Robot Toy Car – The Next steps

In our last project, we started working on repurposing an old toy car. In this part, Robot Toy Car – The next steps, we will take a look at the controller board for this project and discuss some of the problems that we have encountered up to now. Most of the various components for this project are still in the prototype stage, but It is quite important to get them tested to verify the final designs.

There are quite a few unique challenges in a project like this, which looks quite easy to solve but turn out to become quite challenging to get working just right in practice…

One of the most important, as well as the most frustrating part, turned out to be the H-Bridge Motor controller. The first prototype of this was introduced in the first part of this project. While functional on paper, as well as working quite well in real life, (when tested with an Arduino, as well as manually), It performs extremely poorly when used with the actual controller for this project, an ESP8266 12-E…

What could the reason be? How will I fix it…? The answers to that will be provided in a follow-up post. For now, let us take a look at the controller.

The unassembled ESP-8266 Controller board, straight from the factory
The Assembled ESP-8266 Controller board.

The Controller Board, details

Space inside the toy car is at a premium, so from the start, it was important to design a PCB that was small enough to fit, while also taking into consideration functionality, as well as all additional add-on components to ultimately be fitted to the project.

With this in mind, I have decided on the ESP-8266, which, while bigger than an Atmega328, does offer a few additional features, like WiFi, and ESP-Now, which will greatly help in controlling and even updating firmware OTA. The ESP-8266 does however also have a few serious flaws in this design, like limited useable GPIO pins, a 3.3v working voltage requirement, and quite high operating current requirements.

As the toy will likely not be used continuously, as well as the fact that it will run on batteries, which, can be replaced or recharged, I did not worry too much about the power issue. As far as the limited GPIO, that is where I2C comes in… It is quite easy to expand the GPIO with an IO Expander or two…

My main problem came in the form of the CH340G USB-to-UART converter chip. It seems like there must be quite a lot of counterfeit versions of these around, as none of the chips that I purchased, from many different suppliers, actually functioned, with the best one actually providing a USB port, but, when investigating with a logic analyser, the Rx and Tx lines of the UART, generating garbage…

Replacing it with a known working chip from a NodeMCU V1 board, magically solved the problem, verifying the PCB circuit as correct and working, and also proving that the purchased chips are definitely fake!

This was easily repaired by temporarily soldering jumper cables to the Rx and Tx lines on the ESP-8266, and using an external UART-to-USB converter to upload the initial sketch to the device. Future updates will be OTA, so not a problem in the long run anyway.

Controller Schematic

The controller schematic, above, is basically a rearranged stock NodeMCU v1 circuit, with the only difference being that only specific pins were broken out onto header pins. These will be used for controlling the two H-Bridges, and provide PWM as well as access to the I2C bus.

Software

Due to the fact that this controller is still definitely considered a prototype, my main focus is definitely on getting the control software sorted out first. That way, at least in my opinion, I can then focus on hardware issues responding to verified software inputs, without having to do both at the same time.

As mentioned before, I require OTA capability to upload new firmware to the device, so my starting point was the BasicOTA sketch provided with the Arduino IDE. This sketch was modified to perform some additional functionality, such as controlling the H-Bridges, PWM as well as a roof-mounted “status panel” with LED’s that also doubles as a visual display, to give a bit of colour to the project.

The “status panel” will be shown in a future post, however, with the only mention of it here being that it is I2C controlled, and based on a PCF8574.

The BasicOTA sketch is listed below.

#include <ESP8266WiFi.h>
#include <ESP8266mDNS.h>
#include <WiFiUdp.h>
#include <ArduinoOTA.h>

#ifndef STASSID
#define STASSID "your-ssid"
#define STAPSK  "your-password"
#endif

const char* ssid = STASSID;
const char* password = STAPSK;

void setup() {
  Serial.begin(115200);
  Serial.println("Booting");
  WiFi.mode(WIFI_STA);
  WiFi.begin(ssid, password);
  while (WiFi.waitForConnectResult() != WL_CONNECTED) {
    Serial.println("Connection Failed! Rebooting...");
    delay(5000);
    ESP.restart();
  }

  // Port defaults to 8266
  // ArduinoOTA.setPort(8266);

  // Hostname defaults to esp8266-[ChipID]
  // ArduinoOTA.setHostname("myesp8266");

  // No authentication by default
  // ArduinoOTA.setPassword("admin");

  // Password can be set with it's md5 value as well
  // MD5(admin) = 21232f297a57a5a743894a0e4a801fc3
  // ArduinoOTA.setPasswordHash("21232f297a57a5a743894a0e4a801fc3");

  ArduinoOTA.onStart([]() {
    String type;
    if (ArduinoOTA.getCommand() == U_FLASH) {
      type = "sketch";
    } else { // U_FS
      type = "filesystem";
    }

    // NOTE: if updating FS this would be the place to unmount FS using FS.end()
    Serial.println("Start updating " + type);
  });
  ArduinoOTA.onEnd([]() {
    Serial.println("\nEnd");
  });
  ArduinoOTA.onProgress([](unsigned int progress, unsigned int total) {
    Serial.printf("Progress: %u%%\r", (progress / (total / 100)));
  });
  ArduinoOTA.onError([](ota_error_t error) {
    Serial.printf("Error[%u]: ", error);
    if (error == OTA_AUTH_ERROR) {
      Serial.println("Auth Failed");
    } else if (error == OTA_BEGIN_ERROR) {
      Serial.println("Begin Failed");
    } else if (error == OTA_CONNECT_ERROR) {
      Serial.println("Connect Failed");
    } else if (error == OTA_RECEIVE_ERROR) {
      Serial.println("Receive Failed");
    } else if (error == OTA_END_ERROR) {
      Serial.println("End Failed");
    }
  });
  ArduinoOTA.begin();
  Serial.println("Ready");
  Serial.print("IP address: ");
  Serial.println(WiFi.localIP());
}

void loop() {
  ArduinoOTA.handle();
}

Controlling the Toy Car Robot

Controlling the Toy Car is a complicated question, with many ideas jumping into my mind, only to be pushed aside by technical issues, as well as real-world constraints on what is physically possible to be mounted on the plastic body of the toy car, space available on the inside, as well as not interfering with suspensions, springs, turning wheels etc.

