4 layers58.5 × 58.5 mm
Transmitter
andrew153d/RemoteWelderController
A pair of devices meant to retrofit older welders with wireless connectivity. This document covers the usage and mechanical makeup, the cost overview can be found here.
111 parts1
4 layers65 × 42 mm
A pair of devices meant to retrofit older welders with wireless connectivity. This document covers the usage and mechanical makeup, the cost overview can be found here.
- Size
- 65 × 42 mm
- Copper layers
- 4
- Thickness
- 1 mm
- Parts
- 131
- Nets
- 125
- Pads
- 485
- Tracks, vias
- 850, 320
- Pours
- 29
- Routed
- Yes
- KiCad
- KiCad 7 (file 20221018)
- Created
- 22 Oct 2023
- Updated
- 27 May 2024
Overview
Receiver is an open-source printed circuit board by andrew153d, from the andrew153d/RemoteWelderController repository on GitHub. It is a 4-layer board of 65 × 42 mm with 131 parts on 125 nets, routed with 850 tracks and 320 vias.
It is built around the ESP32-S3-MINI-1-N8, TLV493DA1B6HTSA2 and DMG6602SVTQ, with the TPS22810DRV and WS2812B among its other parts. Its parts include 45 capacitors, 45 resistors, 15 diodes, 8 ICs and 4 transistors. It belongs with the ESP32 boards of this library.
Main components
5
ESP32-S3-MINI-1-N8
SMD-104.5dBm -40℃~+85℃ 2.4GHz 20.5dBm 330mA 3V~3.6V 97mA Bluetooth5.0 ESP32-S3FN8 Chip On-board PCB Antenna UART、SPI、I2C、I2S、USB SMD WiFi Modules ROHSEspressif SystemsWiFi Modules
TLV493DA1B6HTSA2
SOP-6-1.5mm-40℃~+125℃ 10uA 12bit 2.8V~3.5V I2C ±130mT ±130mT SOP-6-1.5mm 3D Magnetic Sensors ROHSInfineon Technologies3D Magnetic Sensors
DMG6602SVTQ
TSOT-23-6-55℃~+150℃ 1 N-Channel + 1 P-Channel 1V、1.9V 2.8A、3.4A 30V 60mΩ@10V、95mΩ@10V 7nC@10V、9nC@10V 840mW、1.27W N-Channel + P-Channel TSOT-23-6 MOSFETs ROHSDiodes IncorporatedMOSFETs
TPS22810DRV
WSON-6-EP(2x2)-40℃~+105℃ 1 2.7V~18V 3A 79mΩ Active High Load Switch Undervoltage Protection(UVP)、Over Temperature Protection WSON-6-EP(2x2) Power Distribution Switches ROHSTexas InstrumentsPower Distribution Switches
WS2812B
5mm X 5mm Surface Mount RGB LED with Intelligent ControlWorldsemiUncategorised
README
README.mdRemoteWelderController
A pair of devices meant to retrofit older welders with wireless connectivity. This document covers the usage and mechanical makeup, the cost overview can be found here. There is also a preview of the site at this link, note functionality is limited.
Usage
There are three main modes of operation: Standard, Web Control, and Extended Web Control
Standard Control
To enter standard control mode, toggle the Transmitter power switch to the 'ON' position and press the Power button on the Receiver. While the devices are searching for each other, their status LEDs will flash blue and will transition to solid green when connected. Rotation input on the control knob will result in proportional motion on the output shaft of the receiver.
Web Control
Web Control Mode will allow the user to make use of the web interface to control the output of the receiver. Press the power button on the receiver to turn the device on. After the status LED flashes blue, hold the power button for 3 seconds or until the LED turns to solid green. Connect your phone to the wifi network named Weld_---, open a browser and go to 'Weld.local'.
Extended Web Control
Extended Web Control uses the Transmitter to host the webpage and repeats control to the receiver. After turning on both devices, hold both the up and down buttons for 3 seconds until the status LED turns green. Connect your phone to the Wifi network named Weld_--- and open the site 'Weld.Local'. In order to increase the usable distance, place the transmitter between the user and the receiver.
