Two PCB Variants for ESP32 Stair-Lighting Controller - WS2812 LEDs & Multiple Sensors
Budget: £50 – £165 GBP
Hi,
I’m looking for a freelancer to help me design two PCB variants for a stair-lighting controller using a 38-pin ESP32 Dev Module (USB-C). This system will power and control WS2812 LED strips and incorporate multiple sensors for an intelligent lighting setup. Below is an overview of what I need, followed by detailed requirements. At the end, I’ve included links and attachments referencing a similar board and my own sketches.
>>> Overview of the Project
1. Goal: Create two PCB variants (Version A and Version B) of a stair-lighting controller for WS2812 LEDs:
- Variant A: 2 LED outputs,
- Variant B: 16 LED outputs.
2. Board: Uses an ESP32 Dev Module (38-pin, USB-C) mounted on female headers (no extra programming buttons needed).
3. Sensors: 2× PIR, 2× ToF (I²C + XSHUT), 1× BH1750 (I²C), 2× external switches, plus a 2-bit DIP switch for addressing.
4. Power: 5 V input, onboard regulation to 3.3 V. Needs wide 5 V traces and capacitors for higher currents.
5. Long Wires: Because this will be used on stair installations with potentially long cable runs, I expect proper > ESD protection, filtering, pull-ups/pull-downs, and series resistors <
>>> Detailed Requirements
1. ESP32 & Power
- 38-pin ESP32 Dev Module (USB-C), no extra BOOT/RESET headers.
- 5 V supply with onboard regulator for 3.3 V (ESP32, sensors).
- Bulk capacitors (e.g., 470–1000 µF) on the 5 V rail, decoupling (100 nF) near ICs.
- Wide 5 V/GND traces for LED current, especially on the 16-output variant.
2. Sensors & Inputs
- 2× PIR** (digital input, each with a 3-pin connector: 5 V, GND, signal).
- 2× ToF** (I²C + XSHUT pin), each on a 5-pin connector: 5 V, GND, SDA, SCL, XSHUT.
- 1× BH1750** (I²C), 4-pin connector: 5 V, GND, SDA, SCL.
- 2× Switches** (digital input), each on a 2-pin connector: GPIO + GND.
- 1× DIP switch** (2 bits) with pull-ups (10 kΩ) to 3.3 V.
3. I²C Pull-Ups & ESD
- SDA/SCL lines: 4.7 kΩ pull-ups to 3.3 V, small series resistors (~47–100 Ω), ESD diodes if necessary.
- XSHUT lines: 10 kΩ pull-ups, small resistors, ESD protection.
4. WS2812 LED Outputs
- Each Data line must have a level shifter (e.g., 74HCT14, 74HC125, or equivalent) to convert 3.3 V → 5 V.
- A series resistor (~330 Ω) right before the LED Data output, plus possible ESD diode for long cable runs.
- Output connectors: Data, 5 V, GND (3 pins).
- Large electrolytic cap (470–1000 µF) on the 5 V rail near the LED outputs.
5. Two PCB Variants
Variant A (Ver_A) – 2 Outputs
- 2 WS2812 Data lines (each with level shifting, resistors).
- Same sensor arrangement.
- Designed for simpler installations.
Variant B (Ver_B) – 16 Outputs
- 16 WS2812 Data lines (level shifting + resistors each).
- Must handle higher currents (wider 5 V traces, more capacitors).
- Same sensor configuration.
- Ensure no conflict with ESP32’s boot/strapping pins when assigning 16 GPIOs.
6. Deliverables
- Complete design files (schematics, PCB layout, Gerbers, BOM) for both variants.
- Confirm pin assignments vs. ESP32 datasheet (no boot pin conflicts).
- Integrate all necessary filters and protective components for reliable operation over long cables.
- Optional help for the first manufacturing order (PCB specs, part sourcing, etc.).
-- Attachments & Reference
1. Ver_A Diagram (2-channel example) and Ver_B Diagram (16-channel example) – attached below, showing how I envision the wiring.
2. Reference Board Link: A similar design that also uses a 74HCT14 for level shifting. Although that board supports fewer LEDs/sensors than I need, it’s a helpful reference to show a proven 5 V driver approach.
https://www.ebay.co.uk/itm/134965754238?itmmeta=01JJ3853STNCNR68BS55FCEPV9&hash=item1f6c95f97e:g:01gAAOSwGtRl53~b
I look forward to collaborating with you on a robust, real-world solution that meets all these requirements!
