Button pcb kicad

matrix_clock

"I DON’T EVEN SEE THE CODE ANYMORE" - The Matrix.

Shown above is a clock that presents the current time on an 64x32 RGB LED matrix. The clock has other selectable modes, including a view that includes the numbers:

and some other selectable views:

Although the images above give you a basic idea, they can't show you the dynamic range of the LED or the visual impression of 200 FPS animations,

The project's firmware is designed to easily incorporate support for other hardware configurations. Included is a 8x8 "Dotstar" matrix version that was my first version:

This document focuses on the newer 62x32-based model, which I prefer. If you want to learn more details on the 8x8 build, I have a separate document for it here.

In the upcoming sections, I explain how I built the clock. I also explain how to modify the design in different ways.

Parts List

You can of course modify the design to use different ones. Prices are "at time of writing":

• Microcontroller: Raspberry PI Pico ($4)
• LED Matrix 62x32: ($30) Note there are many vendors of this display - I assume they have similar interfaces.
• Clock: DS3231-based RTC module ($4). This part is optional-but-recommended. The firmware can be built to use the Pi Pico clock libraries but you will lose battery backup and the time will drift more.
• Buttons: I used 2 6mm push buttons for control (<$1) and one 6x3 SMD button for optional reset capability.
• Connectors:
  • I used one 8x2 2.54 pitch male pin header to interface the Pico PCB with the matrix (using the usually-included interface cable)
  • I used a 2x1 angled 2.54 pitch pin header for connecting the LED to the PCB.
  • I used a 3x1 angled 2.54 pitch pin header for connecting the buttons to the PCB
• I used a 220uF capacitor to reduce 5V noise. Somewhat larger or smaller values should also work fine.
• Circuit board for assembling components.
  • There are many options. I ended up ordering a PCB from http://oshpark.com for the main board because my PCB layout needs a two-layer board. I could have wired it up on perf board, but the large number of pin connections would have make it difficult to get a clean result.
  • There is a separate PCB for the buttons. This board is very simple so any build technique should be straight-forward. I used my CNC machine to cut a board within an hour. If you order a main board, you might opt to bundle the button pcb with the order.

Optional:

The LED display can pull over 3A if all LEDs are set to white. The firmware I wrote never does this and needs about 100-300 mA for most of the modes (as-measured with a multimeter). Thus I'm using the Pi Pico's VDD pin, which is directly connected to USB power. This connection should be limited to 500 mA or less, thus I added the following electronic components to enforce the current limit:

• NCP380 current limiting IC
• Two additional 1uf capacitors for stability. I am using SMD but ceramic through-hole are also an option.

My hardware has this current protection but it has never activated outside of testing thus one might argue that it's not needed. If you plan to make your own display modes, I suggest including the protection.

Reading the clock

How can the clock be read when no numbers are shown? By noting the colors and speed of the particles. Here is my color mapping for each number, as shown in the time setting interface:

Colors are defined in src/colors.c if you would like to edit them.

Feature Overview

This is a quick tour of the built in-features

Power On

When you plug in the clock via any USB power source you will get a matrix clock display that indicates the current time as-reported by the RTC clock hardware.

Setting the Time

The clock has two buttons on it's side: "set" and "increment". Pressing "set" goes into time change mode where you can use "set" and "increment" to change each time digit.

You can also set the clock via the USB connection.

Changing the Display Mode

If you press the "increment" button while the matrix is showing, the clock will cycle through display modes. Currently defined modes include:

• Simple Shows the time with no animations. The color of the time changes throughout the day to approximate a sunrise/daytime/sunset color temperature.
• Matrix With Numbers The default
• Matrix Only For those who want a challenge
• Bounce Particles bounce around the numbers.
• Number Cascade Digits fall from the top of the display to the bottom. The size and speed of the digit represent the place in the time (hours vs minutes).
• Waveform Waveforms progress from the bottom of the display to the top at different speeds based on the time digit.
• Drops A water droplet effect appears behind the numbers.
• Off - Useful if you want a darkened room.

Each display mode uses color as described earlier to accent the current time.

Console Configuration

If you plug the clock into a computer, you can run a terminal emulator program to access many additional settings. In Linux, I use the "minicom" terminal emulator and my command looks like this:

minicom -b 115200 -P /dev/ttyUSB0

The serial device (/dev/ttyUSB0) can vary between computers and operating systems.

