Cheapest part with real inventory, a third the price of the STM32F072, and pin-compatible with the STM32F103 layout (32 of 33 connected pins identical).

Costs of the choice:

• RISC-V firmware, WCH HAL, no CubeMX.
• An ST-Link will not work. Debug is WCH 2-wire SDI on J9 — needs a WCH-LinkE. Routine flashing is over USB, so the probe is only for debugging.
• PB2 is BOOT1 on this chip, so it is tied low by R17 (5.1 kΩ).

---

3. Hardware

                            U4 INA180A2 (Kelvin across R18) ─► PA5 I_SENSE
J2 Servo V+ ── R18 5mΩ ──┬────────► servo header V+ rail (unfused)
  (VSRV_RAW)              ├─ R19..R22 ÷4 ─► PA4 V_SENSE
                          └─ JP1 ──D2──┐
                                       ├─► HT7533-1 ─► 3V3 ─► CH32V203, LED
USB-C VBUS 5V ─────────────D1──────────┘
GND: one continuous plane, common to both supplies

• Two supply domains, one ground. D1/D2 are a diode-OR so neither feeds the other. Every servo amp crosses R18, so the current reading covers the whole board.
• JP1 (2-pin header, open by default): fit a shunt cap to run the logic from the servo supply with no USB — the Maestro's VSRV=VIN block.
• JP2 (2-pin header): BOOT0 high, for first flash / recovery only.
• Logic draw ≈ 15 mA, so the HT7533-1 (100 mA, 2.5 µA quiescent) dissipates 0.07 W even from 2S LiPo.
• USB-C: CC pull-downs R14/R15, SRV05-4 clamps D+, D−, CC1, CC2.
• Servo signals are 3.3 V through 220 Ω (R1–R12). Headers are SIG / V+ / GND.

Channel map

Ch	0	1	2	3	4	5	6	7	8	9	10	11
Pin	PA0	PA1	PA2	PA3	PA6	PA7	PB0	PB1	PA8	PA9	PA10	PB8
Timer	T2C1	T2C2	T2C3	T2C4	T3C1	T3C2	T3C3	T3C4	T1C1	T1C2	T1C3	T4C3
Analog	✅	✅	✅	✅	✅	✅	✅	✅	—	—	—	—

Reserved: PA4/PA5 rail sensing · PA11/PA12 USB · PA13/PA14 SDI · PD0/PD1 crystal · PC13 LED · PB2 BOOT1. LQFP-48 has only 10 ADC pins, and PA4/PA5 went to sensing, so analog is 8 of 12 — the Maestro 12 has all twelve.

Rail sensing

	Current (R18 + U4)	Voltage (R19–R22)
Parts	5 mΩ 1 W shunt, INA180A2 gain 50, high side	4 × 5.1 kΩ, ÷4, 100 nF
Full scale	13.2 A	13.2 V
Resolution	≈ 3.2 mA	≈ 3.2 mV

High side keeps the ground plane unbroken. It measures total rail current, not per channel. The ADC reference is VDDA = the LDO output (no VREF+ on LQFP-48), so readings are good for thresholds, not calibrated metering. The firmware trips all channels off after 5 bad readings (~50 ms): 5 A default overcurrent, and undervoltage chosen automatically (2S → 6.4 V, 3S → 9.6 V, anything else off). Details in USER.md §4.4.

Power limits

Limit	Set by	Value
Absolute max on J2	C15/C16, 16 V electrolytics	16 V
Full function (voltage sense)	÷4 divider	13.2 V
Continuous current	2.4 mm pour between header rows	~5 A (6.1 A at 20 °C rise)

The 24 A terminal is not the limit; the copper behind it is.

PCB

2 × 1 oz, 1.6 mm, 0.2 mm min trace/space, 0.3/0.6 mm vias. GND is a solid pour on both layers; SERVO_V+ is carried by three priority-ordered top-layer zones. Headers along the bottom edge, USB-C right, screw terminal left, MCU centre.