The chassis of the toy car

As is clearly visible, there is really not a lot of space available here for sensors. Mounting sensors to the body will also provide a bit of a challenge, as well as won’t really look nice either…

Give an old toy car new life

I have thus decided to implement remote control for the time being, and later, maybe after 3d-printing a more suitable body, to add sensors for autonomous functionality. The ESP-Now protocol will be used extensively for the remote control, as, in my opinion, it required no additional hardware, is quite fast, as well as being extremely easy to use. It does however make it necessary to use another ESP deice in the remote control unit.

Manufacturing the PCB

The PCB for this project is currently on its way from China, after having been manufactured at PCBWay.
Please consider supporting them if you would like your own copy of this PCB, or if you have any PCB of your own that you need to be manufactured.

PCBWay

If you would like to have PCBWAY manufacture one of your own, designs, or even this particular PCB, you need to do the following…
1) Click on this link
2) Create an account if you have not already got one of your own.
If you use the link above, you will also instantly receive a $5USD coupon, which you can use on your first or any other order later. (Disclaimer: I will earn a small referral fee from PCBWay. This referral fee will not affect the cost of your order, nor will you pay any part thereof.)
3) Once you have gone to their website, and created an account, or login with your existing account,

4) Click on PCB Instant Quote

5) If you do not have any very special requirements for your PCB, click on Quick-order PCB

6) Click on Add Gerber File, and select your Gerber file(s) from your computer. Most of your PCB details will now be automatically selected, leaving you to only select the solder mask and silk-screen colour, as well as to remove the order number or not. You can of course fine-tune everything exactly as you want as well.

7) You can also select whether you want an SMD stencil, or have the board assembled after manufacturing. Please note that the assembly service, as well as the cost of your components, ARE NOT included in the initial quoted price. ( The quote will update depending on what options you select ).

8) When you are happy with the options that you have selected, you can click on the Save to Cart Button. From here on, you can go to the top of the screen, click on Cart, make any payment(s) or use any coupons that you have in your account.

Then just sit back and wait for your new PCB to be delivered to your door via the shipping company that you have selected during checkout.

Give an old toy car new life…

Give an old toy car new life

Many of us have old toys laying around the house, they belong to our children or the children of our friends. In this article, I will attempt to show you how to give an old toy car new life, as well as hopefully teach a child a few interesting things with electronics.

The inspiration for this article comes from my friend’s 7-year-old boy, who, way too clever for his age, always has a lot of very interesting questions. His mother and I have thus decided to do an experiment:
“Let us try to teach him Arduino programming, so he can start to make his own toys”

Obviously, the challenges in this venture are many…
To name a few:
The boy speaks only Thai, so English is a no-go.
Soldering is out of the question, due to his age, as well as safety issues – All teaching will have to be done on a breadboard.

My challenges apart, this is a project that many people would want to attempt, so it is important to start with a bit of theory.

Controlling a DC Motor from a microcontroller

DC motors, like those found in toy cars, are inductive loads, and that means that they induce electromagnetic fields when switched on or off. These EMF fields can damage your sensitive microcontroller quite easily. Another thing to remember is that your typical microcontroller can only source or sink in the region of 25mA to 50mA of current, not quite enough to drive a motor, let alone a toy car.

Directional control of the motor

In our toy car, we would definitely want the driving motor to be able to change direction, meaning spin forwards or backwards, thereby changing the direction that the car is travelling. This is achieved by using a circuit called an H-Bridge. In this circuit, four transistors, either BJTs or MOSFETs are arranged in a particular way to allow us to change the direction that the motor spins by changing certain logic signals.

Implementing an H-Bridge with switches

In the picture above, we simulate the H-Bridge circuit using slide switches in order to explain the method of operation. It should be clear that the direction is changed by switching on diagonally opposite switches.

Driving a motor with a transistor

In the picture above, we implement a simple, one-directional motor control circuit using a single transistor. This circuit still has the limitation that the motor can only spin in a single direction.

Half of an H-Bridge

In the circuit above, we combine the two motor driver circuits (with PNP and NPN transistor ) to complete one half of the H-Bridge circuit. This circuit still has the limitation that we can only spin the motor in a single direction.

The completed H-Bridge circuit

In the picture above, we added another half H-Bridge to complete the circuit. We will thus have 2 PNP and 2 NPN transistors, which form the completed circuit. This circuit will give us full bi-directional control of the motor. We can also control the speed of the motor if we apply a suitable PWM signal to the bases of the NPN transistors – we do need to be careful of SHOOT THROUGH and shorts though.

My proposed Motor Driving Circuit

the inside of the toy car, without the old broken circuit-board

In the picture above, we can clearly see that there is not a lot going on inside this toy car. An On-Off switch is connected to the battery compartment, and two wires go to the drive- and steering motor.

Interfacing this car to a microcontroller is thus going to require two separate H-Bridge circuits. One for the drive motor, and the second for the steering.

