MPS-Smart-Farm-Controller
Assembling the Mushroom House Controller – Part 2
A Collaboration with Maesai Prasisart School, Measai, Chiang Rai, Thailand
In part two of the project, we let the students assemble the Mushroom house controller that they helped to design. It is important to note that they have never done any of this before, and also that most of the components are SMD.
This made for some interesting moments…
The PCB Arrives
The PCB arrived from the factory, and after an initial inspection by myself, we took it to the school so that a specially selected group of students can try their hand at assembling it.
One of the first remarks by the students was that everything was so tiny… Having never seen SMD assembly, they wrongly assumed that they would be required to manually solder the components using traditional solder and a soldering iron… This feeling of “dismay” was greatly increased when we started laying out the small bags with components.
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The Assembly
To make things easier for them, I had previously selected all components, and together with a label and component designators, placed each component into a separate anti-static plastic bag. This achieved two things – it shielded the students from having to handle reels of components, potentially resulting in a lot of wastage, and it make it almost impossible to place a wrong component in a wrong place, as each of the bags were clearly marked with the specific component designator of the component it contained.
Their feelings of “dismay” were quickly replaced with wonder as I used a stencil to apply solder paste to the PCB. There were also confusing present, as they could not understand how the “sticky” solder would melt and keep the component in place. They were also quite worried about placing the components onto the PCB – that was until they saw that there was a selection of fine tweezers set out to use for exactly this purpose…
They now became very excited and took turns to each place a few components onto the PCB. I took special care to keep the diodes, optic isolators and microcontroller well away from them, at least until I explained that these components were polarised, or had to be placed in a specific orientation onto the board.
After a bit of struggling with the diodes, as well as the microcontroller, all the SMD components were eventually correctly placed onto the PCB. I now took over and used a hotplate to reflow the PCB.
This process completely amazed them, or at least, most of them, as some took this opportunity to continue with the ever present interaction of students and mobile phones that are so common in SE Asia 🙂
The PCB was now reflowed, and after a short break to let things cool down, we continued with the soldering and assembly of the through-hole components.
The proceedings would not be complete without a group photo of the students and the PCB that they assembled.
Conclusion of part 2
With the PCB now assembled, I used my desktop CNC machine to cut acrylic plastic to form a protective shell. The PCB will soon be installed at the remote site shown in part 1, and while it will be inside a IP65 electrical enclosure, I still felt the need for a little bit of added protection.
The firmware development is complete, and we are currently busy bringing the students up to date with the exact operation thereof. Our goal is that they would at least try to create their own version of the firmware for use in the electronics lab, as well as a comparison between my version of the firmware and theirs.
From the smiles on their faces during the entire process, it was quite obvious that they really enjoyed this project.
#include <SPI.h>
#include <Wire.h>
#include <Adafruit_GFX.h>
#include <Adafruit_SSD1306.h>
#include <Adafruit_Sensor.h>
#include <DHT.h>
#include <DHT_U.h>
/*
* Conditional Defines
*
* These are switches to allow for different versions of the Smart Farm Controller
* to be used with the same firware, as well as to enable/disable serial debugging
* NOTE that deep sleep does NOT FUNCTION CORRECTLY when serial debugging is active.
* THIS IS AN ISSUE WITH THE ESP32S3 AND NOT THE FIRMWARE.
*
*
*/
//#define DEBUG-SERIAL
// Enable below for the 3.3v version of the hardware, IF it has a lipo battery installed
//#define HAS_LIPO
// Enable only is NO lipo battery installed, DONT USE together with HAS_LIPO
#define MAINS_PWR
// ENABLE if the DHT11 Sensor's power is controlled with a transistor.
// This is standard on the 3.3v version, where power saving is important.
