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Thaddeus Hughes
2025-10-09 20:43:40 -05:00
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1. MCU
Looks like the **ESP32-WROOM-32** will work swimmingly. Pinout is as follows:
| Peripheral | Pin Assignment | GPIO Number | Notes/Functions |
| ---------------- | -------------- | ----------- | ------------------------------------ |
| Analog Input 1 | SENSOR_VP | 36 | ADC1_CH0, input-only |
| Analog Input 2 | SENSOR_CAPP | 37 | ADC1_CH1, input-only |
| Analog Input 3 | SENSOR_CAPN | 38 | ADC1_CH2, input-only |
| Analog Input 4 | SENSOR_VN | 39 | ADC1_CH3, input-only |
| Digital Output 1 | IO25 | 25 | General I/O, output-capable |
| Digital Output 2 | IO26 | 26 | General I/O, output-capable |
| Digital Output 3 | IO27 | 27 | General I/O, output-capable |
| Digital Output 4 | MTCK/IO13 | 13 | General I/O, output-capable |
| Digital Output 5 | MTMS/IO14 | 14 | General I/O, output-capable |
| Digital Output 6 | MTDO/IO15 | 15 | General I/O, output-capable |
| Digital Input 1 | VDET_1 | 34 | General input, input-only |
| Digital Input 2 | VDET_2 | 35 | General input, input-only |
| I2C SDA | IO21 | 21 | I2C data, configurable |
| I2C SCL | IO22 | 22 | I2C clock, configurable |
| CAN TX | IO4 | 4 | TWAI TX, connects to transceiver TXD |
| CAN RX | IO5 | 5 | TWAI RX, connects to transceiver RXD |
| RTC Crystal XP | 32K_XP | 32 | 32.768 kHz crystal for RTC |
| RTC Crystal XN | 32K_XN | 33 | 32.768 kHz crystal for RTC |
GPIO0, 2, 12, 16, 17, 18, 19, 23 are available for future expansion.
2. CAN Bus
1. Just need a 3.3V CAN Transceiver - **SN65HVD231DR**
2. Connector - M12 bulkhead? BoardLock bulkhead?
1. https://www.digikey.com/en/products/filter/circular-connectors/circular-connector-assemblies/436?s=N4IgjCBcoGwJxVAYygMwIYBsDOBTANCAPZQDaIAzABwUDscMIh1dcEAuoQA4AuUIAZR4AnAJYA7AOYgAvoXi1EIFJAw4CxMpQCscOFUXNdegCxMdeveYowADLe1Vrd2zAjMXMAEzP7MRh62YGBOgWBe7pR24WZhdL5g2toJdr5etoZRtukI8tq0XibJnCC8-EJiUrKEALQ%2B0MpQIgCuGiSQ5MUyciCMDaIAJvw1YEHmZZAg5jwAnly4-OjYKN1AA
2. T4140012081-000 $13.09
3. RTS712ND4S03 $15.97
4. https://www.digikey.com/en/products/filter/circular-connector-assemblies/436?s=N4IgjCBcoGwJxVAYygMwIYBsDOBTANCAPZQDaIAzABwUDscMIhALGGFXLSALqEAOAFyggAygIBOASwB2AcxABfQgFpmiECkgYcBEADdpaLHkIlI5GOwo9%2BQyCEUqATOs0SArrrPkArDwVKIIzQIJIAJsLKYAAMELbCTCACAJ58uMLo2CgBQA
5. 54-00216 $4.80 (4p male)
6. 54-00235 $5.05 (4p female)
7. I think we're gonna end up at M12 connectors for sensors and flying pigtails for motors
3. Voltage Regulator
1. Most of the time will be spent sleeping. A low quiescent current, then, is actually more important than live current, perhaps?
2. **TLV1117-33IDCYR** would work but emits 4.35W at 500mA - thermals need looked into for this.
3. **TPS629210DRLR** is also good. Just need 2 resistors and an inductor as well. Good cost. Probably better.