Dual H-Bridge Circuit diagram

I have designed the circuit above to control both motors of the toy car, the control signals are simplified to 2 per H-Bridge, and a common PWM signal to control speed.

Manufacturing the PCB

The PCB for this project is currently on its way from China, after having been manufactured at PCBWay.
Please consider supporting them if you would like your own copy of this PCB, or if you have any PCB of your own that you need to be manufactured.

PCBWay

If you would like to have PCBWAY manufacture one of your own, designs, or even this particular PCB, you need to do the following…
1) Click on this link
2) Create an account if you have not already got one of your own.
If you use the link above, you will also instantly receive a $5USD coupon, which you can use on your first or any other order later. (Disclaimer: I will earn a small referral fee from PCBWay. This referral fee will not affect the cost of your order, nor will you pay any part thereof.)
3) Once you have gone to their website, and created an account, or login with your existing account,

4) Click on PCB Instant Quote

5) If you do not have any very special requirements for your PCB, click on Quick-order PCB

6) Click on Add Gerber File, and select your Gerber file(s) from your computer. Most of your PCB details will now be automatically selected, leaving you to only select the solder mask and silk-screen colour, as well as to remove the order number or not. You can of course fine-tune everything exactly as you want as well.

7) You can also select whether you want an SMD stencil, or have the board assembled after manufacturing. Please note that the assembly service, as well as the cost of your components, ARE NOT included in the initial quoted price. ( The quote will update depending on what options you select ).

8) When you are happy with the options that you have selected, you can click on the Save to Cart Button. From here on, you can go to the top of the screen, click on Cart, make any payment(s) or use any coupons that you have in your account.

Then just sit back and wait for your new PCB to be delivered to your door via the shipping company that you have selected during checkout.


Build your own USB-ASP Programmer Clone

Using more ATMEGA based MCU’s in my recent projects, and not using ready-made Arduino boards for any of them, it became necessary to invest in a dedicated ASP programmer to flash the MCU’s. Huge delays on electronics components, with confirmed orders being mysteriously cancelled due to sourcing issues, and the high cost of “original OEM ASP programmers”, send me on a search for a DIY style programmer, like the old “NOPPP” ( NO PARTS PIC Programmer) in the good old days…

Personal computers have changed a lot, and while ATMEGA chips are not PIC’s, I did feel that it could be done. Given the fact that you could also use an Arduino UNO as an ISP, and doing a little more digging, I finally found a very attractive alternative…

Thomas Fischl, on his website,https://www.fischl.de/usbasp, has an open-source hardware project, that seemed to be exactly what I needed. His device is capable of programming 5v devices, at various speeds, including a super slow one. He has also written firmware for the device, and although the last update was in 2011, It still seems to be working well, or at least as far as I can see…

I did however decide to add my own twist to the design and build in a logic level converter, to be able to program 3.3v devices as well…

The modified schematic is below:

Schematic Page 1
Schematic Page 2

I chose to do my own PCB layout, to incorporate the changes listed earlier, namely the logic level conversion from 5v to 3v, as well as adding a 3.3v LDO voltage regulator to provide 3.3v to the target in case it is required.

PCB Topside
PCB Bottom Side
3D Render of the PCB

The PCB is still in transit from the factory, and thus I will update this article later with pictures of the actual device.

Firmware can be flashed using any ASP programmer, Arduino as ISP as well, but with the caveat that you have to use AVRDude from the command line… More on that in the follow-up post… ( I would like to show actual screenshots of the process, and not theory.. ). The links to the firmware are available on https://www.fischl.de/usbasp, courtesy of Thomas Fischl, whom I would like to thank for making this open-source hardware project available freely, as well as for writing and maintaining the firmware.


The PCB can be ordered, or the design files downloaded ( a free download ) from my Projects page at PCBWay soon…

This PCB was manufactured at PCBWAY. The Gerber files and BOM, as well as all the schematics, will soon be available as a shared project on their website. If you would like to have PCBWAY manufacture one of your own, designs, or even this particular PCB, you need to do the following…
1) Click on this link
2) Create an account if you have not already got one of your own.
If you use the link above, you will also instantly receive a $5USD coupon, which you can use on your first or any other order later. (Disclaimer: I will earn a small referral fee from PCBWay. This referral fee will not affect the cost of your order, nor will you pay any part thereof.)
3) Once you have gone to their website, and created an account, or login with your existing account,

4) Click on PCB Instant Quote

5) If you do not have any very special requirements for your PCB, click on Quick-order PCB

6) Click on Add Gerber File, and select your Gerber file(s) from your computer. Most of your PCB details will now be automatically selected, leaving you to only select the solder mask and silk-screen colour, as well as to remove the order number or not. You can of course fine-tune everything exactly as you want as well.

7) You can also select whether you want an SMD stencil, or have the board assembled after manufacturing. Please note that the assembly service, as well as the cost of your components, ARE NOT included in the initial quoted price. ( The quote will update depending on what options you select ).

8) When you are happy with the options that you have selected, you can click on the Save to Cart Button. From here on, you can go to the top of the screen, click on Cart, make any payment(s) or use any coupons that you have in your account.

Then just sit back and wait for your new PCB to be delivered to your door via the shipping company that you have selected during checkout.