#define DHT_SW
// THIS IS THE TIME THAT THE "FOG" relay will allow water to be released
#define FOG_DELAY 10000
// TOP Value of the Humidity Window
#define FOG_HIGH 80
// BOTTOM Value of the Humidity Window
#define FOG_LOW 70
// HOW LONG to Sleep During DEEP SLEEP MODE - 10 Minutes is Maximum, Value is in seconds
#define TIME_TO_SLEEP 600
// HOW LONG TO STAY AWAKE (RUN) - Value is in seconds
#define TIME_AWAKE 300
/*
* PLEASE NOTE THAT THE DEVICE SHALL NOT ENTER DEEP SLEEP IN THE EVENT THAT HUMIDITY LEVELS
* HAVE DROPPED OUTSIDE OF THE ALLOWED WINDOW.
* NORMAL DEEP SLEEP SHALL RESUME WHEN THE HUMIDITY VALUE IS BACK IN THE CORRECT WINDOW
*/
/*
* ===================================================================================================
* ============ DO NOT EDIT BELOW THIS BLOCK - UNLESS YOU KNOW WHAT YOU ARE DOING ====================
* ===================================================================================================
*/
// Variables and Constants
#define DHTPIN 9
#define DHTTYPE DHT11 // DHT 11
#define Relay1 8
#define Relay2 7
#define SCREEN_WIDTH 128 // OLED display width, in pixels
#define SCREEN_HEIGHT 64 // OLED display height, in pixels
#define OLED_RESET -1 // Reset pin # (or -1 if sharing Arduino reset pin)
#define SCREEN_ADDRESS 0x3C ///< See datasheet for Address; 0x3D for 128x64, 0x3C for 128x32
#ifdef DHT_SW
#define DHT_Pin 3 // THIS IS NOT THE DATA PIN, IT IS A CONTROL TRANSISTOR, PRESENT ONLY ON THE 3.3v Version of the controller
#endif
#define uS_TO_S_FACTOR 1000000ULL /* Conversion factor for micro seconds to seconds */
const int ledPin = LED_BUILTIN;
int ledState = LOW;
unsigned long previousMillis = 0;
unsigned long previousFog = 0;
uint32_t delayMS;
float temperature = 0;
float humidity = 0;
#ifdef HAS_LIPO
int rawBattVoltage = 0;
float BattVoltage = 0.00;
#endif
bool MAY_FOG = 0;
bool RUN_FOG = 0;
bool DELAY_FOG = 0;
int FOG_LOOP = 0;
RTC_DATA_ATTR int LoopCount = 0;
bool MaySleep = 1;
bool SensorActive = 0;
/*
* CLASS DEFINITIONS FOR EXTERNAL COMPONENTS
*/
Adafruit_SSD1306 display(SCREEN_WIDTH, SCREEN_HEIGHT, &Wire, OLED_RESET);
DHT_Unified dht(DHTPIN, DHTTYPE);
/*
* FUNCTIONS AND PROCEDURES
*/
void print_wakeup_reason(){
#ifdef DEBUG-SERIAL
esp_sleep_wakeup_cause_t wakeup_reason;
wakeup_reason = esp_sleep_get_wakeup_cause();
switch(wakeup_reason)
{
case ESP_SLEEP_WAKEUP_EXT0 : Serial.println("Wakeup caused by external signal using RTC_IO"); break;
case ESP_SLEEP_WAKEUP_EXT1 : Serial.println("Wakeup caused by external signal using RTC_CNTL"); break;
case ESP_SLEEP_WAKEUP_TIMER : Serial.println("Wakeup caused by timer"); break;
case ESP_SLEEP_WAKEUP_TOUCHPAD : Serial.println("Wakeup caused by touchpad"); break;
case ESP_SLEEP_WAKEUP_ULP : Serial.println("Wakeup caused by ULP program"); break;
default : Serial.printf("Wakeup was not caused by deep sleep: %d\n",wakeup_reason); break;
}
#endif
}
/*
* SETUP FUNCTION - HARDWARE INITIALISATION
*/
void setup() {