Once started, you will see something like this:

By default, minicom turns on local echo, making my typed characters appear twice. minicom allows this to be turned off with ctrl-a e.

Type help or ? for help.

Build Instructions

Electronics

Here is the schematic for the 64x32 version:

Here is a description on major components and their purpose:

• Pi Pico: This is the main controller
• RTC (Real Time Clock, Optional): This provides time to the Pico via an I2C connection. You could use alternate clock hardware as described in a later section. In terms of the I2C connection, note that the RTC clock is powered by 3.3V instead of the specified 5V. This is the easiest way to make the clock compatible with the 3.3V maximum voltage of the PI Pico. If your RTC really does need 5V, there are solutions but the details are not the focus of this document. Thus I suggest doing a Google search for "3.3 to 5V I2C" to learn more.
• 64x32 matrix: This is also a 5V part and is connected to the 5V VDD of the Pico, allowing ~500mA to be safely consumed by the panel. The Pico is directly connected and will deliver 0-3.3V signals to the panel. Unlike I2C for the RTC clock, the LED pins are high impedance inputs with no pullup thus there is no hardware risk in connecting them directly to the Pico. The main risk is that the LED panel will not accept 3.3V as a legitimate "high" signal and thus it wont work. For my panel 3.3V was accepted without a problem thus no level converters were needed. I suspect this is the common scenario with these panels.
• 100 uF-470 uF capacitor. The actual value is not important other than "big". The purpose of the capacitor is to support the power requirements of the LED, which can be a "noisy" load, needing near zero current one moment and several hundred mA the next.
• Buttons. Select, increment and reset as described earlier.
• NCP380 current limiting chip (optional). This chip provides insurance for the case where you one day decide to change the firmware to light up many LEDs and draw too much current. If you really want to do support high current draw, you'll need to rework the power design so that the LED panel can be directly powered from a capable (3A+) source instead of VDD on the Pico.

VDD on the Pico is a direct passthrough to the USB power so it's the USB regulator (wall adapter or computer) and the PCB traces of the Pico that are the main power bottlenecks.

If you don't us use the NCP380, simply connect the Pico VDD pin directly to the LED. Keep the 100u capacitor for noise purposes.

In terms of layout, here is the KiCAD layout for the schematic above (with ground plane hidden):

and here is a photo of the completed PCB. Note that the capacitor can't be seen because it is on the backside of the board:

As for the buttons, here is the simple KiCAD layout:

and the finished board that I cut out with my CNC machine (just using a perf board would also work fine):

Firmware

TLDR: If you don't want to build the firmware (matrix_clock_led_64x32.uf2) yourself, I have a couple of precompiled versions under the firmware directory.

Source files (written in C) are provided in the src/ directory. If you have never built PI Pico firmware before, run through the official Getting started with the Raspberry Pi PICO documentation first to get the needed tools up-and-running on your system.

The instructions for building the clock firmware are the same as the guide linked above, but I created a small/simple bootstrap.sh script to lessen the number to needed steps:

./bootstrap.sh 
cd build/
make -j

I encourage you to view the contents of bootstrap.sh yourself instead of blindly running it. You'll see something like this:

$ cat bootstrap.sh 
#!/bin/bash

if [ ! -f pico_uart_console/CMakeLists.txt ]; then
  git submodule init
  git submodule update
fi

rm -rf build
mkdir build
cd build
cmake ..

If building under Windows, you may opt to run the DOS-equivalent commands contained within bootstrap.sh manually. The good news is that there are only a few commands to run.

The two major things done here are getting some dependencies (git submodules) and setting up a new build environment under build/

If all went well above, you will have a src/build/matrix_clock.uf2 file available to load onto a PI Pico. Note that firmware/matrix_clock_led_64x32.uf2 will not be changed.

Hardware build

The hardware build is fairly minimalistic, solving the given problems:

• Securing the PI Pico, RTC hardware and buttons at the bottom of the panel
• Keeping the connection cables constrained so the clock can mount flat on a wall
• Providing a wall mount

I solved all of these problem by creating a couple of 3D models and printing them out. I used OpenSCAD for the modeling.

This model is located at case/led_matrix_64x32/led_matrix_64x32.scad. It can be modified with any text editor and viewed in the free OpenSCAD software.

If you don't want to mess around with OpenSCAD, I also have the models available for direct download at case/led_matrix_64x32/export. These are .3mf files (the successor to .stl format) that most modern slicer programs can directly load.

