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FIXME finished project picture with LED tape -.. raw:: html - - <figure> - <img src="images/lyza_board_in_case.small.jpg"> - <figcaption>The completed driver board installed in the 3D-printed case. This device can now be connected to - 12V and two segments of LED tape that can then be controlled trough Wifi. The ESP8266 module goes on the pin - header on the left and was removed for this picture. - </figcaption> - </figure> - -After the `multichannel LED driver`_ was completed, I was just getting used to controlling LEDs at 14-bit resolution. -I liked the board we designed in this project, but at 32 channels it was a bit large for most use cases. Sometimes I -just want to pop a piece of LED tape or two somewhere, but I don't need a full 32 channels of control. I ended up -thinking that a smaller version of the 32-channel driver that didn't require a separate control computer would be -handy. So I sat down and designed a variant of the design with only 8 channels instead of 32 and an on-board ESP8266_ -module instead of the RS485_ transceiver for WiFi connectivity. - -The Electronics -=============== - -The schematic was mostly copy-pasted from the 32-channel design. The PCB was designed from scratch. This time, I went -for a 5x7cm form factor to allow for enough room for all connectors and to give the ESP8266_'s WiFi antenna enough -space. The board has two 5-pin Phoenix-style_ for two RGB-White (RGBW) tapes and one 2-pin Phoenix-style_ connector for -12V power input. The control circuitry and the serial protocol are unchanged, but the STM32_ now talks to an ESP-01_ -module running custom firmware. - -The LEDs are driven using a 74HC595_ shift register controlling a bunch of AO3400_ MOSFETs_, with resistors in front of -the MOSFETs_' gates to slow down the transitions a bit to reduce brighntess nonlinearities and EMI_ resulting from -ringing of the LED tape's wiring inductance. - -The board has two spots for either `self-resettable fuses (polyfuses) <polyfuse_>`__ or regular melting-wire fuses_ in -a small SMD_ package, one for each RGBW output. For low currents the self-resettable fuses should be okay but at higher -currents their `trip times get long enough that they become unlikely to trip in time to save anything -<littlefuse-16r-datasheet_>`__, so plain old non-resettable fuses would be the way to go there. - -.. FIXME finished board photos -.. FIXME board with test tape picture - -.. raw:: html - - <figure> - <figure class="side-by-side"> - <img src="images/schematic.png"> - <figcaption> - The schematic of the driver board, with the ESP8266 on the top left, the STM32 microcontroller for LED - modulation below, the shift register in the middle and the LED drivers and outputs on the right. - <a href="resource/lyza_schematic_and_pcb.pdf">Download PDF</a> - </figcaption> - </figure><figure class="side-by-side"> - <img src="images/layout.png"> - <figcaption> - The board layout with the top side being visible. The top side contains the footprint for the ESP8266, the - microcontroller, fuses, filter cap, connectors and the shift register. The LEDs are connected on the left, - with one connector per LED tape segment. The power input connector is on the bottom right. The LED driver - MOSFETs are in small SOT-23 packages on the back of the board. Since this board is not intended for - super-high currents, the MOSFETs are adequately cooled just through the board's copper planes. - <a href="resource/lyza_schematic_and_pcb.pdf">Download PDF</a> - </figcaption> - </figure> - </figure> - -.. raw:: html - - <figure> - <img src="images/lyza_boards.small.jpg"> - <figcaption>The completed PCBs of this project (front) and the `multichannel LED driver`_ project the driver - circuitry was derived from (back). - </figcaption> - </figure> - - -The Firmware -============ - -The STM32_ firmware only had to be slightly modified to accomodate the reduced channel count since the protocol remains -unchanged. The ESP firmware is based on esphttpd_ by Spritetm_. The modifications to the webserver firmware are pretty -basic. First, the UART console has been disabled since I use the UART to talk to the STM32. The few bootloader messages -popping out the UART on boot are not an issue, since they're unlikely to contain the fixed 32-bit address prefix the -serial protocol requires for the STM32_ to do anything. - -Second, I added LED control by adding drivers for the serial protocol and a bunch of colorspace conversion functions. -When I first tested