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nk25719 / PMD___aka-KiCad-esp32-6leds-2switches-1pj-circuit-

In this repo I am practicing KICAD. Created an ESP32 DevKit V1 module and a PCB footprint. I designed a circuit around this ESP32 consisting of six lamps, four switches, and two power jacks and added a voltage regulater to Vin to maintain a supply of +5V. (This project was originally made of two switches and 1 power jack and was named homeWork2.)
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Assemble JLCPCB Order of 202407 #32

Closed ForrestErickson closed 5 days ago

ForrestErickson commented 1 month ago

Is your feature request related to a problem? Please describe. A clear and concise description of what the problem is. Ex. I'm always frustrated when [...] Capture the out of box experience of receiving the JLCPCB Order of 202407 including finish assembly

Describe the solution you'd like A clear and concise description of what you want to happen. Capture of every step.

ForrestErickson commented 1 month ago

Journal of Assembly

The shipping package
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The JLCPCB Box
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Inside the JLCPCB Box
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Wrapping of Assemblies and PCBs
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UNwrapping of Assemblies
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Note the TO220 package tab has poked through the padding near the tip of the scissors. The assemblies appear undamaged but this is not a great packing result.

Assemblies before adding SN
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Assemblies with SN
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Assemblies in antistatic handling
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Assembling with LEDs
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RED Led with clear plastic in one location. White LEDs in clear plastic in six locations. One Green LED.

Solder side view of LED leads before soldering
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Solder side view of LED leads after soldering
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Before adding ESP32, Apply power.
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The REE power LED illuminates as required.

OOPS Wrong pin spacing on DIP for ESP32
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Root Cause Analysis of Pin Spacing Error

We did not catch this because there are different spacing on the kits and Lee measured the wrong kit when checking the pin spacing.

Containment of Pin Spacing

Rework the pins (bend narrower)

First remove the plastic part of header with successively bigger screwdrivers.
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ForrestErickson commented 1 month ago

Powering up the assembly

VIDEO LINK: https://github.com/user-attachments/assets/2181bb16-e46a-4b6e-887a-cb2e88522f4e
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Note the ESP32 kit is a "NodeMCU-ESP32 ESP32 DSEVKIT1" which apparently has some firmware in it.

Boot message on serial port:
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ForrestErickson commented 1 month ago

Smart Phone, Connecting to the AT

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Selecting the AT point image

Opening the page at 192.168.4.1 image

Conclusion

The ESP module is running some kind of "Ai-Thinker" firmware

ForrestErickson commented 1 month ago

Adding LEDs using the GPAD standoffs:
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I have standardized on:

ForrestErickson commented 1 month ago

Factory Test with Firmware

To test out the assembly of hardware several "sketches" are used.

In addition to the running the code which came in the ESP kit which runs a softAP test with:

Test Journal

Test Conditions: Power the DUT with wall supply to measure current.

SN USA1

Serial Terminal on COM6 report with built in code

18:34:05.877 -> get wifi ap mac: 61:05:3D:3D:F0:8C 18:34:05.877 -> get wifi ap ssid: ESP_3DF08C 18:34:05.877 -> get wifi ap password: 18:34:05.924 -> set wifi ap ... 18:34:05.924 -> get wifi sta ssid: 18:34:05.924 -> get wifi sta password: 18:34:05.924 -> set wifi sta ... 18:34:05.924 -> wifi start 18:34:05.924 -> mode : sta(3c:61:05:3d:f0:8c) + softAP(3e:61:05:3d:f0:8c) 18:34:05.924 -> D (383) event: SYSTEM_EVENT_STA_START 18:34:05.924 -> V (386) event: enter default callback 18:34:05.924 -> V (389) event: exit default callback 18:34:05.924 -> D (392) event: SYSTEM_EVENT_AP_START 18:34:05.924 -> V (396) event: enter default callback 18:34:05.924 -> dhcp server start:(ip: 192.168.4.1, mask: 255.255.255.0, gw: 192.168.4.1) 18:34:05.924 -> V (406) event: exit default callback 18:34:05.924 -> mode : softAP(3e:61:05:3d:f0:8c) 18:34:05.924 -> D (412) event: SYSTEM_EVENT_STA_STOP 18:34:05.924 -> V (415) event: enter default callback 18:34:05.970 -> V (419) event: exit default callback 18:34:05.970 -> start led blink task. 18:34:05.970 -> start http server task. Load file: FactoryTest_BRD1 into SN USA1