Mechanical Details
Web Interface
The webpage for control and configuration. Of course you can stay loyal to your brand while still bringing your welder into the modern world. The dial can be dragged to rotate, or the user can swipe the arrows at the bottom to rotate the knob. The lock button will match rotation on the output to the knob on the webpage. The align button will automatically measure the range of the output and scale the input accordingly. Settings and more configuration options can be accessed via the menu on the top left.
Transmitter
Top view of the pelican case with reciever stowed on the right side.
The charge port cap can be removed to expose the USBC port and charge the device.
The circuit board and battery pack get mounted under the faceplate. Not shown is a cover to shield the electronics from debris under the faceplate.
Receiver
Receiver is shown without belt mechanism. The hatch is biased closed by a torsion spring and sealed against the surface with a O-ring.
Shown below is the hatch on the receiver that exposes the charging port, status led, and power button. The power button serves multiple alternative functions described in the usage section.
There are several seals on the receiver that maintain water resistance. The upper seal gets compressed between the upper cover and the case. There is also a seal on the access hatch as well as around the motor shaft.
Parts
131| Qty | Value | Footprint | References |
|---|---|---|---|
| 13 | 10u | Capacitor_SMD:C_0805_2012Metric | C2, C3, C6, C10, C12, C13, C15, C16, C17, C18, C26, C33, C34 |
| 11 | 0.1u | Capacitor_SMD:C_0402_1005Metric | C1, C11, C29, C31, C35, C36, C39, C40, C44, C45, C47 |
| 10 | 100k | Resistor_SMD:R_0402_1005Metric | R7, R9, R11, R17, R18, R19, R20, R33, R39, R42 |
| 9 | 10k | Resistor_SMD:R_0402_1005Metric | R1, R2, R16, R34, R35, R36, R38, R41, R45 |
| 5 | 10 | Resistor_SMD:R_0402_1005Metric | R21, R22, R23, R24, R25 |
| 5 | 1N4148WQ-13-F | Diode_SMD:D_SOD-323 | D4, D7, D8, D9, D10 |
| 5 | 220nf | Capacitor_SMD:C_0402_1005Metric | C21, C22, C23, C24, C25 |
| 5 | TVN3V3B1S | Diode_SMD:D_0402_1005Metric | D11, D12, D13, D14, D15 |
| 4 | 100 | Resistor_SMD:R_0402_1005Metric | R10, R26, R28, R29 |
| 4 | 1u | Capacitor_SMD:C_0402_1005Metric | C27, C30, C32, C38 |
| 4 | MountingHole | MountingHole:MountingHole_3.2mm_M3_DIN965_Pad_TopBottom | H1, H2, H3, H4 |
| 3 | 5.1k | Resistor_SMD:R_0402_1005Metric | R6, R31, R32 |
| 3 | 5.1k | Capacitor_SMD:C_0402_1005Metric | R3, R4, R5 |
| 2 | 0.22u | Capacitor_SMD:C_0402_1005Metric | C42, C43 |
| 2 | 22u | Capacitor_SMD:C_0805_2012Metric | C37, C46 |
| 2 | 47n | Capacitor_SMD:C_0402_1005Metric | C4, C5 |
| 2 | 68m | Resistor_SMD:R_0603_1608Metric | R43, R44 |
| 2 | DMG6602SVTQ | Package_TO_SOT_SMD:TSOT-23-6 | U2, U3 |
| 2 | NMOS | Package_TO_SOT_SMD:SOT-23 | Q2, Q3 |