Port Extender Card for the MCU-8266-12E

Port Extender Card for the MCU-8266-12E IoT Controller

Introduction

After quite a few experiments, and playing with a lot of ideas, we have finally produced and tested an almost final prototype for the MCU-8266-12E IoT Controller Port Extender Card. While the baseboard already has quite a lot of free GPIO pins for additional sensors and devices, It did however have quite a few issues, namely a lack of sufficient Power outputs, difficulty access to the I2C bus, as well as only 2 relay outputs. Granted that you do have access to unused pins on the PCF8574 Port Extender, We nonetheless decided that an add-on card would definitely make sense to allow this device to really be more useable.

While looking at various ideas for this card, the most flexible seemed to be the APE Protocol device as documented in ESPHome. They used a standard Arduino board for that, but we decided that, after testing it with an Arduino Nano, since it seems to work well, let us just design a dedicated PCB. It also looks much better as well 🙂

Some Features (Aside from being a fully functional Arduino clone as well)

1). Dedicated LDO Regulators for 5v and 3.3v (800mA each), with jumpers to switch them on or off (receive power only from the IoT Motherboard).
2.) Dedicated Logic Level Converter on the I2C Bus ( This is sort of very much needed 🙂 The Atmega 328P-AU is running at 5v on this device, to enable it to run at 16Mhz.. and the ESP8266 on the Motherboard is a 3.3v device..

There are also 3x 3.3V I2C Headers, complete with 3.3v and Ground, as well as a single 5v I2C header
3). 8 Analog Inputs ( While practically you can only use 6 of these if you use I2C )
4). Voltage Divider provided on A0 to measure VIN ( to be safe, we calculated the resistors for 22v)
5). 100R current limiting resistor on A1 and A2, to measure 5v and 3.3v as well…
Analog inputs A0, A1 and A2 can be switched back to normal operation by changing the jumper at J2,J3 or J4 from On to Off.
6). 12 Digital Inputs/Outputs (14 if you use D0 and D1 as well), as well as a Jumper to remove the LED on D13.
7). Full access to the PCF8574 and ESP8266 Pins from the motherboard below.

Pictures of the PCB

Circuit Diagram

ATMega328P-AU Circuit diagram with LDO Regulators, headers and supporting circuitry.
Analog measuring circuitry, level converters and supporting circuitry and headers

Uploading Code to the ATMega328P

Uploading code to the device requires the use of either an ISCP programmer ( Arduino as ISP works well ) or in the case of a pre-boot loaded chip, a USB-to-Serial converter. We did not find it necessary to add a dedicated USB-to-Serial converter onto the PCB. It is quite easy enough to do any flashing with the tools mentioned above.


Make sure that the PCB is not stacked when doing this. ( This will prevent excessive current use of other components when you supply 5v to the PE card.


Procedure to upload using ICSP

During assembly, you are required to solder a single 90-degree bend pin header on the bottom side of the PCB, in the same hole as the board side edge of the RESET push-button. This will serve as the RESET Pin for the ISCP. Other connections are as follows:

H2 Header <- > ICSP Programmer
MOSI (E11~) – MOSI ( or Pin 11 on Arduino as ISP )
MISO (E12 ) – MISO ( or Pin 12 on Arduino as ISP )
SCK (E13) – D13 (or Pin 13 on Arduino as ISP )
RESET – D10 (or Pin 10 on Arduino as ISP )

5v and Ground from Arduino as ISP or ISCP Programmer to any 5v and ground pin on the PE Card

Please note the description above for assembly of the RESET pin header



Procedure to upload using USB-to-Serial converter

H1 Header

E0/Rx <- to Tx of USB-to-Serial converter
E1/Tx -> to Rx of USB-to-Serial converter

H2 Header

DTR <-> to DTR of USB-to-Serial converter [ This connection is needed for successful uploading. Don’t leave it out ]


5v and Ground from the USB-to-Serial converter to any 5v and ground pin on the PE Card


Testing with ESPHome APE protocol and the MCU-8266-12E IoT controller

The following Arduino Sketch needs to be uploaded to the device.
It will allow the device to function as a custom I2C device. Feel free to change the I2C address in the sketch as you choose, but remember to use the same address in your ESPHome YAML configuration file

/*
Ports:
  0 0 .. 13 13
  A0: 14, A1: 15, A2: 16, A3: 17: A4: 18: A5: 19: A6: 20, A7: 21
  port bits: 5 ... 0..32
  0:   0: 00000
  1:   1: 00001
  A7: 21: 10101
*/

#include <Arduino.h>
#include <Wire.h>

//#define DEBUG // remove debug so pin 0 and 1 can be used for IO

#define I2C_ADDRESS 8

void onRequest();
void onReceive(int);

void setup()
{
#ifdef DEBUG
  Serial.begin(115200);
  Serial.println(F("Init "));
#endif

  analogReference(INTERNAL);

  Wire.begin(I2C_ADDRESS);
  Wire.onRequest(onRequest);
  Wire.onReceive(onReceive);

#ifdef DEBUG
  Serial.println(F("Wire ok"));
#endif
}

void loop()
{
  //int temp = analogRead(A1);
  //Serial.println(temp);
}

volatile byte buffer[3];
volatile byte len = 1;

#define DIGITAL_READ(b, pin, mask) \
  if (digitalRead(pin))            \
    buffer[b] |= mask;

void readDigital()
{
  len = 3;
  buffer[0] = 0;
  DIGITAL_READ(0, 0, 1);
  DIGITAL_READ(0, 1, 2);
  DIGITAL_READ(0, 2, 4);
  DIGITAL_READ(0, 3, 8);
  DIGITAL_READ(0, 4, 16);
  DIGITAL_READ(0, 5, 32);
  DIGITAL_READ(0, 6, 64);
  DIGITAL_READ(0, 7, 128);

  buffer[1] = 0;
  DIGITAL_READ(1, 8, 1);
  DIGITAL_READ(1, 9, 2);
  DIGITAL_READ(1, 10, 4);
  DIGITAL_READ(1, 11, 8);
  DIGITAL_READ(1, 12, 16);
  DIGITAL_READ(1, 13, 32);
  DIGITAL_READ(1, A0, 64);
  DIGITAL_READ(1, A1, 128);

  buffer[2] = 0;
  DIGITAL_READ(2, A2, 1);
  DIGITAL_READ(2, A3, 2);

