Browsing posts in: ESP

An ESP-32 Remote Control–Update and Version 1.0 case

About 3 months ago, I wrote a post about an ESP-32 based remote control I’m building. Conceptually, what it does it allow you to press a button and hit a specific web endpoint.

Since the introduction, I wrote some code and got a prototype kindof working – the touch inputs on the ESP32 work fine, the deep sleep works okay, but I ran into a few problems.

First, the ESP32 can run on 3.0 volts but only kindof, and if you use two AAs their voltage drops pretty quickly to the point where the ESP stops working. Which means I needed a better power source, which means lithium based. I looked at primary (non-rechargeable) lithiums but they are also 3 volts (IIRC), I looked at lithium-ion, but 4.7 v is a really inconvenient voltage for ESPs; you need a regulator to get down there. Plus the 10850 cells are a bit big. Then I settled on LiFePo4 batteries, which very conveniently have a nominal voltage of 3.3 volts and are the same diameter (but shorter) than a AA, so they work well for packaging.

I bought a little battery monitoring board to protect the battery, but I’ve decided to skip it for this version. So, I think I’m set for batteries.

The second issues came up during my deep sleep testing. The ESP32 can get down to 10 uA in deep sleep, which looks great, *and* it supports “wait on touch” where it will turn on based on a touch input, which is also great. But…

The devkit boards that I have don’t support using it that way; even with the power led removed I think I was seeing about over 10mA when the ESP was in deep sleep. Not good enough. Some people have hacked their boards to remove some of the components, but traces are tiny and the board is dense, and I gave up after a few tries. I could use a module programmer like this which pulls the dev kit components onto the programmer and leaves just the raw board, but the problem there is I need a mounting solution that lets me program the same module every time.

What I really need is the dip part of the devkit board without any of the power supply or usb stuff and an adapter to hook that to the module programmer.

Since I haven’t figured that out, I went with the best deep sleep approach that I know, a rocker switch. I’m thinking that will get the power use all the way down to 0 uA.

The case

I have some plans for the version 2.0 case, but those require a fair amount of prework and new tools, and it’s nice enough that I could really use the remote *now*, so I went with with the easy approach – a laser cut box.

For touch points, I wanted some screw together pieces or screw studs, which I finally discovered were commonly known as “chicago screws”.

Chicago Screws - "Flat Beveled" Design - Solid Brass (10-pack ...

I wanted them in brass so that I can solder to them. The ones I got are 1/4” (6mm, actually) in length, which would be fine for my “real remote” design, but meant that I need to use 1/4” plywood for the face.

I did the design in Fusion 360. This design was not one of my better moments. I did the face in 1/4” but the sides on 1/8” so they would be thinner, but it turned out that I don’t have any 1/8” plywood left; what I have is 1/10”, so I had to redo the design. Then I measured the size of the studs very accurately with my calipers and then entered the shaft length (0.235”) instead of the shaft diameter (0.165”). And the power switch was too close to the corner so the top and side wouldn’t fit. Then I cut the top piece out of a piece of 1/8” scrap, so it was too big.

More trips back and forth than I had hoped, but it’s only computer and laser time plus a bit of wood, so it wasn’t that bad. Here’s the result:

IMG_9719

Which is honestly pretty nice. The labels are engraved into the wood, and all it is missing is the power LED. The current plan is to glue the sides to the front and leave the back removable for access, but it’s not clear to me how that is going to work yet.

Video here:


Next up will be wiring up the front panel, assembling most of the box, and then hooking in the ESP and battery.


An ESP-32 Remote Control–Introduction

A couple of years ago I did an ESP-32 based controller for our landscape lights and fountain. It has a nice web-based interface, if you like the way interfaces looked when HTML was young…

image

In addition to this web page, you can hit http endpoints directly, so you can control things with either a browser or an HTTP app on your phone. It’s a bit of a pain to dig your phone out and run an app to turn on lights, so I’ve always planned on doing a handheld controller. It’s going to be pretty simple; just a set of buttons and an app that sends requests to the actual controller.

At least, that’s how it started…

My original plan was to use an ESP8266 because it’s smaller and to use some normal momentary pushbuttons:

Momentary-ON-OFF-Push-Button-Switch-Waterproof-12mm-Black-M122-Mini-10pcs

That would have been fully functional, but I didn’t really like the way the buttons looked and I didn’t like the low-power options very much. I was looking through the ESP-32 technical manual and remembered that the ESP-32 has a touch-sensor subsystem that supports 10 separate inputs. That means I can do a cleaner-looking controller that has metal touch points rather than buttons, and the ESP supports wake on touch, so I can put the controller into deep sleep.

Conceptual design

Here’s a very quick drawing:

image

Here’s what I’m thinking for the design. There are 5 circuits to control:

  • Fountain pump
  • Bed lights
  • House lights
  • Umbrella lights (strips under umbrella)
  • All lights

In addition, I want to be able to control the brightness of the umbrella lights in 5 steps; 20%, 40%, 60%, 80%, and 100%

Coincidentally that requires 10 different controls, which is exactly how many touch inputs the ESP has, so that worked out well.

The controller will be remote-control-shaped, with batteries (tentatively 2 AA alkalines) near the bottom, the ESP in the middle, and an array of touch points at the top.

Sleep battery calculations

There is an assertion that the ESP32 in deep sleep only pulls 2.5uA. A typical alkaline AA cell has a capacity of about 2000-3000 mAH, so if we do some math:

Hours = 2000 mAH * 1000 (convert to uAH) / 2.5 = 800,000 H, or 33,000 days. If we could really get that, that would be 91 years on standby.

Let’s do the calculation the other way; if we wanted batteries to last a year, that would give us:

2000 mAH / 365 = 5mAH per day, or 228 uA of constant current. If I can hit something under that, I’ll get a year out of the batteries.

Getting that to work is going to require me to either modify the ESP-32 devkit boards I’m using or switch over to a raw module and separate programmer, but that’s a matter for another post/video