the prototype software, I noticed that color reproduction was extremely poor. When I just sent a -HSV_ rainbow fade from a python command line, the result looked totally wrong. The fade did not seem to go at a constant -speed and some colors, in particular yellow, orange and greens, were not visible at all. The problem turned out to be a -stark mismatch of the red, green and blue channels of the LED tape and less-than-optimal color reproduction of the pure -colors. I decided to properly measure the LED tape's color reproduction so I could compensate for it in software. This -turned out to be an extremely interesting project, the details of which you can read in my `LED characterization`_ -article. - -Third, I updated the built-in websites with some ad-hoc documentation on how to use the thing and a basic interface for -LED control. - -.. FIXME screenshot of firmware website - -Making an enclosure -=================== - -To be actually useful, the driver needed a robust enclosure. Bare PCBs are nice for prototyping, but for actually -putting the thing anywhere it needs a case to protect it against random destruction. - -The board has four mounting holes with comfortable spacing in its corners to allow easy mounting inside a 3D-printed -case. The case itself is described in an OpenSCAD_ script. To make it look a little nicer, a little 3D relief is laid -into the lid. The 3D relief is generated with a bit of blender magic. The source STL_ model is loaded into blender, then -blender's amazingly flexible rendering system is used to export a depth map of a projection of the model as a PNG_ file. -This depth map is then imported as a triangle mesh into OpenSCAD_. - -For the relief to look good, I chose a rather high resolution for the depth map. This unfortunately leads to extreme -memory use and processing time on the part of OpenSCAD_, but since I have access to a sufficiently fast machine that is -not a problem. Just be careful if you try opening the OpenSCAD_ file on your machine, OpenSCAD_ will probably crash -unless you're on a beefy machine or interrupt it when it starts auto-rendering the file. - -The board is mounted into the enclosure using knurled insert nuts that are pressed into a 3D-printed hole using a bit of -violence. - -.. FIXME openscad screenshot -.. FIXME enclosure parts -.. FIXME finished enclosure with board inside - -.. raw:: html - - <figure> - <figure class="side-by-side"> - <img src="images/lyza_case_raw.small.jpg"> - <figcaption>The 3D-printed case with threaded inserts before painting.</figcaption> - </figure><figure class="side-by-side"> - <img src="images/lyza_case_complete.small.jpg"> - <figcaption>The 3D-printed case with the board installed after painting. This was my first attempt at - painting a 3D-printed case so it looks pretty bad.</figcaption> - </figure> - </figure> - -.. _`multichannel LED driver`: {{<ref "posts/multichannel-led-driver/index.rst">}} -.. _`LED characterization`: {{<ref "posts/led-characterization/index.rst">}} -.. _ESP8266: https://en.wikipedia.org/wiki/ESP8266 -.. _RS485: https://en.wikipedia.org/wiki/RS-485 -.. _Phoenix-style: https://www.phoenixcontact.com/online/portal/de?uri=pxc-oc-itemdetail:pid=1757019&library=dede&tab=1 -.. _STM32: http://www.st.com/resource/en/datasheet/stm32f030f4.pdf -.. _ESP-01: http://www.watterott.com/de/ESP8266-WiFi-Serial-Transceiver-Modul -.. _74HC595: http://www.ti.com/lit/ds/symlink/sn74hc595.pdf -.. _AO3400: http://aosmd.com/pdfs/datasheet/AO3400.pdf -.. _MOSFETs: https://en.wikipedia.org/wiki/MOSFET -.. _EMI: https://en.wikipedia.org/wiki/Electromagnetic_interference -.. _polyfuse: https://en.wikipedia.org/wiki/Resettable_fuse -.. _SMD: https://en.wikipedia.org/wiki/Surface-mount_technology -.. _fuses: https://en.wikipedia.org/wiki/Fuse_(electrical) -.. _littlefuse-16r-datasheet: http://m.littelfuse.com/~/media/electronics/datasheets/resettable_ptcs/littelfuse_ptc_16r_datasheet.pdf.pdf -.. _OpenSCAD: http://www.openscad.org/ -.. _STL: https://en.wikipedia.org/wiki/STL_(file_format) -.. _PNG: https://en.wikipedia.org/wiki/Portable_Network_Graphics -.. _esphttpd: https://github.com/Spritetm/esphttpd -.. _Spritetm: http://spritesmods.com/ -.. _`HSV`: https://en.wikipedia.org/wiki/HSL_and_HSV - diff --git a/content/posts/wifi-led-driver/resource/lyza_schematic_and_pcb.pdf b/content/posts/wifi-led-driver/resource/lyza_schematic_and_pcb.pdf Binary files differdeleted file mode 100644 index 6532888..0000000 --- a/content/posts/wifi-led-driver/resource/lyza_schematic_and_pcb.pdf +++ /dev/null |