//Set relays to initialise as OFF (N/O)
digitalWrite(Relay1,HIGH);
digitalWrite(Relay2,HIGH);
pinMode(Relay1,OUTPUT);
pinMode(Relay2,OUTPUT);
#ifdef DEBUG-SERIAL
Serial.begin(115200);
#endif
LoopCount = 0;
digitalWrite(ledPin,HIGH);
pinMode(ledPin,OUTPUT);
#ifdef DHT_SW
digitalWrite(DHT_Pin,HIGH);
pinMode(DHT_Pin,OUTPUT);
#endif
// SSD1306_SWITCHCAPVCC = generate display voltage from 3.3V internally
if(!display.begin(SSD1306_SWITCHCAPVCC, SCREEN_ADDRESS)) {
//Serial.println(F("SSD1306 allocation failed"));
for(;;); // Don't proceed, loop forever
}
display.ssd1306_command(SSD1306_DISPLAYON);
display.clearDisplay();
display.display();
delay(20);
display.setTextSize(1);
display.setTextColor(SSD1306_WHITE);
display.setCursor(10,10);
display.print("Booting...");
display.display();
delay(2000);
dht.begin();
#ifdef DEBUG-SERIAL
Serial.println(F("DHT11 Unified Sensor TEST"));
#endif
sensor_t sensor;
dht.temperature().getSensor(&sensor);
#ifdef DEBUG-SERIAL
Serial.println(F("------------------------------------"));
Serial.println(F("Temperature Sensor"));
Serial.print (F("Sensor Type: ")); Serial.println(sensor.name);
Serial.print (F("Driver Ver: ")); Serial.println(sensor.version);
Serial.print (F("Unique ID: ")); Serial.println(sensor.sensor_id);
Serial.print (F("Max Value: ")); Serial.print(sensor.max_value); Serial.println(F("°C"));
Serial.print (F("Min Value: ")); Serial.print(sensor.min_value); Serial.println(F("°C"));
Serial.print (F("Resolution: ")); Serial.print(sensor.resolution); Serial.println(F("°C"));
Serial.println(F("------------------------------------"));
#endif
display.clearDisplay();
display.display();
display.setTextSize(1);
display.setTextColor(SSD1306_WHITE);
display.setCursor(10,1);
display.print("Temperature Sensor");
display.setCursor(10,10);
display.print(F("Type: "));
display.print(sensor.version);
display.setCursor(10,20);
display.print(F("Min: "));
display.print(sensor.min_value);
display.print(F(" Deg C"));
display.setCursor(10,30);
display.print(F("Max: "));
display.print(sensor.max_value);
display.print(F(" Deg C"));
display.setCursor(10,40);
display.print(F("Resolution: +/- "));
display.setCursor(10,50);
display.print(sensor.resolution);
display.print(F(" Deg C"));
display.display();
delay(4000);
// Print humidity sensor details.
dht.humidity().getSensor(&sensor);
#ifdef DEBUG-SERIAL
Serial.println(F("Humidity Sensor"));
Serial.print (F("Sensor Type: ")); Serial.println(sensor.name);
Serial.print (F("Driver Ver: ")); Serial.println(sensor.version);
Serial.print (F("Unique ID: ")); Serial.println(sensor.sensor_id);
Serial.print (F("Max Value: ")); Serial.print(sensor.max_value); Serial.println(F("%"));
Serial.print (F("Min Value: ")); Serial.print(sensor.min_value); Serial.println(F("%"));
Serial.print (F("Resolution: ")); Serial.print(sensor.resolution); Serial.println(F("%"));
Serial.println(F("------------------------------------"));
// Set delay between sensor readings based on sensor details.