// I2C
//DIGITAL_READ(2, A4, 4);
//DIGITAL_READ(2, A5, 8);

// DIGITAL READ not supports on A3 .. A7
#ifdef DEBUG_READ
  Serial.print(F("Read 3 bytes: "));
  Serial.print(buffer[0]);
  Serial.print(' ');
  Serial.print(buffer[1]);
  Serial.print(' ');
  Serial.println(buffer[2]);

#endif
}
void readAnalog(int pin)
{
  int val = analogRead(A0 + pin);
  len = 2;
  buffer[0] = val & 0xFF;
  buffer[1] = (val >> 8) & 0b11;
#ifdef DEBUG_READ
  Serial.print(F("Read analog pin "));
  Serial.println(pin);
#endif
}

void onRequest()
{
  Wire.write(const_cast<uint8_t *>(buffer), len);
}

#define CMD_DIGITAL_READ 0x0

#define CMD_WRITE_ANALOG 0x2
#define CMD_WRITE_DIGITAL_HIGH 0x3
#define CMD_WRITE_DIGITAL_LOW 0x4

#define CMD_SETUP_PIN_OUTPUT 0x5
#define CMD_SETUP_PIN_INPUT_PULLUP 0x6
#define CMD_SETUP_PIN_INPUT 0x7

// 8 analog registers.. A0 to A7
// A4 and A5 not supported due to I2C
#define CMD_ANALOG_READ_A0 0b1000 // 0x8
// ....
#define CMD_ANALOG_READ_A7 0b1111 // 0xF

#define CMD_SETUP_ANALOG_INTERNAL 0x10
#define CMD_SETUP_ANALOG_DEFAULT 0x11

void onReceive(int numBytes)
{
#ifdef DEBUG_READ
  Serial.print("Received bytes: ");
  Serial.println(numBytes);
#endif
  int cmd = Wire.read();

  switch (cmd)
  {
  case CMD_DIGITAL_READ:
    readDigital();
    break;
  }

  if (cmd >= CMD_ANALOG_READ_A0 && cmd <= CMD_ANALOG_READ_A7)
  {
    readAnalog(cmd & 0b111);
    return;
  }

  int pin = Wire.read();

  switch (cmd)
  {
  case CMD_WRITE_DIGITAL_HIGH:
  case CMD_WRITE_DIGITAL_LOW:
  {
    bool output = cmd == CMD_WRITE_DIGITAL_HIGH;
    digitalWrite(pin, output);
#ifdef DEBUG
    Serial.print(F("Pin "));
    Serial.print(pin);
    Serial.println(output ? F(" HIGH") : F(" LOW"));
#endif
    break;
  }
  case CMD_WRITE_ANALOG:
  {
    int val = Wire.read() & (Wire.read() << 8);
    analogWrite(pin, val);
#ifdef DEBUG
    Serial.print(F("Pin "));
    Serial.print(pin);
    Serial.print(F(" Analog write "));
    Serial.println(val);
#endif
    break;
  }
  case CMD_SETUP_PIN_OUTPUT:
    pinMode(pin, OUTPUT);
#ifdef DEBUG
    Serial.print(F("Pin "));
    Serial.print(pin);
    Serial.println(F(" OUTPUT"));
#endif
    break;
  case CMD_SETUP_PIN_INPUT:
    pinMode(pin, INPUT);
#ifdef DEBUG
    Serial.print(F("Pin "));
    Serial.print(pin);
    Serial.println(F("INPUT"));
#endif
    break;
  case CMD_SETUP_PIN_INPUT_PULLUP:
    pinMode(pin, INPUT_PULLUP);
#ifdef DEBUG
    Serial.print(F("Pin "));
    Serial.print(pin);
    Serial.println(F("INPUT PULLUP"));
#endif
    break;
  case CMD_SETUP_ANALOG_INTERNAL:
    analogReference(INTERNAL);
#ifdef DEBUG
    Serial.println(F("Analog reference INTERNAL"));
#endif
    break;
  case CMD_SETUP_ANALOG_DEFAULT:
    analogReference(DEFAULT);
#ifdef DEBUG
    Serial.println(F("Analog reference DEFAULT"));
#endif
    break;
  }
}

The following C header file needs to be uploaded to your Home Assistant ESPHome folder.