⚠️ F8 (Update PCB from Schematic) deletes H1–H4 — they have no schematic symbol. Untick Delete footprints with no symbols, or re-add them at (16, 4), (61.5, 4), (16, 33), (61.5, 33).

⚠️ HT7533-1 is not pin-compatible with the AMS1117 it replaced (SOT-89: GND / VIN+tab / VOUT). The tab is VIN.

---

4. Bill of materials and cost

Class: B Basic · P Preferred (both fee-free) · E Extended ($3.07 feeder fee if SMT).

Ref	Part	LCSC	Class	Qty	$/board
U1	CH32V203C8T6, LQFP-48	C3001172	E	1	0.8770
U2	HT7533-1, SOT-89-3	C14289	B	1	0.1430
U3	SRV05-4 ESD, SOT-23-6	C558418	E	1	0.0270
U4	INA180A2, SOT-23-5	C192764	E	1	0.1920
J1	USB-C 16P TYPE-C-31-M-12	C165948	E	1	0.1860
J2	Screw terminal 5.08 mm 2P	C474952	E (THT)	1	0.1920
J3–J8	Pin header 1×6 2.54 mm	C37208	E (THT)	6	0.2520
JP1, JP2	Pin header 1×2 2.54 mm	C358684	E (THT)	2	0.0180
Y1	Crystal 8 MHz SMD5032	C115962	B	1	0.2450
D1–D2	B5819W, SOD-123	C7420330	P	2	0.0340
D3	LED red 0603	C2286	B	1	0.0070
R1–R13	220 Ω 0603 (servo series + LED)	C22962	B	13	0.0650
R14–R17, R19–R22	5.1 kΩ 0603	C23186	B	8	0.0160
R18	5 mΩ 1 W shunt, 1206	C7419996	E	1	0.0370
C1–C8, C17–C18	100 nF 0603 X7R	C14663	B	10	0.1200
C9–C11	10 µF 0603 X5R	C19702	B	3	0.0960
C12	1 µF 0603	C15849	B	1	0.0170
C13–C14	30 pF 0603 C0G	C1658	B	2	0.0160
C15–C16	470 µF 16 V electrolytic	C46550400	E	2	0.2140
				58	$2.7540

J9 (SDI) is not fitted. Shunt caps (C100114, two per board) cannot be fitted by JLCPCB — order them loose, ≈ $1.80 per 100.

100 units	Total	Per board
Components	$275.40	$2.754
Assembly: setup $8.18, stencil $1.53, SMT 167 joints $26.72, THT 42 joints $68.88 + $3.58, 6 feeder fees $18.42	$127.31	$1.273
PCB fabrication (est.)	~$40	~$0.40
Total	≈ $443	≈ $4.43

Excludes shipping and duties. Prices are LCSC qty-100; stock checked 2026-09-19/20 (CH32V203 the thinnest at 8,643) — re-verify before ordering.

What drives cost:

• Through-hole soldering is 57 % of assembly. J3–J8 cost $0.25 in parts and $0.59 in hand soldering. SMT-only with loose headers would cut assembly to $0.55/board.
• Unique Extended SMT parts, not unit price. Hence 220 Ω doubles as the LED resistor, 5.1 kΩ serves CC1/CC2/BOOT0/BOOT1/divider, one SRV05-4 replaces discrete TVS diodes, and JP1/JP2 share one header part.

---

5. Firmware (embedded-ch32/)

RISC-V, WCH ch32v20x HAL and USB device library, xPack riscv-none-elf-gcc 15.2 (make GCC_PATH=... to override). Version USBServoController 0.4.