To assemble, I used M2 bolts to attach the buttons to the bottom, 6mm long I think but something in that area should be fine. I used M3 bolts (around 12-16mm) to attach the 3D printed parts to the led matrix.

The PCB settles into a custom slot in the bottom 3d part (see the grooves in the red image above) and is held in place with no bolts required, just make sure it's in the proper position before tightening the frame bolts.

The hex matrixes on the back hold the power and led interface cables within the unit so that it will mount flush on the wall. A guide and slot is provided for wall hanging the unit.

Customization Guide

This part of the documentation points you in the right direction if you want to modify the project. This entire section should be consider optional and more advanced than others.

Using Different LED Hardware

The file src/led_matrix.h, contains the interface your hardware driver will be called with. src/led_matrix_62x32.c implements it for the 64x32 LED hardware. There is also a src/led_matrix_dotstar.c file which is used instead when building the dotstar version. To add additional hardware support, create a new .c file (for example src/led_matrix_neopixel.c) and change src/CMakeLists.txt to point to your new file.c`. The main function you'll be implementing is:

#define LED_MATRIX_WIDTH 8
#define LED_MATRIX_HEIGHT 8

// render the matrix.
// data is of the form 0xIIRRGGBB where
// II -> Intensity (brightness)
// RR -> Red
// GG -> Green
// BB -> Blue
//
// Values are 0-255
// format is horizontal rows.  The first pixel
// sent is the southwest corner of the matrix.
void led_matrix_render(uint32_t* data);

Again, look at src/led_matrix_dotstar.c for a straight-forward implementation of led_matrix_render.

Using Different Clock Hardware

Instead of an RTC, you might want to go with a radio-based clock, a GPS clock, or keeping the time with the Pi Pico.

The PICO SDK provides time functions but you'll lose battery backup and accuracy is not as good as a real RTC.

src/clock.h gives the interface:

// gets the current time in HHMM format (0000 - 2359)
// For example, if 1354 is returned, the time is 13:54 (or
// 1:34 PM if you prefer)
uint16_t clock_get_time();

// Sets the time.  For example: time_hhmm = 1234 would set the
// time to 12:34.  Note that 24h time is always used so 1234
// is 12:34 PM and 0034 is 12:34 AM.
void clock_set_time(uint16_t time_hhmm);

and src/clock_ds3231.c gives a concrete implementation for the RTC module. The file src/clock_pico_internal.c provides an implementation that does not need RTC hardware. It can be selected in src/CMakeLists.txt.

Adding / Changing Display Modes

There are two files and one directory to consider. The first file is src/clock_render.c. Specifically, this section:

  struct DisplayMode display_modes[] = {
    {"matrix_with_numbers", matrix_with_numbers_render},  // This entry will be the default power-on mode
    {"matrix", matrix_render},
    {"bounce", bounce_render},
    {"number_cascade", number_cascade_hires_render},
    {"waveform", waveform_render},
    {"drops", drops_render},
    {"off", blank_render},  // always put this entry at the end of the list
  };

This section lists the display modes, names them and provides a function pointer to each one. If you were to remove a line from this array, or reorder the lines, you would see the corresponding change when you build/load new firmware. In order for the function pointers to have any meaning, you'll need to include the corresponding files:

#include "render/matrix_with_numbers.h"
#include "render/matrix.h"
#include "render/bounce.h"
...

Note that, by convention, all rendering functions are defined in the src/render directory. Here is an example src/render/blank.c:

void blank_render(
    uint32_t* led,
    uint32_t frame_index,
    uint16_t time_hhmm,
    const struct ClockSettings* settings) {
  memset(
    led,
    0,
    LED_MATRIX_WIDTH * LED_MATRIX_HEIGHT * sizeof(uint32_t));
}

This simple function simply clears the led array to zero which effectively turns off the display.

The time_hhmm provides the time as an integer. For example, 1:45 AM would be represented as 0145 and 1:45 PM would be represented as 1345.

The frame_index parameter can be useful for initialization. It is always set to 0 when the display mode is made active.

The settings structure has several potentially-useful fields but especially useful is getting the user preference for LED brightness:

  const uint8_t br = brightness_step_to_brightness(settings);

This value (0-255), would then be used as a baseline brightness when turning on LEDs in led

Changing the Console

The file src/clock_settings.c contains all of the commands available to the USB shell. Adding your own is straight-forward but I suggest skimming through https://github.com/mattwach/pico_uart_console to get up-to-speed on how the console works first.