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--- door_access_controllers [2019-04-29 17:50] – tim
+++ door_access_controllers [2023-04-08 10:24] (current) – [PCB ESP32 (draft)] tim
@@ Line 5: / Line 5: @@
 The Hacklab door controllers are based on an ESP8266 wifi microcontroller and a PN532 NFC reader module. One controller is installed for each door, and each controller can operate a single 12V channel for an electric door release or magnetic lock. Inputs can be connected for door open/closed reed switch, exit request and local lock/unlock "snib" function.
-===== PCB =====
+===== PCB v2 =====
-https://github.com/timhawes/onyx_robot/
+https://github.com/timhawes/onyx_robot/tree/or2
 ^ Reference ^ Component ^ Farnell ^
@@ Line 33: / Line 33: @@
 Errata: a generic through-hole flyback diode should be fitted between GND and 12V_OUT, on the underside of the screw terminal.
-==== Lessons Learned ====
+===== PCB v4 =====
+https://github.com/timhawes/onyx_robot/tree/or4
+  * Removed custom 12V-3.3V converter circuit
+  * Replaced with standard 12V-5V converter and 5V-3.3V LDO
+  * I2C devices running on 5V instead of 3.3V
+  * Removed LED series resistor (appropriate resistors must be used at installation time)
+  * Replace relay diode with M7
+  * Added flyback diode to 12V relay output
+  * Removed ESD protection diodes
+  * Removed 3.3V connection from FTDI connector
+  * Solder jumpers for no-volt relay output
+^ Reference ^ Component ^
+| C1 | 0805 10uF 25V |
+| C2 | 0805 10uF 10V |
+| C3 | 0805 10uF 6.3V |
+| C4 | 0603 0.1uF 6.3V |
+| D1 | S1M+ |
+| D2 | S1M+ |
+| JP1 | PCB male header 2.54mm pitch 3-way |
+| JP2 | PCB male header 2.54mm pitch 2-way |
+| P1, P2, P3 | PCB screw terminals 5.08mm pitch 2-way (9 total) |
+| P4 | PCB male header 2.54mm pitch 6-way |
+| Q1, Q2 | MOSFET-N SOT-23 (e.g. On Semi FDV303N) |
+| R6 | 0603 10K |
+| R7 | 0603 31K6 |
+| R8 | 0603 2K2 |
+| R9 | 0603 10K |
+| R10 | 0603 10K |
+| R11 | 0603 10K |
+| R12 | 0603 4K7 |
+| R13 | 0603 4K7 |
+| R14 | 0603 10K |
+| SW1 | EVQPT5 tactile switch |
+| U1 | Recom R-78E5.0-1.0 |
+| U2 | Songle SRD-12VDC-SL-C |
+| U3 | ESP-12E or ESP-12F |
+| U4 | SPX3819M5-L-3-3/TR |
+===== PCB ESP32 (draft) =====
+This is draft design for migrating to ESP32.
+Goals:
+  * ESP32 series
+  * compatibility with existing wiring
+  * fit into the existing plastic enclosures
+  * nice to haves:
+    * fit existing enclosures better
+    * make wiring easier
+{{:20230407_doorman_esp32.pdf?direct&200|schematic}}
+{{:20230407_doorman_esp32.png?direct&200|}} \\
+(placement and routing isn't finished)
+What's changed:
+  * PCB is bigger, designed to screw into the enclosure as the manufacturer intended
+  * Uses the ESP32-S3-WROOM-1 module
+    * available with large flash/ram
+    * supports circuitpython
+    * supports native USB
+  * USB-C connector (plus optional UART pinout for low-level debugging)
+  * Pluggable 3.5mm terminal blocks for easier wiring (can be replaced with fixed blocks to reduce costs)
+  * MOSFET instead of relay (smaller, cheaper, probably more reliable)
+  * Dropped the PN532 reset pin in favour of a switchable power output (one less wire to manage)
+  * Reader connector has spare pins for existing LED and buzzer, but future readers can be I2C only for even less wiring
+  * Onboard RGB LED (will use with a light-pipe to eliminate the wiring for the current LED)
+  * Onboard buzzer
+  * Exit/Snib/Door inputs replaced with 4 general purpose I/O
+  * One I/O also has a power pin (e.g. to run the touch door handle)
+  * Optional Stemma QT (I2C) connector
-Future PCB revisions are likely to be based on a Wemos D1 Mini module to reduce component count and allow easier debugging. The onboard DC-DC converter will be replaced with an off-the-shelf "LDO replacement" DC-DC converter module.