Current consumption is 190 to 200 mA

SN USA2

Serial Terminal on COM6 report with ???? in code

18:47:49.801 -> ets Jun 8 2016 00:22:57 18:47:49.801 -> 18:47:49.801 -> rst:0x1 (POWERON_RESET),boot:0x13 (SPI_FAST_FLASH_BOOT) 18:47:49.801 -> configsip: 0, SPIWP:0xee 18:47:49.801 -> clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00 18:47:49.801 -> mode:DIO, clock div:1 18:47:49.801 -> load:0x3fff0030,len:1344 18:47:49.801 -> load:0x40078000,len:13864 18:47:49.801 -> load:0x40080400,len:3608 18:47:49.834 -> entry 0x400805f0 18:47:49.945 -> 18:47:51.928 -> 18:47:51.928 -> Hello World 18:47:51.928 -> LED is on 18:47:51.928 -> 1 18:47:52.928 -> LED is off 18:47:53.911 -> LED is on 18:47:53.911 -> 2 18:47:54.928 -> LED is off 18:47:55.927 -> LED is on 18:47:55.927 -> 3 18:47:56.911 -> LED is off 18:47:57.910 -> LED is on 18:47:57.910 -> 4 18:47:58.925 -> LED is off 18:47:59.918 -> LED is on 18:47:59.918 -> 5 18:48:00.928 -> LED is off 18:48:01.927 -> LED is on 18:48:01.927 -> 6 18:48:02.927 -> LED is off Current consumption is 70 to 80 mA

SN USA3

Serial Terminal on COM6 report with built in code

18:49:58.217 -> get wifi ap mac: 61:05:3D:3D:F6:3C 18:49:58.217 -> get wifi ap ssid: ESP_3DF63C 18:49:58.217 -> get wifi ap password: 18:49:58.217 -> set wifi ap ... 18:49:58.217 -> get wifi sta ssid: 18:49:58.217 -> get wifi sta password: 18:49:58.217 -> set wifi sta ... 18:49:58.217 -> wifi start 18:49:58.217 -> mode : sta(3c:61:05:3d:f6:3c) + softAP(3e:61:05:3d:f6:3c) 18:49:58.217 -> D (382) event: SYSTEM_EVENT_STA_START 18:49:58.217 -> V (385) event: enter default callback 18:49:58.217 -> V (388) event: exit default callback 18:49:58.261 -> D (391) event: SYSTEM_EVENT_AP_START 18:49:58.261 -> V (395) event: enter default callback 18:49:58.261 -> dhcp server start:(ip: 192.168.4.1, mask: 255.255.255.0, gw: 192.168.4.1) 18:49:58.261 -> V (405) event: exit default callback 18:49:58.261 -> mode : softAP(3e:61:05:3d:f6:3c) 18:49:58.261 -> D (411) event: SYSTEM_EVENT_STA_STOP 18:49:58.261 -> V (414) event: enter default callback 18:49:58.261 -> V (418) event: exit default callback 18:49:58.261 -> start led blink task. 18:49:58.261 -> start http server task.