I’m looking for a freelancer to help me design two PCB variants for a stair-lighting controller using a 38-pin ESP32 Dev Module (USB-C). This system will power and control WS2812 LED strips and incorporate multiple sensors for an intelligent lighting setup. Below is an overview of what I need, followed by detailed requirements. At the end, I’ve included links and attachments referencing a similar board and my own sketches.
>>> Overview of the Project
1. Goal: Create two PCB variants (Version A and Version B) of a stair-lighting controller for WS2812 LEDs:
- Variant A: 2 LED outputs,
- Variant B: 16 LED outputs.
2. Board: Uses an ESP32 Dev Module (38-pin, USB-C) mounted on female headers (no extra programming buttons needed).
3. Sensors: 2× PIR, 2× ToF (I²C + XSHUT), 1× BH1750 (I²C), 2× external switches, plus a 2-bit DIP switch for addressing.
4. Power: 5 V input, onboard regulation to 3.3 V. Needs wide 5 V traces and capacitors for higher currents.
5. Long Wires: Because this will be used on stair installations with potentially long cable runs, I expect proper > ESD protection, filtering, pull-ups/pull-downs, and series resistors <
>>> Detailed Requirements
1. ESP32 & Power
- 38-pin ESP32 Dev Module (USB-C), no extra BOOT/RESET headers.
- 5 V supply with onboard regulator for 3.3 V (ESP32, sensors).
- Bulk capacitors (e.g., 470–1000 µF) on the 5 V rail, decoupling (100 nF) near ICs.
- Wide 5 V/GND traces for LED current, especially on the 16-output variant.
2. Sensors & Inputs
- 2× PIR** (digital input, each with a 3-pin connector: 5 V, GND, signal).
- 2× ToF** (I²C + XSHUT pin), each on a 5-pin connector: 5 V, GND, SDA, SCL, XSHUT.
- 1× BH1750** (I²C), 4-pin connector: 5 V, GND, SDA, SCL.
- 2× Switches** (digital input), each on a 2-pin connector: GPIO + GND.
- 1× DIP switch** (2 bits) with pull-ups (10 kΩ) to 3.3 V.
3. I²C Pull-Ups & ESD
- SDA/SCL lines: 4.7 kΩ pull-ups to 3.3 V, small series resistors (~47–100 Ω), ESD diodes if necessary.
- XSHUT lines: 10 kΩ pull-ups, small resistors, ESD protection.
4. WS2812 LED Outputs
- Each Data line must have a level shifter (e.g., 74HCT14, 74HC125, or equivalent) to convert 3.3 V → 5 V.
- A series resistor (~330 Ω) right before the LED Data output, plus possible ESD diode for long cable runs.
- Output connectors: Data, 5 V, GND (3 pins).
- Large electrolytic cap (470–1000 µF) on the 5 V rail near the LED outputs.
5. Two PCB Variants
Variant A (Ver_A) – 2 Outputs
- 2 WS2812 Data lines (each with level shifting, resistors).
- Same sensor arrangement.
- Designed for simpler installations.
Variant B (Ver_B) – 16 Outputs
- 16 WS2812 Data lines (level shifting + resistors each).
- Must handle higher currents (wider 5 V traces, more capacitors).
- Same sensor configuration.
- Ensure no conflict with ESP32’s boot/strapping pins when assigning 16 GPIOs.
6. Deliverables
- Complete design files (schematics, PCB layout, Gerbers, BOM) for both variants.
- Confirm pin assignments vs. ESP32 datasheet (no boot pin conflicts).
- Integrate all necessary filters and protective components for reliable operation over long cables.
- Optional help for the first manufacturing order (PCB specs, part sourcing, etc.).
-- Attachments & Reference
1. Ver_A Diagram (2-channel example) and Ver_B Diagram (16-channel example) – attached below, showing how I envision the wiring.
2. Reference Board Link: A similar design that also uses a 74HCT14 for level shifting. Although that board supports fewer LEDs/sensors than I need, it’s a helpful reference to show a proven 5 V driver approach.
https://www.ebay.co.uk/itm/134965754238?itmmeta=01JJ3853STNCNR68BS55FCEPV9&hash=item1f6c95f97e:g:01gAAOSwGtRl53~b
I look forward to collaborating with you on a robust, real-world solution that meets all these requirements!