Flash region	Address	Size	Contents
Bootloader	0x0000	12 KB	own USB CDC bootloader (bootloader/)
Application	0x3000	48 KB	servo firmware
Script	0xF000	2 KB	stored board script
Settings	0xF800	256 B used	travel limits, Maestro speed/accel (User/settings.c, W)

Layout lives in User/flash_layout.h and both Link.ld files.

make                 # build/USBServoController-ch32.{elf,hex,bin}
make flash           # BOOT command -> bootloader -> write, CRC-32 check, restart (~3 s)
make hosttest        # on the PC: sense.c protection (21 supply scenarios), maestro.c protocol, ramps and limits (11)
python tools/verify_pinmap_ch32.py   # schematic <-> pin table <-> firmware

Blank chip or recovery: make full, fit JP2, plug in USB, wchisp flash build/USBServoController-ch32-full.bin, remove JP2, replug. Jumping to the ROM bootloader from firmware does not work on this chip (tested), which is why the board has its own.

Timing: 96 MHz timers, PSC 47 → 0.5 µs ticks, ARR 39999 → 20 ms frame. 0.25 µs would need a 4 MHz tick, which only fits 16 bits at ≥ 100 Hz.

Protocol: one ASCII command per line, one OK / OK <value> / ERR <reason> reply. Servo (S G E X A), rail sensing (I U F L P C Z N), stored script (QC QA QS QI QG QR QX), system (V BOOT). Full reference: USER.md §4.3.

Maestro protocols (User/maestro.c): bytes of 0x80 and above are Pololu Maestro commands — Compact, Pololu (device 12) and Mini SSC framings, with on-board speed and acceleration ramps in the Maestro's units. Both protocols share the port. Reference: USER.md §4.3b.

Script engine (User/script.c): up to 254 instructions — move with ramp time, wait, sync, loop, jump, analog wait/branch — compiled from text by tools/servoscript.py, runs without a PC, optionally at power-up.

Toolchain traps

• interrupt("WCH-Interrupt-fast") is silently dropped by upstream GCC — one warning, then ISRs end in ret instead of mret. Use interrupt("machine").
• GCC 15 defaults to C23, where bool is a keyword; WCH's usb_type.h typedefs it. Built with -std=gnu11 and a patched header.
• -march=rv32imac_zicsr_zifencei — GCC 15 split CSR and fence.i out.
• No printf at runtime. A WCH example printf in the USB suspend hook hung the ISR at bring-up, and PA9 (USART1 TX) is a servo output.

Modified vendor files: usb_endp.c (OUT endpoint → parser), usb_prop.c (line coding via User/cdc_glue.c), ch32v20x_it.c (TIM2 drives servos).

---

6. Limitations and Maestro 12 comparison

Maestro 12	This board	Fix
mini-USB	USB-C	better
no rail sensing	current + voltage, overcurrent and LiPo cut-off	better
$29.95	≈ $4.43	better
5–16 V servo supply	5–16 V (13.2 V full function)	parity
12 analog inputs	8	respin (pin limit)
5 V signals, 5 V user pin	3.3 V, no 5 V rail	respin
TTL serial, daisy-chain, ERR pin, 3 LEDs	USB only, 1 LED	respin
Pololu / Compact / Mini SSC protocols	supported (0.4): set target(s), speed, acceleration, get position / moving state / errors, go home	parity
per-channel min/max 64–4080 µs, 1–333 Hz	per-channel limits 64–4080 µs, saved with W; fixed 50 Hz	rate: firmware
0.25 µs resolution	0.5 µs	firmware, at ≥ 100 Hz
Speed + acceleration in firmware	supported through the Maestro protocol	parity
Settings, home positions, startup behaviour in flash	limits and speed/accel stored; no home positions, all channels boot off	firmware
Error register, serial-timeout failsafe	protocol-error bit only; no serial timeout	firmware
8 KB script language	254-instruction motion script	simpler
Maestro Control Center	own GUI (servogui.py)	Pololu VID-locked
28 × 36 mm	66 × 38 mm	—

Other known gaps: no reverse-polarity protection on J2 — a reversed pack kills U4 and can vent C15/C16 (a P-FET ideal diode, ≈ $0.19, was deliberately left out); the current-sense zero (Z) is lost at power-off.