// Must disable logging if using logging in main.cpp or in other custom components for the
//  __c causes a section type conflict with __c thingy
// you can enable logging and use it if you enable this in logger:
/*
logger:
  level: DEBUG
  esp8266_store_log_strings_in_flash: False
  */

//#define APE_LOGGING

// take advantage of LOG_ defines to decide which code to include
#ifdef LOG_BINARY_OUTPUT
#define APE_BINARY_OUTPUT
#endif
#ifdef LOG_BINARY_SENSOR
#define APE_BINARY_SENSOR
#endif
#ifdef LOG_SENSOR
#define APE_SENSOR
#endif

static const char *TAGape = "ape";

#define APE_CMD_DIGITAL_READ 0
#define APE_CMD_WRITE_ANALOG 2
#define APE_CMD_WRITE_DIGITAL_HIGH 3
#define APE_CMD_WRITE_DIGITAL_LOW 4
#define APE_CMD_SETUP_PIN_OUTPUT 5
#define APE_CMD_SETUP_PIN_INPUT_PULLUP 6
#define APE_CMD_SETUP_PIN_INPUT 7
// 8 analog registers.. A0 to A7
// A4 and A5 not supported due to I2C
#define CMD_ANALOG_READ_A0 0b1000 // 0x8
// ....
#define CMD_ANALOG_READ_A7 0b1111 // 0xF

#define CMD_SETUP_ANALOG_INTERNAL 0x10
#define CMD_SETUP_ANALOG_DEFAULT 0x11

#define get_ape(constructor) static_cast<ArduinoPortExpander *>(constructor.get_component(0))

#define ape_binary_output(ape, pin) get_ape(ape)->get_binary_output(pin)
#define ape_binary_sensor(ape, pin) get_ape(ape)->get_binary_sensor(pin)
#define ape_analog_input(ape, pin) get_ape(ape)->get_analog_input(pin)

class ArduinoPortExpander;

using namespace esphome;

#ifdef APE_BINARY_OUTPUT
class ApeBinaryOutput : public output::BinaryOutput
{
public:
  ApeBinaryOutput(ArduinoPortExpander *parent, uint8_t pin)
  {
    this->parent_ = parent;
    this->pin_ = pin;
  }
  void write_state(bool state) override;
  uint8_t get_pin() { return this->pin_; }

protected:
  ArduinoPortExpander *parent_;
  uint8_t pin_;
  // Pins are setup as output after the state is written, Arduino has no open drain outputs, after setting an output it will either sink or source thus activating outputs writen to false during a flick.
  bool setup_{true};
  bool state_{false};

  friend class ArduinoPortExpander;
};
#endif

#ifdef APE_BINARY_SENSOR
class ApeBinarySensor : public binary_sensor::BinarySensor
{
public:
  ApeBinarySensor(ArduinoPortExpander *parent, uint8_t pin)
  {
    this->pin_ = pin;
  }
  uint8_t get_pin() { return this->pin_; }

protected:
  uint8_t pin_;
};
#endif

#ifdef APE_SENSOR
class ApeAnalogInput : public sensor::Sensor
{
public:
  ApeAnalogInput(ArduinoPortExpander *parent, uint8_t pin)
  {
    this->pin_ = pin;
  }
  uint8_t get_pin() { return this->pin_; }

protected:
  uint8_t pin_;
};
#endif

class ArduinoPortExpander : public Component, public I2CDevice
{
public:
  ArduinoPortExpander(I2CBus *bus, uint8_t address, bool vref_default = false)
  {
    set_i2c_address(address);
    set_i2c_bus(bus);
    this->vref_default_ = vref_default;
  }
  void setup() override
  {
#ifdef APE_LOGGING
    ESP_LOGCONFIG(TAGape, "Setting up ArduinoPortExpander at %#02x ...", address_);
#endif

    /* We cannot setup as usual as arduino boots later than esp8266
            Poll i2c bus for our Arduino for a n seconds instead of failing fast,
            also this is important as pin setup (INPUT_PULLUP, OUTPUT it's done once)
        */
    this->configure_timeout_ = millis() + 5000;
  }
  void loop() override
  {
    if (millis() < this->configure_timeout_)
    {
      bool try_configure = millis() % 100 > 50;
      if (try_configure == this->configure_)
        return;
      this->configure_ = try_configure;

      if (ERROR_OK == this->read_register(APE_CMD_DIGITAL_READ, const_cast<uint8_t *>(this->read_buffer_), 3))
      {
#ifdef APE_LOGGING
        ESP_LOGCONFIG(TAGape, "ArduinoPortExpander found at %#02x", address_);
#endif
        delay(10);
        if (this->vref_default_)
        {
          this->write_register(CMD_SETUP_ANALOG_DEFAULT, nullptr, 0); // 0: unused
        }

        // Config success
        this->configure_timeout_ = 0;
        this->status_clear_error();
#ifdef APE_BINARY_SENSOR
        for (ApeBinarySensor *pin : this->input_pins_)
        {
          App.feed_wdt();
          uint8_t pinNo = pin->get_pin();
#ifdef APE_LOGGING
          ESP_LOGCONFIG(TAGape, "Setup input pin %d", pinNo);
#endif
          this->write_register(APE_CMD_SETUP_PIN_INPUT_PULLUP, &pinNo, 1);
          delay(20);
        }
#endif
#ifdef APE_BINARY_OUTPUT
        for (ApeBinaryOutput *output : this->output_pins_)
        {
          if (!output->setup_)
          { // this output has a valid value already
            this->write_state(output->pin_, output->state_, true);
            App.feed_wdt();
            delay(20);
          }
        }
#endif
#ifdef APE_SENSOR
        for (ApeAnalogInput *sensor : this->analog_pins_)
        {
          App.feed_wdt();
          uint8_t pinNo = sensor->get_pin();
#ifdef APE_LOGGING
          ESP_LOGCONFIG(TAGape, "Setup analog input pin %d", pinNo);
#endif
          this->write_register(APE_CMD_SETUP_PIN_INPUT, &pinNo, 1);
          delay(20);
        }
#endif
        return;
      }
      // Still not answering
      return;
    }
    if (this->configure_timeout_ != 0 && millis() > this->configure_timeout_)
    {
#ifdef APE_LOGGING
      ESP_LOGE(TAGape, "ArduinoPortExpander NOT found at %#02x", address_);
#endif
      this->mark_failed();
      return;
    }

