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Ribbit-Network
ESP32: Enclosure Updates for ESP32 Based Frog
Hey @eaudiffred !
As we discussed in our team call earlier, I have fairly high confidence in the new processor that we would use for the microcontroller based version of the Frog.
Here is the actual part and link to adafruit: Adafruit ESP32-S3 Feather with 4MB Flash 2MB PSRAM - STEMMA QT / Qwiic
Implementation Notes
The power connector is a USB Type connector again shown on the left hand side of the image below. I imagine we would want to orient the board such that the power connector faces down like our previous designs
One thing that is a bit annoying is that USBC Power Adapters tend to be fairly large and not designed for outdoor applications, so I'm wondering if it might be worth designing around a USBC to Barrel Jack to USB C Adapter like this one?
Electrically this would be fine, but physically it will be perhaps mechanically wasteful as that adapter is almost the same length as the whole ESP board haha.
Would love any thoughts or opinions there :)
Thanks @keenanjohnson. One initial question about the power supply. Are there any USB-C power supply units that will work? It looks like it's 3V and I think a max on 150mA. I can look around for something so that we don't have to use an adapter. If you know it doesn't exist, just let me know and I'll tie in the adapter.
I believe this is a STEP file of the board, but I can't seem to figure out how to download it. It's my lack of GitHub knowledge I think. https://github.com/UnexpectedMaker/esp32s3/blob/main/3d%20models/FeatherS3_P4.step
Got it! Remembered the Desktop App. The board is not in the CAD imports folder.
@eaudiffred ! Any standard 5V Usb C Power Supply should work (where did you see the 3V number)? I've confirmed that here :)
@keenanjohnson, ok cool. That eliminates the need for the adapter, correct?
I misread the data sheet. I thought it was limited to 3V, but that is incorrect.
There are adapters, but the USBC plug I've read does less well outdoors overtime than a barrel jack, but perhaps that's not really a problem worth solving for the moment until we are sure we have an issue.
I've started to work on the enclosure based on the ESP32 and we will be able to reduce the size significantly. Here is an initial idea for the model.
Wow this would be excellent if we could take the size down significantly!
Looking at your renderings, I'm a little bit suspect that there is enough room there for the USBC cable. Unfortunately, the power connector on the cable end is usually quite long. We might need to include that in the model to check out if there is enough space?
This thing from a common USBC suply
@keenanjohnson, good point. I went ahead and make a model for the USBC supply. It does cause issues. We may be able to reduce the width of the enclosure by taking out space between the clips (red circles). Then rotating the whole board to almost vertical and lengthening the base.
I think I can squish the depth a little too. The width and depth adjustments would make the shroud and head incompatible between versions, but I don't see that as a huge problem right now. The amount of material and time that can be saved seems to be worth the changes.
Yeah, I wouldn't worry about head capability between versions at the moment.
One thing we could consider is a right-angle USB C adapter? Perhaps this would help us with the cable routing out of the side?
https://www.adafruit.com/product/4432
Yeah, I was thinking about that and weighing pros and cons of one additional part on the BOM. I'll model that up too and see what configuration seems to save the most material.
I was able to shrink the depth and width a decent amount. We are able to save quite a bit of material by using this smaller board.
@muditprotect3d, now would be a great time to introduce any ideas regarding the hanging mechanisms! While we are remodeling for the ESP32 we will have lots of opportunity to prototype. Also, any ideas concerning the enclosure in general is more than welcome!
This was one I created, could be attached easily to the back and allow to hook on to a pipe or fencing material
This is another one, basically similar to the last one except would span the entire width of the back of the enclosure
This one would be a variable one where you could slide the two ends across the channel to fit across any component of varying length
I created it on the shroud but the ideal location would be on the back of the enclosure
These are more simple hooks, but im working on a design right now to make the bottom hook slideable through a channel
Im working on another design this week, and I had some ideas about the enclosure as well I can send in here by end of week
@muditprotect3d Awesome work! Thanks for sharing. I realize we should document this design work in a separate GitHub issue just to keep projects organized. I'll open a GitHub issue for Hanging Mechanism Designs, and we can keep developing these ideas in there. I'll tag you and reference the posts above. Then we can use this issue for enclosure design related to the ESP32 change.
Reading this thread again, have we considered/thought about using the space tradeoff to include an external battery instead of a power cable? ( Instead of reducing the size of the enclosure, we could use the extra space due to a smaller processor to include an external battery/power source)?
Great question @muditprotect3d! In the future once we create a solar powered version of the frog, we will need a battery, but right now even with the microcontroller, we will need to have an external power source to power things. The power management for a battery system is a bit complex and I think needs to be designed first before we could scope modifying an enclosure around that.
I have some prototypes printed and was able to test fit with the main electrical components.
CAD files can be found here.
Here are some pictures comparing V3 and V4:
Here are some pictures showing the electrical component fit.
The biggest problem remaining is figuring out the clip design for the ESP32 board. I still have not gotten a reliable design that has enough flex for repeated use. I keep snapping the clips when inserting the board on the 1st or second try. Let me know if anyone has ideas! The goal here is just to reduce the amount of hardware (screws in this case) needed for the sensor.
Excellent work @eaudiffred ! Were you able to try plugging in the USB C cable while it's in the enclosure? I'm wondering if there will be any problems with the weight of the hanging cable tilting the hanging sensor and allowing more water into the shields at a high angle as the sensor is getting so small and light now.
Perhaps @muditprotect3d might have some suggestions on the mechanical side for the clips?
@keenanjohnson, excellent point on the cable weight. I just hung the sensor and plugged it in. It did tilt slightly. Enough that its worth moving the power cable entry point.