Joining the Maestro ecosystem

Maestro software splits in two. Runtime control — nearly every community library (FRC4564/Maestro, maestro-servo, ROS 1/2 drivers, Node, C++) — opens the CDC port and speaks the Pololu/Compact/Mini SSC byte protocols without checking USB IDs. Configuration (Control Center, UscCmd) uses control transfers bound to Pololu's VID 0x1FFB and can never work here.

Firmware 0.4 implements those serial protocols, so the runtime libraries work unchanged: verified on hardware with an unmodified FRC4564 maestro.py (targets, speed, acceleration, position, moving state). One dispatch on the first byte serves everything: 0xAA Pololu, 0xFF Mini SSC, 0x80–0xFE Compact, printable ASCII the existing protocol.

Still different from a Maestro: 0.5 µs output steps (0.25 µs needs ≥ 100 Hz frames), a fixed 50 Hz rate, no home positions, CRC or serial timeout. Per-channel travel limits (64–4080 µs) and start-up speed/acceleration are stored on the board with W — the GUI's gear button sets the limits. Next steps: configurable frame rate → serial-timeout failsafe → home positions.

---

7. Design notes

JP1 is a header, not a power-mux IC. Automatic muxing above 6 V needs an ideal-diode controller plus FETs (LM5050 +$2.12/board); TPS2116 stops at 5.5 V. The diode-OR costs $0.03 and JP1 carries only the ~15 mA logic current. A header and shunt cap ($0.05) beat slide switches on price and have no voltage limit of their own.

JP2 is a header too, so the one jumper every board needs for its first flash needs no soldering iron.

HT7533-1 replaced the AMS1117, which was 66× oversized, drew 5 mA quiescent and wanted 22 µF tantalum. The HT7533 is cheaper, takes 30 V, and is stable with the existing 10 µF ceramics.

---

8. Repository layout

Path	Contents
PCB/usbservocontroller/	KiCad 10 schematic and board; production/ = Fabrication Toolkit output
embedded-ch32/	application firmware (User/), bootloader (bootloader/), host test (test/)
embedded-ch32/tools/	verify_pinmap_ch32.py; put a wchisp download here (not in the repo)
tools/	host tools — see tools/README.md
USER.md	user manual

The Fabrication Toolkit reads LCSC from footprints, not symbols. After a schematic sync, check grep -c 'property "LCSC"' usbservocontroller.kicad_pcb (58 today) — a missing field shows as "part not found" at JLCPCB.

---

9. Before the next fab run

Checked against the files on 2026-09-29: ERC 0, DRC 11 errors, all the inherent header courtyard overlaps (three rows on a 2.54 mm grid), 0 unconnected.

1. Fix JP2's board reference. The footprint is labelled BOOT0_SEL instead of JP2, so DRC reports JP2 missing plus an extra footprint, and fab files would carry the wrong designator. Run F8 (with Delete footprints with no symbols unticked).
2. Set DNP on J9 and exclude H1–H4 from BOM/position files. Neither flag is set yet, so EXCLUDE DNP in fabrication-toolkit-options.json does nothing.
3. R13 220 Ω → 1 kΩ (C21190, Basic). PC13 is rated 3 mA; 220 Ω drives the LED at ~6 mA. Works on the first board, but out of spec.
4. Remove the 3 duplicated vias (GND at 11.5, 35.2; I_SENSE and V_SENSE near 32, 16–18) and decide on the courtyard errors — shrink the courtyards or add DRC exclusions so a real error cannot hide among them.
5. Regenerate production/ — it dates from 2026-09-20, before the last board edit. Then check that H1–H4 and J9 are gone from bom.csv and positions.csv.
6. Re-verify JLCPCB stock (§4).

Re-run the checks with kicad-cli sch erc usbservocontroller.kicad_sch and kicad-cli pcb drc --schematic-parity usbservocontroller.kicad_pcb.

---

License

MIT — hardware design files, firmware and host tools.

Files carrying a WCH (Nanjing Qinheng Microelectronics) copyright header — the ch32v20x HAL, USB library, startup code and the WCH-derived files in embedded-ch32/User/ — remain under WCH's own terms, which limit their use to WCH microcontrollers.