1. 4.7 uF input cap
2. 22 uF output cap
3. 2.2 uH inductor - **BDCD002520122R2MS1** (1008 case)
4. RTC (use builtin to MCU)
1. Need ext. osc: **CM315D32768DZFT** (2-SMD package)
5. Jack Motor - 1 AI, 2 DO
1. Motor: **RP-785615**
2. Motor connector: **AT06-2S**
3. Motor to cable connector: **AT04-2P**
4. Cable: **16/2 PVC jacket cable**
5. Cable to Control Box: **PG9 Cord Grip + Faston Tabs**
6. Relays (2): **A161CS12VDC.64** (25A current, 53.3 mA coil)
7. Relay driver: **2N7002AK-Q** (240 mA max) (TO-236AB, TO-236-3, SC-59, SOT-23-3 package)
8. Fuse: **20A ATO fuse**
9. Current sensor: **ACS37042KLHBLT-030B3** (30A max, -030B5 exists which is a 5v variant)
6. Fluffer (Accessory) Motor - 1 AI, 2 DO
1. Motor: *TBD*
2. Motor connector: **AT06-2S**
3. Motor to cable connector: **AT04-2P**
4. Cable: **16/2 PVC jacket cable**
5. Cable to Control Box: **PG9 Cord Grip + Faston Tabs** ([1217861-1](https://www.digikey.com/en/products/detail/te-connectivity-amp-connectors/1217861-1/1148769))
6. Relays (2): **A161CS12VDC.64** (25A current, 53.3 mA coil)
7. Relay driver: **2N7002AK-Q** (240 mA max)
8. Fuse: **20A ATO fuse** (3522-2 holder)
9. Current sensor: **ACS37042KLHBLT-030B3** (30A max, -030B5 exists which is a 5v variant) (SOT-23W)
7. Drive Motor - 1 AI, 2 DO
1. Motor: **80ZYT-12/JW-7** -OR- **80ZYT-12/JW-3B** (50A)
2. Motor connector: **6mm Ring Terminals with Boots**
3. Cable: **12/2 PVC jacket cable**
4. Cable to Control Box: **PG9 Cord Grip + Faston Tabs**
5. Relays (2): **A31CSP12VDC2** (70A current, 150 mA coil)
6. Relay driver: **2N7002AK-Q** (240 mA max)
7. Fuse: No fuse, just the fuse/breaker for the main battery
8. Current sensor: **ACS37220LEZATR-100B3** (100A max, -100B5 exists which is a 5v variant) (7-PowerLQFN / 7-QFN)
8. Jack Limit Switch - 1 DI
1. Sensor: **PBM6-AN-1H** (-1A exists also which is a 2m pigtail. -1H is a M12 connector)
9. Odometry Geartooth Sensor - 1 DI
1. Sensor: **PBM6-AN-1H** (-1A exists also which is a 2m pigtail. -1H is a M12 connector)
10. Solar Charging Circuit
1. **BQ24650 charge controller**
2. N-channel MOSFETs (Q1 high-side, Q2 low-side): 40V-rated, low RDS(on) (e.g., 20mΩ), such as **AO3400** or equivalent, for synchronous rectification.
3. Inductor (L): 10µH, rated for at least 5A saturation current (e.g., Wurth **7447788220**) to support switching at 400kHz.
4. Current sense resistor (R\_SR): 10mΩ, 1% tolerance, 5W rating (e.g., **WSMS5515L1000FEK**) for \~4A maximum charge current (differential voltage of 40mV).
5. Input capacitors: 10µF ceramic (X7R, 35V) × 3, placed near MOSFETs.
6. Output capacitors: 4.7µF ceramic (X7R, 25V) × 2, near the battery connection.
7. Schottky diodes: For reverse protection (e.g., **1N5819**) and status indication.
8. Resistors for voltage setting: Precision 1% types (e.g., R1 \= 100kΩ, R2 \= 576kΩ for 14.4V regulation).
9. Optional: LEDs and resistors for charge status (e.g., bulk/absorption indication).
11. Battery - 1 AI
1. Battery: **TL1212**
2. Battery to cable conn: **Female Fastons**
3. Cable: **12/2 PVC jacket cable with fuseholder**
4. Cable to control box: **PG9 Cord Grip + Faston Tabs**
5. Voltage divider to sense battery voltage (goes to ESP32) - **1M + 150k resistors**
12. Display
1. Focus LCDs **C162A-FTW-DS23** (-30 to +80C operating range)
2. This will be driven by an I/O Expander. It could be shared with the buttons.
1. 8 bit: **PCF8574**
2. 16 bit: **MCP23017** - pin 7 of each 8-bit bank can only be used as an output which is odd. or PCF8575 which is a little more $. Or best yet TCA9555PWR
13. Settings Adjust Buttons (4 buttons)
1. Option (SMD): **TL3305BF260QG**
2. Option (THT): **TS02-66-43-BK-260-SCR-D**
14. Manual Override Buttons (4 buttons)
1. Option A: Hardwired, with an enclosed PCB
2. Option B: Hardwired, with simple waterproof switches
3. Option C: Remote
| Pros of Remote | Pros of Hardwire |
| ------------------------------------ | ------------------------------------------ |
| Can operate from all around the coop | Can't lose it |
| Easiest cable management | Easy to repair |
| | No pairing required |
| | Easy interrupt (wake from sleep) |
| | If you need to make it custom, it's easier |
| | No batteries to die |