 ===== Controller Unit =====
@@ Line 45: / Line 117: @@
   * [[http://cpc.farnell.com/kingbright/rtf5010/led-clip-prominent-5mm-pk25/dp/SC08862|5mm LED bezel]]
   * [[http://cpc.farnell.com/unbranded/r13-502ma-05-b/switch-black-push-button-spst/dp/SW03314|push-button switch]]
-  * Laser-cut mounting plate: {{:nfc-controller-mount-20150925.dwg|DWG}} {{:nfc-controller-mount-20150925.dxf|DXF}}
+  * Laser-cut mounting plate: {{:nfc-controller-mount-20200730.dxf|DXF}}
 {{:nfc-controller-20151031-231947.jpg?200|}}
@@ Line 67: / Line 139: @@
 ===== Reader Unit =====
+==== Version 1 ====
 CAD files: {{:nfc-reader-20160626.dwg|DWG}} {{:nfc-reader-20160626.dxf|DXF}}
@@ Line 79: / Line 153: @@
   * 3mm blue LED
-  * 120R resistor (this is low, but an additional resistor is used on the controller PCB)
+  * 120R resistor (or higher)
   * [[http://uk.farnell.com/multicomp/mcabt-456-rc/audio-element-piezo-9-5khz-12mm/dp/2433032|12mm piezo disc]]
   * [[http://www.elechouse.com/elechouse/index.php?main_page=product_info&cPath=90_93&products_id=2242|PN532 module]]
@@ Line 92: / Line 166: @@
 Cable colours in Hacklab installations:
-^ Pin ^ G1/G2/G8 ^ G11 (and photos) ^
+^ Pin ^ G1/G2/G8 ^ G11 (and photos) ^ Alarm Wire ^
-| GND | blue | blue |
+| GND | blue | blue | black |
-| VCC | green | orange |
+| VCC | green | orange | red |
-| RST | brown | brown |
+| SDA | orange | green | yellow |
-| SDA | orange | green |
+| SCL | white-green | white-green | blue |
-| SCL | white-green | white-green |
+| RST | brown | brown | green |
-| LED +ve | white-brown | white-brown |
+| LED +ve | white-brown | white-brown | orange |
-| Piezo | white-blue | white-blue |
+| Piezo | white-blue | white-blue | white |
 The LED should be connected between LED and GND, with a 120R series resistor. To avoid damaging the LED, use hot-melt glue to secure it in place (not cyanoacrylate).
@@ Line 106: / Line 180: @@
 Test the reader and controller together before securing the reader to the wall with double-sided adhesive foam tape.
+==== Version 2 ====
+The goal of this version is to make the assembly process easier and more reliable.
+It consists of a laser-cut acrylic plate that fits over a standard 1-gang UK electrical box. A PCB is glued to the inside of the plate, and this PCB integrates the PN532 module, buzzer, LED and wiring connections.
+CAD files: {{:back-box-1g-20190703.dxf|DXF}}\\
+PCB files: https://github.com/timhawes/onyx_reader
 ===== Software =====
-Two versions of firmware and server back-end are currently in operation.
+[[https://github.com/timhawes/doorman-firmware|Firmware]] - Arduino C++ built with PlatformIO \\
+[[https://github.com/timhawes/doorman-backend|Backend]] - Python 3 asyncio
-Common features:
+Features:
   * Ability to read any 13.54MHz ISO-14443 Type A token including MIFARE Classic/UltraLight and NFC tags.
@@ Line 121: / Line 205: @@
   * Remote enable/disable/renewal/timeout of snib state to allow presence detection to trigger timeout of snib state.
   * Input DC voltage measurement, using low voltage as an indication of battery backup during a power outage. Snib feature can be disabled during power outage to extend battery life (for fail-secure locks).
+  * TLS-enabled TCP networking with OTA updates.
-Legacy/Stable: The older version uses UDP networking and requires a dedicated wifi network for security. All of the Hacklab doors use this version at the time of writing.
-New: A new firmware and back-end use TLS-enabled TCP networking, so do not require a special wifi network. The modern codebase is better-written, more flexible and features OTA upgrades.