#endif
display.clearDisplay();
display.display();
display.setTextSize(1);
display.setTextColor(SSD1306_WHITE);
display.setCursor(10,1);
display.print("Humidity Sensor");
display.setCursor(10,10);
display.print(F("Type: "));
display.print(sensor.version);
display.setCursor(10,20);
display.print(F("Min: "));
display.print(sensor.min_value);
display.print(F(" % RH"));
display.setCursor(10,30);
display.print(F("Max: "));
display.print(sensor.max_value);
display.print(F(" % RH"));
display.setCursor(10,40);
display.print(F("Resolution: +/- "));
display.setCursor(10,50);
display.print(sensor.resolution);
display.print(F(" % RH"));
display.display();
delay(4000);
delayMS = sensor.min_delay / 1000;
print_wakeup_reason();
#ifdef HAS_LIPO
rawBattVoltage = analogRead(A0);
BattVoltage = ((rawBattVoltage * 2) * (3.34 / 4095.00));
if (BattVoltage > 4.05) {
esp_sleep_enable_timer_wakeup(TIME_TO_SLEEP * uS_TO_S_FACTOR);
} else if ((BattVoltage > 3.20) && (BattVoltage < 4.20)){
esp_sleep_enable_timer_wakeup(TIME_TO_SLEEP * uS_TO_S_FACTOR);
} else {
// Below 3.2 volt we consider the battary too low for operation.
// We do not set a wakeup time for deepsleep.
// This will cause the ESP32 to go to sleep and not wakeup until manual reset
}
#endif
#ifdef MAINS_PWR
esp_sleep_enable_timer_wakeup(TIME_TO_SLEEP * uS_TO_S_FACTOR);
#endif
}
/*
* MAIN LOOP
*/
void loop() {
#ifdef DHT_SW
SensorActive = digitalRead(DHT_Pin);
#else
SensorActive = 1;
#endif
unsigned long currentMillis = millis();
unsigned long FogMillis = millis();
// 10 second "FOG" loop
if (FogMillis - previousFog >= FOG_DELAY) {
previousFog = FogMillis;
if ((digitalRead(Relay1) == LOW) && (RUN_FOG == 1) && (DELAY_FOG == 0)) {
digitalWrite(Relay1,HIGH);
DELAY_FOG = 1;
#ifdef DEBUG-SERIAL
Serial.println(F("RELAY OFF AFTER 10 SEC"));
#endif
} else if (DELAY_FOG == 1) {
DELAY_FOG = 0;
if (RUN_FOG == 1) RUN_FOG = 0;
#ifdef DEBUG-SERIAL
Serial.println(F("RELAY DELAY OFF FOR 10 SEC"));
#endif
}
}
// Main 1 second loop - Non blocking
if (currentMillis - previousMillis >= delayMS) {
// save the last time you blinked the LED
previousMillis = currentMillis;
++LoopCount;
if (ledState == LOW) {
ledState = HIGH;
} else {
ledState = LOW;
}
// TEST RELAY2
digitalWrite(Relay2,!digitalRead(Relay2));
// set the LED with the ledState of the variable:
digitalWrite(ledPin, ledState);
#ifdef HAS_LIPO
rawBattVoltage = analogRead(A0);
BattVoltage = ((rawBattVoltage * 2) * (3.34 / 4095.00));
#endif
display.clearDisplay();
display.setTextSize(2);
display.setTextColor(SSD1306_WHITE);
sensors_event_t event;
dht.temperature().getEvent(&event);
if (isnan(event.temperature)) {
#ifdef DEBUG-SERIAL
Serial.println(F("Error reading temperature!"));
#endif
}
else {
display.setCursor(10,1);
display.setCursor(10,1);
display.print(event.temperature);
display.setCursor(80,1);
display.println(F(" C"));
temperature = event.temperature;
}
// Get humidity event and print its value.