#ifdef APE_BINARY_SENSOR
    if (ERROR_OK != this->read_register(APE_CMD_DIGITAL_READ, const_cast<uint8_t *>(this->read_buffer_), 3))
    {
#ifdef APE_LOGGING
      ESP_LOGE(TAGape, "Error reading. Reconfiguring pending.");
#endif
      this->status_set_error();
      this->configure_timeout_ = millis() + 5000;
      return;
    }
    for (ApeBinarySensor *pin : this->input_pins_)
    {
      uint8_t pinNo = pin->get_pin();

      uint8_t bit = pinNo % 8;
      uint8_t value = pinNo < 8 ? this->read_buffer_[0] : pinNo < 16 ? this->read_buffer_[1] : this->read_buffer_[2];
      bool ret = value & (1 << bit);
      if (this->initial_state_)
        pin->publish_initial_state(ret);
      else
        pin->publish_state(ret);
    }
#endif
#ifdef APE_SENSOR
    for (ApeAnalogInput *pin : this->analog_pins_)
    {
      uint8_t pinNo = pin->get_pin();
      pin->publish_state(analogRead(pinNo));
    }
#endif
    this->initial_state_ = false;
  }

#ifdef APE_SENSOR
  uint16_t analogRead(uint8_t pin)
  {
    bool ok = (ERROR_OK == this->read_register((uint8_t)(CMD_ANALOG_READ_A0 + pin), const_cast<uint8_t *>(this->read_buffer_), 2));
#ifdef APE_LOGGING
    ESP_LOGVV(TAGape, "analog read pin: %d ok: %d byte0: %d byte1: %d", pin, ok, this->read_buffer_[0], this->read_buffer_[1]);
#endif
    uint16_t value = this->read_buffer_[0] | ((uint16_t)this->read_buffer_[1] << 8);
    return value;
  }
#endif

#ifdef APE_BINARY_OUTPUT
  output::BinaryOutput *get_binary_output(uint8_t pin)
  {
    ApeBinaryOutput *output = new ApeBinaryOutput(this, pin);
    output_pins_.push_back(output);
    return output;
  }
#endif
#ifdef APE_BINARY_SENSOR
  binary_sensor::BinarySensor *get_binary_sensor(uint8_t pin)
  {
    ApeBinarySensor *binarySensor = new ApeBinarySensor(this, pin);
    input_pins_.push_back(binarySensor);
    return binarySensor;
  }
#endif
#ifdef APE_SENSOR
  sensor::Sensor *get_analog_input(uint8_t pin)
  {
    ApeAnalogInput *input = new ApeAnalogInput(this, pin);
    analog_pins_.push_back(input);
    return input;
  }
#endif
  void write_state(uint8_t pin, bool state, bool setup = false)
  {
    if (this->configure_timeout_ != 0)
      return;
#ifdef APE_LOGGING
    ESP_LOGD(TAGape, "Writing %d to pin %d", state, pin);
#endif
    this->write_register(state ? APE_CMD_WRITE_DIGITAL_HIGH : APE_CMD_WRITE_DIGITAL_LOW, &pin, 1);
    if (setup)
    {
      App.feed_wdt();
      delay(20);
#ifdef APE_LOGGING
      ESP_LOGI(TAGape, "Setup output pin %d", pin);
#endif
      this->write_register(APE_CMD_SETUP_PIN_OUTPUT, &pin, 1);
    }
  }

protected:
  bool configure_{true};
  bool initial_state_{true};
  uint8_t read_buffer_[3]{0, 0, 0};
  unsigned long configure_timeout_{5000};
  bool vref_default_{false};

#ifdef APE_BINARY_OUTPUT
  std::vector<ApeBinaryOutput *> output_pins_;
#endif
#ifdef APE_BINARY_SENSOR
  std::vector<ApeBinarySensor *> input_pins_;
#endif
#ifdef APE_SENSOR
  std::vector<ApeAnalogInput *> analog_pins_;
#endif
};

#ifdef APE_BINARY_OUTPUT
void ApeBinaryOutput::write_state(bool state)
{
  this->state_ = state;
  this->parent_->write_state(this->pin_, state, this->setup_);
  this->setup_ = false;
}
#endif

The file should be named “arduino_port_expander.h”

Make the following changes to your ESPHome YAML configuration file for the MCU-8266-12E device

esphome:
  name: mcu-8266-12e-01
  platform: ESP8266
  board: nodemcuv2
  includes:
      - arduino_port_expander.h
# Note the include file - This loads the APE Header

# Enable logging
logger:

# Enable Home Assistant API
api:

ota:
  password: "<your password will be different - dont change it>"

wifi:
  ssid: <your ssid>
  password: <your password>

  # Enable fallback hotspot (captive portal) in case wifi connection fails
  ap:
    ssid: "MCU-8266-Hotspot"
    password: "password"

captive_portal:

i2c:
# PCB Prototype
  sda: GPIO5
  scl: GPIO4
# PCB Rev 1.5 or higher, comment the above 2 lines
# and uncomment
#sda: GPIO4
#scl: GPIO5
#################### - IMPORTANT ###########
  scan: true
  id: i2c_bus_a
  
pcf8574:
  - id: 'pcf8574_hub'
    address: 0x22 # Set at 0x22, feel free to change to your liking, Remember to set the chip to the address you choose as well
    pcf8575: false

time:
  - platform: sntp
    id: ha_time
    timezone: "Etc/GMT+7"

status_led:
  pin:
    number: GPIO16
    inverted: true

#Define the APE as a custom component, taking care to ensure that:
#1). The I2C Bust ID is the same as the one you have defined in the I2C: Section
#2). The address of the APE is the same as the one you set in the sketch
    
custom_component:
  - id: ape
    lambda: |-
      auto ape_component = new ArduinoPortExpander(i2c_bus_a, 0x08,true);
      return {ape_component};
    

sensor:

