In the realm of DIY electronics, there are few challenges more rewarding than tailoring automotive electronics to your own vehicle’s needs. Whether you’re building a custom off-road expedition rig, restoring a vintage car, or enhancing the electrical system of a daily driver, the ability to control and distribute power safely and efficiently is invaluable. In this project, we’ll dive into a specific DIY build: creating a Smart Power Distribution Hub for vehicle accessories using the BSP762T—an intelligent power switch from Infineon.

This project isn’t about theory or general advice. It’s about one practical, real-world build that turns a handful of high-side switches into a rock-solid solution for controlling auxiliary lights, pumps, fans, and sensors—anything that might need switched 12V power in your automotive setup. No programming, no formulas, and no abstract advice—just a clear, hands-on experience.

Understanding the Role of the BSP762T

At the core of this build is the BSP762T, a protected high-side power switch designed specifically for automotive and industrial use. This tiny device punches far above its weight, combining switching functionality with robust protection features.

Here’s what makes the BSP762T ideal for this kind of project:

● It switches power on the high side, meaning it controls the positive voltage line, which is safer and more practical for automotive loads.

● Built-in protection includes overload, short circuit, overtemperature, and ESD protection.

● It has diagnostic feedback, so you can tell if a load is connected or if a fault has occurred.

● It’s low-power logic controllable, allowing easy interfacing with switches, microcontrollers, or even manual buttons.

These properties make it perfect for building a modern, reliable, and modular power control hub—especially for 12V automotive systems.

The Concept: Modular Power Distribution for a Custom Vehicle Dashboard

This project was born out of necessity. The builder—an enthusiast restoring an old 4x4 SUV—wanted to install modern lighting, an electric air compressor, a dash camera, seat warmers, and a CB radio. Instead of hacking together inline fuses and bulky mechanical relays, the goal was to build a sleek, compact power hub with:

● Six independent switched channels

● Resettable electronic protection (no need for fuse replacement)

● Diagnostic feedback (LED indicators for faults or overloads)

● Centralized wiring and easy mounting behind the dashboard

The BSP762T was chosen for its reliability and simplicity, and the hub was designed to live in a steel enclosure mounted near the vehicle’s glove compartment.

Gathering Materials and Planning the Build

The parts list was short and efficient:

● Six BSP762T power switches (one per load)

● Terminal block for connecting loads

● Heavy-gauge input wiring (to deliver 12V from battery or fusebox)

● Toggle switches or low-current control lines for each channel

● LED indicators and resistors

● Compact perforated protoboard or custom PCB

● Aluminum enclosure for housing the final assembly

● Heatsink material for thermal relief if loads exceed normal expectations

No microcontroller or programming was used—this was designed as a purely hardware-driven solution, using the intelligence built into the BSP762T.

Building the Module Step by Step

The first step was laying out the circuit board. Since the BSP762T is a surface-mount part in a TO-252 package, an adapter board or careful soldering onto a custom PCB was required. Each of the six switches was allocated a corner of the board, with its input tied to a shared 12V bus and output routed to a screw terminal for the load.

To control the switches, each gate pin was connected to a switch on the dashboard via a current-limiting resistor. This allowed the user to manually toggle each circuit using rocker switches mounted in a custom dashboard panel. Alternatively, the gate could have been connected to an ignition-switched relay or sensor output for automation.

Diagnostic outputs from each BSP762T were wired to LEDs on the front panel. These would illuminate green under normal operation, and change to red or turn off entirely if a fault condition was detected. This added real-time visibility into the system’s state.

Thermal management was handled by mounting the BSP762T units on a small aluminum backing plate that was thermally bonded to the enclosure, helping to dissipate heat under higher current conditions. While each switch can handle up to ~1.5A continuously, grouping them together required some attention to temperature rise.

The power bus was made from a thick copper braid that ran across the top of the board, connected to the vehicle’s fused 12V supply via an inline circuit breaker. This provided a robust and safe method to distribute incoming power across all switches.

Installing the Module in the Vehicle

Once the smart power hub was assembled and tested on the bench using a lab power supply and dummy loads, it was time to install it in the SUV. A flat spot behind the glove box was chosen—protected from the elements but accessible for future maintenance.

Mounting the unit was done using rivnuts and rubber isolators to avoid vibration fatigue. The power feed was taken from a dedicated fused line in the engine bay, routed through a grommet in the firewall, and terminated on the input terminal of the hub.

Each output wire was color-coded and connected to its respective accessory: roof lights, rear work lights, air compressor, dashcam, seat heaters, and CB radio. Each load was also grounded locally to the chassis to complete the circuit.

The control lines from the dashboard switches were run neatly alongside existing wiring, terminating at the BSP762T gate inputs. The LED indicators were mounted in a 3D-printed bezel for a clean, modern look.

Real-World Use and Observations

The smart power distribution hub performed flawlessly once installed. Accessories powered up cleanly, even under load, and the electronic protection meant that in the case of a short (simulated during testing), the channel shut down safely and could be reset by toggling the switch off and back on.

The LED indicators were especially helpful—when a connector came loose during off-road use, the fault light immediately signaled the issue. Diagnosing problems became a matter of glancing at the dashboard, rather than crawling under the car with a multimeter.

Noise suppression was another unexpected benefit. The BSP762T switches created far less electrical noise than mechanical relays, reducing interference in the CB radio and dashcam recording.

The builder later added a feature: a momentary button to toggle all channels off, useful for parking the car or doing maintenance without pulling individual fuses.

Potential Extensions and Upgrades

This project lays the groundwork for more advanced automotive control systems. Some potential additions include:

● Microcontroller integration: Although not used in the initial build, the BSP762T can be controlled by a microcontroller to enable time-based control, remote access, or automation.

● CAN bus interface: For modern vehicles with CAN systems, these switches can be integrated into more complex control schemes.

● Wireless app control: With a Bluetooth relay board or an ESP32, the hub could be remotely switched using a smartphone app.

● Smart monitoring: Current sensing ICs could be added to track power consumption in real-time.

But even in its simplest form, this project stands on its own as a clean, intelligent, and practical upgrade for any vehicle’s accessory system.

Lessons Learned

As with any hands-on electronics project, there were a few key takeaways from building the smart power hub:

1. Thermal management matters: Even low-current devices can generate surprising heat when grouped together. Mounting considerations are important for long-term reliability.

2. Diagnostic feedback is underrated: Being able to see at a glance whether a circuit is working or not makes a huge difference in usability and safety.

3. Modular design pays off: By designing each channel to be independent, future upgrades were simple. One switch was later swapped for a higher-rated version to power a fridge, without redesigning the whole board.

4. Using specialized components simplifies design: The BSP762T’s built-in protection and switching logic eliminated the need for external relays, flyback diodes, and fuse blocks. This dramatically reduced the size and complexity of the system.

Final Thoughts

The Smart Power Distribution Hub built with the BSP762T is a great example of how modern electronic components can elevate even basic DIY automotive projects. It replaces outdated mechanical systems with a reliable, compact, and intelligent solution, turning a tangle of wires and fuses into a professional-grade control system.

This project also highlights the joy of working at the intersection of electronics and mechanics. It's not just about lighting up LEDs—it’s about building systems that improve everyday experiences, add safety and convenience, and reflect the builder’s skill and understanding.

For anyone looking to move beyond basic projects, this type of real-world build offers a perfect next step. With components like the BSP762T, the future of DIY electronics is smarter, safer, and more integrated than ever.