dht.humidity().getEvent(&event);
if (isnan(event.relative_humidity)) {
#ifdef DEBUG-SERIAL
Serial.println(F("Error reading humidity!"));
#endif
}
else {
#ifdef DEBUG-SERIAL
Serial.print(F("Humidity: "));
Serial.print(event.relative_humidity);
Serial.println(F("%"));
#endif
display.setCursor(10,20);
display.print(event.relative_humidity);
display.setCursor(80,20);
display.println(F(" %"));
humidity = event.relative_humidity;
}
#ifdef HAS_LIPO
display.setTextSize(1);
display.setCursor(10,40);
display.print("LiPo ");
display.print(String(BattVoltage));
display.print("v ");
if (BattVoltage >= 4.00)
{
display.println("Charging");
} else if ((BattVoltage >= 3.30) and (BattVoltage <= 4.00)) {
display.println("Batt PWR");
} else {
display.println("LOW BATT");
}
#endif
#ifdef DEBUG-SERIAL
Serial.println("=== TEST DATA ===");
Serial.print("TEMP ");
Serial.print(String(temperature));
Serial.println(F("°C"));
Serial.print("HUMIDITY ");
Serial.print(String(humidity));
Serial.println(F(" %"));
#ifdef HAS_LIPO
Serial.print("LiPo Battery Voltage : ");
Serial.print(BattVoltage);
Serial.println("v ");
Serial.println();
#endif
Serial.print("Time to sleep :");
Serial.print(String(TIME_AWAKE - LoopCount));
Serial.println(" seconds");
Serial.println("=== END ===");
#endif
display.setTextSize(1);
if ((MaySleep == 1) && (RUN_FOG == 0)) {
display.setCursor(10,50);
display.print("DEEPSLEEP in ");
display.print(String(TIME_AWAKE - LoopCount));
display.print("sec ");
} else if ((MaySleep == 0) && (RUN_FOG == 0)){
display.setCursor(10,50);
display.print("DISP OFF in ");
display.print(String(TIME_AWAKE - LoopCount));
display.print("sec ");
}
}
display.display();
if (LoopCount >= TIME_AWAKE)
{
display.clearDisplay();
display.setTextSize(1);
display.setTextColor(SSD1306_WHITE);
if ((MaySleep == 1) && (RUN_FOG ==0)) {
display.setCursor(10,10);
display.print("Going to sleep...");
display.display();
} else {
display.setCursor(10,10);
display.print("Dimming Display...");
display.display();
}
delay(2000);
display.clearDisplay();
display.display();
#ifdef DEBUG-SERIAL
Serial.flush();
#endif
#ifdef DHT_SW
digitalWrite(DHT_Pin,LOW);
#endif
if (digitalRead(Relay1) == LOW) digitalWrite(Relay1,HIGH);
if (digitalRead(Relay2) == LOW) digitalWrite(Relay2,HIGH);
display.ssd1306_command(SSD1306_DISPLAYOFF);
delay(2000);
if ((MaySleep == 1) && (RUN_FOG ==0)){
esp_deep_sleep_start();
}
}
// we only care about readings if and when the sensor is active AND we have valid data...
if (SensorActive == 1) {
if ((humidity < FOG_LOW) && (RUN_FOG == 0)) {
RUN_FOG = 1;
MAY_FOG = 1;
#ifdef DEBUG-SERIAL
Serial.println(F("HUMIDITY BELOW 70"));
#endif
} else if ((humidity >= FOG_LOW) && (humidity <= FOG_HIGH)) {
RUN_FOG = 0;
MAY_FOG = 0;
if (digitalRead(Relay1) == LOW) digitalWrite(Relay1,HIGH);
#ifdef DEBUG-SERIAL
Serial.print("Humidity in Range ");
Serial.print(String(FOG_LOW));
Serial.print(" % to ");
Serial.print(String(FOG_HIGH));
Serial.println(" %");
#endif
}
}
if ((digitalRead(Relay1) == HIGH) && (RUN_FOG == 1) && DELAY_FOG == 0) digitalWrite(Relay1,LOW);
if ((DELAY_FOG == 1) && (MAY_FOG ==1 )) digitalWrite(Relay1,HIGH);
}
MPS-Smart-Farm-Controller
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