| 2 | TPS22810DRV | Package_SON:WSON-6-1EP_2x2mm_P0.65mm_EP1x1.6mm | U1, U5 |
| 1 | .1u | Capacitor_SMD:C_0402_1005Metric | C7 |
| 1 | 0 | Resistor_SMD:R_0402_1005Metric | R30 |
| 1 | 100p | Capacitor_SMD:C_0402_1005Metric | C28 |
| 1 | 10u | Capacitor_SMD:C_0603_1608Metric | C8 |
| 1 | 127k | Resistor_SMD:R_0402_1005Metric | R12 |
| 1 | 1825027-8 | Button_THT:SW2_1825027-C_TEC | SW3 |
| 1 | 1M | Resistor_SMD:R_0402_1005Metric | R8 |
| 1 | 1m | Resistor_SMD:R_0402_1005Metric | R27 |
| 1 | 1u | Inductor_SMD:L_1008_2520Metric | L1 |
| 1 | 20k | Resistor_SMD:R_0402_1005Metric | R40 |
| 1 | 2N7002 | Package_TO_SOT_SMD:SOT-23 | Q1 |
| 1 | 30.31k | Resistor_SMD:R_0402_1005Metric | R14 |
| 1 | 4.7u | Capacitor_SMD:C_0402_1005Metric | C9 |
| 1 | 47u | Capacitor_SMD:CP_Elec_6.3x5.4 | C41 |
| 1 | 5.24k | Resistor_SMD:R_0402_1005Metric | R13 |
| 1 | 6.04k | Resistor_SMD:R_0402_1005Metric | R15 |
| 1 | AZ1117-3.3 | Package_TO_SOT_SMD:SOT-223 | U7 |
| 1 | BQ76905 | Package_DFN_QFN:UQFN-20-1EP_3x3mm_P0.4mm_EP1.85x1.85mm | U6 |
| 1 | BQ76905_Bypass | Jumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mm | JP1 |
| 1 | Boot | Switch:Tactile_5.5mmx2.85mm | SW2 |
| 1 | Conn_01x04 | Connector_JST:JST_PH_B4B-PH-K_1x04_P2.00mm_Vertical | J4 |
| 1 | D_Zener | Diode_SMD:D_SOD-323F | D5 |
| 1 | ESP32-S3-MINI-1-N8 | XCVR_ESP32-S3-MINI-1-N8:XCVR_ESP32-S3-MINI-1-N8 | U8 |
| 1 | EVVO SS16 | Diode_SMD:D_SMA | D6 |
| 1 | JST_PH | Connector_JST:JST_PH_B6B-PH-K_1x06_P2.00mm_Vertical | J3 |
| 1 | LED | Capacitor_SMD:C_0805_2012Metric | D2 |
| 1 | LED | LED_SMD:LED_0603_1608Metric | D1 |
| 1 | NP | Capacitor_SMD:C_0402_1005Metric | C14 |
| 1 | NP | Resistor_SMD:R_0402_1005Metric | R37 |
| 1 | PMOS | Package_TO_SOT_SMD:SOT-23 | Q4 |
| 1 | Reset | Switch:Tactile_5.5mmx2.85mm | SW1 |
| 1 | TLV493DA1B6HTSA2 | Package_TO_SOT_SMD:SOT-23-6 | U4 |
| 1 | USB_C_Receptacle_USB2.0 | Connector_USB:USB_C_Receptacle_JAE_DX07S016JA1R1500 | J1 |
| 1 | WS2812B | LED_SMD:LED_WS2812B_PLCC4_5.0x5.0mm_P3.2mm | D3 |
| 1 | ~ | Lipo_Charger:BQ25792 | BQ25792RQMR1 |
| 1 | ~ | Package_DFN_QFN:QFN-28_4x4mm_P0.5mm | A1 |
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Questions
How big is the Receiver PCB?
It measures 65 × 42 mm and has 4 copper layers, 1 mm thick.
What parts does the Receiver use?
131 parts, built around the ESP32-S3-MINI-1-N8, TLV493DA1B6HTSA2, DMG6602SVTQ and TPS22810DRV. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.
Where can I download the Receiver KiCad files?
From the andrew153d/RemoteWelderController repository on GitHub, at the commit this page was made from: the board is hardware/Receiver/Receiver.kicad_pcb and its schematic hardware/Receiver/Receiver.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the Receiver design in my own project?
Its repository states no licence, so its author keeps all rights: ask andrew153d before reusing the design.