Current consumption is 180 to 190 mA

SN USA4

Serial Terminal on COM6 report with built in code

18:52:20.411 -> rst:0x1 (POWERON_RESET),boot:0x13 (SPI_FAST_FLASH_BOOT) 18:52:20.411 -> configsip: 0, SPIWP:0xee 18:52:20.411 -> clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00 18:52:20.411 -> mode:DIO, clock div:2 18:52:20.411 -> load:0x3fff0018,len:4 18:52:20.411 -> load:0x3fff001c,len:5564 18:52:20.411 -> load:0x40078000,len:0 18:52:20.411 -> load:0x40078000,len:13756 18:52:20.411 -> entry 0x40078fb4 18:52:20.457 -> I (29) boot: ESP-IDF v3.0.3 2nd stage bootloader 18:52:20.457 -> I (29) boot: compile time 08:53:32 18:52:20.457 -> I (30) boot: Enabling RNG early entropy source... 18:52:20.457 -> I (34) boot: SPI Speed : 40MHz 18:52:20.457 -> I (38) boot: SPI Mode : DIO 18:52:20.457 -> I (42) boot: SPI Flash Size : 4MB 18:52:20.457 -> I (46) boot: Partition Table: 18:52:20.457 -> I (49) boot: ## Label Usage Type ST Offset Length 18:52:20.457 -> I (57) boot: 0 phy_init RF data 01 01 0000f000 00001000 18:52:20.649 -> I (64) boot: 1 otadata OTA data 01 00 00010000 00002000 18:52:20.649 -> I (72) boot: 2 nvs WiFi data 01 02 00012000 0000e000 18:52:20.649 -> I (79) boot: 3 at_customize unknown 40 00 00020000 000e0000 18:52:20.649 -> I (87) boot: 4 ota_0 OTA app 00 10 00100000 00180000 18:52:20.649 -> I (94) boot: 5 ota_1 OTA app 00 11 00280000 00180000 18:52:20.649 -> I (102) boot: End of partition table 18:52:20.649 -> I (106) boot: No factory image, trying OTA 0 18:52:20.649 -> I (111) esp_image: segment 0: paddr=0x00100020 vaddr=0x3f400020 size=0x200f4 (131316) map 18:52:20.649 -> I (166) esp_image: segment 1: paddr=0x0012011c vaddr=0x3ffc0000 size=0x02d6c ( 11628) load 18:52:20.649 -> I (171) esp_image: segment 2: paddr=0x00122e90 vaddr=0x40080000 size=0x00400 ( 1024) load 18:52:20.649 -> I (173) esp_image: segment 3: paddr=0x00123298 vaddr=0x40080400 size=0x0cd78 ( 52600) load 18:52:20.649 -> I (203) esp_image: segment 4: paddr=0x00130018 vaddr=0x400d0018 size=0xdf390 (914320) map 18:52:20.943 -> I (524) esp_image: segment 5: paddr=0x0020f3b0 vaddr=0x4008d178 size=0x01f14 ( 7956) load 18:52:20.943 -> I (527) esp_image: segment 6: paddr=0x002112cc vaddr=0x400c0000 size=0x00064 ( 100) load 18:52:20.943 -> I (539) boot: Loaded app from partition at offset 0x100000 18:52:20.943 -> I (539) boot: Disabling RNG early entropy source... 18:52:21.009 -> Bin version(Wroom32):1.1.2 18:52:21.009 -> I (659) wifi: wifi firmware version: de47fad 18:52:21.009 -> I (660) wifi: config NVS flash: enabled 18:52:21.009 -> I (660) wifi: config nano formating: disabled 18:52:21.009 -> I (670) wifi: Init dynamic tx buffer num: 32 18:52:21.058 -> I (671) wifi: Init data frame dynamic rx buffer num: 32 18:52:21.058 -> I (671) wifi: Init management frame dynamic rx buffer num: 32 18:52:21.058 -> I (676) wifi: wifi driver task: 3ffdecc0, prio:23, stack:3584 18:52:21.058 -> I (681) wifi: Init static rx buffer num: 10 18:52:21.058 -> I (684) wifi: Init dynamic rx buffer num: 32 18:52:21.058 -> I (689) wifi: wifi power manager task: 0x3ffdfd8c prio: 21 stack: 2560 18:52:21.093 -> I (752) wifi: mode : softAP (10:06:1c:68:6a:15) 18:52:21.126 -> I (760) wifi: mode : sta (10:06:1c:68:6a:14) + softAP (10:06:1c:68:6a:15) 18:52:21.126 -> I (764) wifi: mode : softAP (10:06:1c:68:6a:15)

Current consumption is 80 mA No flashing LEDs Conclusion, this default firmware is different from that of SN1, SN2 and SN3.

SN USA5

Serial Terminal on COM6 report with built in code

19:01:30.957 -> ets Jul 29 2019 12:21:46 19:01:30.957 -> 19:01:30.957 -> rst:0x1 (POWERON_RESET),boot:0x13 (SPI_FAST_FLASH_BOOT) 19:01:30.957 -> configsip: 0, SPIWP:0xee 19:01:30.957 -> clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00 19:01:30.957 -> mode:DIO, clock div:2 19:01:30.957 -> load:0x3fff0018,len:4 19:01:30.957 -> load:0x3fff001c,len:5564 19:01:30.957 -> load:0x40078000,len:0 19:01:30.957 -> load:0x40078000,len:13756 19:01:30.957 -> entry 0x40078fb4 19:01:30.996 -> I (29) boot: ESP-IDF v3.0.3 2nd stage bootloader 19:01:30.996 -> I (29) boot: compile time 08:53:32 19:01:30.996 -> I (30) boot: Enabling RNG early entropy source... 19:01:30.996 -> I (34) boot: SPI Speed : 40MHz 19:01:30.996 -> I (38) boot: SPI Mode : DIO 19:01:30.996 -> I (42) boot: SPI Flash Size : 4MB 19:01:30.996 -> I (46) boot: Partition Table: 19:01:30.996 -> I (49) boot: ## Label Usage Type ST Offset Length 19:01:31.039 -> I (57) boot: 0 phy_init RF data 01 01 0000f000 00001000 19:01:31.039 -> I (64) boot: 1 otadata OTA data 01 00 00010000 00002000 19:01:31.039 -> I (72) boot: 2 nvs WiFi data 01 02 00012000 0000e000 19:01:31.039 -> I (79) boot: 3 at_customize unknown 40 00 00020000 000e0000 19:01:31.039 -> I (87) boot: 4 ota_0 OTA app 00 10 00100000 00180000 19:01:31.039 -> I (94) boot: 5 ota_1 OTA app 00 11 00280000 00180000 19:01:31.089 -> I (102) boot: End of partition table 19:01:31.089 -> I (106) boot: No factory image, trying OTA 0 19:01:31.089 -> I (111) esp_image: segment 0: paddr=0x00100020 vaddr=0x3f400020 size=0x200f4 (131316) map 19:01:31.106 -> I (166) esp_image: segment 1: paddr=0x0012011c vaddr=0x3ffc0000 size=0x02d6c ( 11628) load 19:01:31.106 -> I (171) esp_image: segment 2: paddr=0x00122e90 vaddr=0x40080000 size=0x00400 ( 1024) load 19:01:31.140 -> I (173) esp_image: segment 3: paddr=0x00123298 vaddr=0x40080400 size=0x0cd78 ( 52600) load 19:01:31.140 -> I (203) esp_image: segment 4: paddr=0x00130018 vaddr=0x400d0018 size=0xdf390 (914320) map 19:01:31.467 -> I (524) esp_image: segment 5: paddr=0x0020f3b0 vaddr=0x4008d178 size=0x01f14 ( 7956) load 19:01:31.467 -> I (527) esp_image: segment 6: paddr=0x002112cc vaddr=0x400c0000 size=0x00064 ( 100) load 19:01:31.507 -> I (539) boot: Loaded app from partition at offset 0x100000 19:01:31.507 -> I (539) boot: Disabling RNG early entropy source... 19:01:31.547 -> Bin version(Wroom32):1.1.2

