Two PCB Variants for ESP32 Stair-Lighting Controller - WS2812 LEDs & Multiple Sensors

Completed Posted 3 weeks ago Paid on delivery
Completed Paid on delivery

Hi,

I’m looking for a freelancer to help me design two PCB variants for a stair-lighting controller using a 38-pin ESP32 Dev Module (USB-C). This system will power and control WS2812 LED strips and incorporate multiple sensors for an intelligent lighting setup. Below is an overview of what I need, followed by detailed requirements. At the end, I’ve included links and attachments referencing a similar board and my own sketches.

>>> Overview of the Project

1. Goal: Create two PCB variants (Version A and Version B) of a stair-lighting controller for WS2812 LEDs:

- Variant A: 2 LED outputs,

- Variant B: 16 LED outputs.

2. Board: Uses an ESP32 Dev Module (38-pin, USB-C) mounted on female headers (no extra programming buttons needed).

3. Sensors: 2× PIR, 2× ToF (I²C + XSHUT), 1× BH1750 (I²C), 2× external switches, plus a 2-bit DIP switch for addressing.

4. Power: 5 V input, onboard regulation to 3.3 V. Needs wide 5 V traces and capacitors for higher currents.

5. Long Wires: Because this will be used on stair installations with potentially long cable runs, I expect proper > ESD protection, filtering, pull-ups/pull-downs, and series resistors <

>>> Detailed Requirements

1. ESP32 & Power

- 38-pin ESP32 Dev Module (USB-C), no extra BOOT/RESET headers.

- 5 V supply with onboard regulator for 3.3 V (ESP32, sensors).

- Bulk capacitors (e.g., 470–1000 µF) on the 5 V rail, decoupling (100 nF) near ICs.

- Wide 5 V/GND traces for LED current, especially on the 16-output variant.

2. Sensors & Inputs

- 2× PIR** (digital input, each with a 3-pin connector: 5 V, GND, signal).

- 2× ToF** (I²C + XSHUT pin), each on a 5-pin connector: 5 V, GND, SDA, SCL, XSHUT.

- 1× BH1750** (I²C), 4-pin connector: 5 V, GND, SDA, SCL.

- 2× Switches** (digital input), each on a 2-pin connector: GPIO + GND.

- 1× DIP switch** (2 bits) with pull-ups (10 kΩ) to 3.3 V.

3. I²C Pull-Ups & ESD

- SDA/SCL lines: 4.7 kΩ pull-ups to 3.3 V, small series resistors (~47–100 Ω), ESD diodes if necessary.

- XSHUT lines: 10 kΩ pull-ups, small resistors, ESD protection.

4. WS2812 LED Outputs

- Each Data line must have a level shifter (e.g., 74HCT14, 74HC125, or equivalent) to convert 3.3 V → 5 V.

- A series resistor (~330 Ω) right before the LED Data output, plus possible ESD diode for long cable runs.

- Output connectors: Data, 5 V, GND (3 pins).

- Large electrolytic cap (470–1000 µF) on the 5 V rail near the LED outputs.

5. Two PCB Variants

Variant A (Ver_A) – 2 or 4 Outputs

- 2 WS2812 Data lines (each with level shifting, resistors).

- Same sensor arrangement.

- Designed for simpler installations.

Variant B (Ver_B) – 16 Outputs

- 16 WS2812 Data lines (level shifting + resistors each).

- Must handle higher currents (wider 5 V traces, more capacitors).

- Same sensor configuration.

- Ensure no conflict with ESP32’s boot/strapping pins when assigning 16 GPIOs.

6. Deliverables

- Complete design files (schematics, PCB layout, Gerbers, BOM) for both variants.

- Confirm pin assignments vs. ESP32 datasheet (no boot pin conflicts).

- Integrate all necessary filters and protective components for reliable operation over long cables.

- Optional help for the first manufacturing order (PCB specs, part sourcing, etc.).

>>> Attachments & Reference

1. Ver_A Diagram (2-channel example) and Ver_B Diagram (16-channel example) – attached below, showing how I envision the wiring.

2. Reference Board Link: A similar design that also uses a 74HCT14 for level shifting. Although that board supports fewer LEDs/sensors than I need, it’s a helpful reference to show a proven 5 V driver approach.

[login to view URL]:g:01gAAOSwGtRl53~b

I look forward to collaborating with you on a robust, real-world solution that meets all these requirements!

PCB Layout Electronics Microcontroller Electrical Engineering Arduino

Project ID: #39013011

About the project

37 proposals Remote project Active 3 weeks ago

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VTElectronics

Hi there I'm an Electronic Engineer with over 8 years experience designing embedded applications and PCBs. I also have C and C++ certifications here on freelancer. You can learn more about me from my Freelancer profi More

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amelectronics

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cpp2048

I can design these two boards nicely with all the required protections as well as design the power section with adequate protections. I will also take care the protection for using long wires. I am just curious, why no More

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mairajali11

As an experienced Electrical/Electronics Engineer and an adept PCB designer, I can assure you a top-notch job in creating two distinct PCB variants for your ESP32 Stair-Lighting Controller project. I have a keen unders More

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electronicsdone

Best ESP32 Stair-Lighting Controller PCB Design Expert! ⭐⭐⭐⭐⭐ Hi, I can help design the two PCB variants for your stair-lighting controller using the 38-pin ESP32 Dev Module. With over 10 years of experience in PCB des More

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AlirezaGashah

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redbrickamerica

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rajkumarr14

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