19:01:31.547 -> I (660) wifi: wifi firmware version: de47fad 19:01:31.547 -> I (660) wifi: config NVS flash: enabled 19:01:31.547 -> I (660) wifi: config nano formating: disabled 19:01:31.593 -> I (670) wifi: Init dynamic tx buffer num: 32 19:01:31.593 -> I (671) wifi: Init data frame dynamic rx buffer num: 32 19:01:31.593 -> I (671) wifi: Init management frame dynamic rx buffer num: 32 19:01:31.593 -> I (676) wifi: wifi driver task: 3ffdecc0, prio:23, stack:3584 19:01:31.593 -> I (681) wifi: Init static rx buffer num: 10 19:01:31.593 -> I (684) wifi: Init dynamic rx buffer num: 32 19:01:31.593 -> I (689) wifi: wifi power manager task: 0x3ffdfd8c prio: 21 stack: 2560 19:01:31.640 -> I (755) wifi: mode : softAP (10:06:1c:68:6a:15) 19:01:31.687 -> I (763) wifi: mode : sta (10:06:1c:68:6a:14) + softAP (10:06:1c:68:6a:15) 19:01:31.687 -> I (767) wifi: mode : softAP (10:06:1c:68:6a:15) 19:01:36.641 -> ⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮⸮ (5746) wifi: n:1 0, o:1 0, ap:1 1, sta:255 255, prof:1 19:01:36.641 -> I (5747) wifi: station: 60:f1:89:f9:62:cd join, AID=1, g, 20

Current consumption is 80 to 90 mA

ForrestErickson commented 1 month ago

@nk25719

Marching One Test

SN USA5

Serial Terminal on COM6. Resume test trying to use the "marchingOneTest" file Fails to compile SoftwareSerial.h: No such file or directory

Comment out five include files not needed in this sketch removed error (and significnatly shorted compile time) image

Compiled and tried to upload and got this error

esptool.py v4.2.1 Serial port COM6 Connecting.... A fatal error occurred: This chip is ESP32 not ESP32-S2. Wrong --chip argument? A fatal error occurred: This chip is ESP32 not ESP32-S2. Wrong --chip argument?

Changed board type image

The firmware compiled, loaded and ran with success!

SN USA2

Serial Terminal on COM6. Resume test trying to use the "marchingOneTest" file as above. The firmware compiled, loaded and ran with success!

SN USA3

Serial Terminal on COM6. Resume test trying to use the "marchingOneTest" file as above. The firmware compiled, loaded and ran with success!

SN USA5

Serial Terminal on COM6. Resume test trying to use the "marchingOneTest" file as above. The firmware compiled, loaded and ran with success!

Marching Zero Test

Also comment out the unused libraries image

SN USA5

Serial Terminal on COM6. Resume test trying to use the "marchingZeroTest" file as above. The firmware compiled, loaded and ran with success!

SN USA4

Serial Terminal on COM6. Resume test trying to use the "marchingZeroTest" file as above. The firmware compiled, loaded and ran with success!

SN USA3

Serial Terminal on COM6. Resume test trying to use the "marchingZeroTest" file as above. The firmware compiled, loaded and ran with success!

SN USA2

Serial Terminal on COM6. Resume test trying to use the "marchingZeroTest" file as above. The firmware compiled, loaded and ran with success!

SN USA2

Serial Terminal on COM6. Resume test trying to use the "marchingZeroTest" file as above. The firmware compiled, loaded and ran with success!

Test Conclusion.

All assemblies passed walking one and walking zero test.

ForrestErickson commented 5 days ago

All assemblies as finished on about 7 September 2024.

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Closing CC: @nk25719