  - platform: custom
    lambda: |-
      return {ape_analog_input(ape, 0),  // 1 = A1
             ape_analog_input(ape, 1),
             ape_analog_input(ape, 2)};
   
#We define 3 analog inputs (A0,A1,A2) to monitor voltages on the card
#Note that you MUST define them in the sensors section below as well AND
#THAT THEY MUST BE IN THE SAME SEQUENCE THAT YOU DEFINED THEM IN ABOVE HERE
#
#ALSO NOTE THAT YOU CAN "NOT" use A4 and A5, as they are used for I2C !
#
# As an example, of adding another 3 analog inputs, your definition above will change to:
#
#    return {ape_analog_input(ape, 0),
#           ape_analog_input(ape, 1),
#           ape_analog_input(ape, 2),
#           ape_analog_input(ape, 3),
#           ape_analog_input(ape, 6),
#           ape_analog_input(ape, 7)};
#
#
# Now define the sensors connected to these analogs below:

             
    sensors:
      - name: "PE Card VIN"
        id: analog_a0
        device_class: "voltage"
        unit_of_measurement: "v"
        accuracy_decimals: 2
        filters:
          - lambda: return x * (22.00/1023.0);
          - throttle: 60s

# We use a lambda to scale the value of VIN - Our Voltage divider was designed around 22 volt
# thus we need 22 volt here in the calculation as well to make it accurate
#
      - name: "PE Card 5v"
        id: analog_a1
        device_class: "voltage"
        unit_of_measurement: "v"
        accuracy_decimals: 2
        filters:
          - lambda: return x * (5.02/1023.0); 
          - throttle: 60s
      - name: "PE Card 3v"
        id: analog_a2
        device_class: "voltage"
        unit_of_measurement: "v"
        accuracy_decimals: 2
        filters:
          - lambda: return x * (5.02/1023.0);
          - throttle: 60s
 
# The ATMega328P 's Analog Reference is set to 5v internally, thus we need to also scale the 
# 3v input with a maximum of 5v ... 

# In case you enabled the other 3 Analog Inputs above, you need to add the following
#
#    - name: "Analog 3"
#      id: analog_a3
#      filters:
#        - throttle: 60s
#    - name: "Analog 6"
#      id: analog_a6
#      filters:
#        - throttle: 60s
#    - name: "Analog 7"
#      id: analog_a7
#      filters:
#        - throttle: 60s
#
#
             
             
             
  - platform: adc
    pin: VCC
    name: "ESP8266 Chip Voltage"
    id: mcu_voltage
    unit_of_measurement: "V"
    device_class: "voltage"
    accuracy_decimals: 2
    update_interval: 60s
    
  - platform: wifi_signal
    name: "WiFi Signal Sensor"
    id: wifi_strength
    device_class: "signal_strength"
    unit_of_measurement: "dBm"
    update_interval: 240s
    

#Digital outputs function the same

output:
- platform: custom
  type: binary
  lambda: |-
    return {ape_binary_output(ape, 2),
            ape_binary_output(ape, 3),
            ape_binary_output(ape, 4),
            ape_binary_output(ape, 5),
            ape_binary_output(ape, 6),
            ape_binary_output(ape, 7)};
  outputs:
    - id: ape_output_p2
      inverted: false
    - id: ape_output_p3
      inverted: false
    - id: ape_output_p4
      inverted: false
    - id: ape_output_p5
      inverted: false
    - id: ape_output_p6
      inverted: false
    - id: ape_output_p7
      inverted: false
      
- platform: gpio
  id: relay_1
  pin:
    pcf8574: pcf8574_hub
    number: 0
    mode: OUTPUT
    inverted: true
- platform: gpio
  id: relay_2
  pin:
    pcf8574: pcf8574_hub
    number: 1
    mode: OUTPUT
    inverted: true
- platform: gpio
  id: led_status_1
  pin:
    pcf8574: pcf8574_hub
    number: 2
    mode: OUTPUT
    inverted: true
- platform: gpio
  id: led_status_2
  pin:
    pcf8574: pcf8574_hub
    number: 3
    mode: OUTPUT
    inverted: true
      
binary_sensor:
  - platform: gpio
    id: push_button_1
    name: 'Relay1 Pushbutton'
    device_class: ''
    pin: 
      pcf8574: pcf8574_hub
      number: 4
      mode: INPUT
      inverted: true
    on_press:
      then:
        - switch.toggle: switch_relay1
        
  - platform: gpio
    id: push_button_2
    name: 'Relay2 Pushbutton'
    device_class: ''
    pin:
      pcf8574: pcf8574_hub
      number: 5
      mode: INPUT
      inverted: true
    on_press:
      #min_length: 50ms
      #max_length: 500ms
      then:
        - switch.toggle: switch_relay2
    filters:
        - delayed_on_off: 50ms
      
  

switch:
  - platform: output
    id: switch_relay1
    name: "Relay No. 1 (#0)"
    output: relay_1
    on_turn_on:
      - output.turn_on: led_status_1
    on_turn_off:
      - output.turn_off: led_status_1
      
  - platform: output
    id: switch_relay2
    name: "Relay No. 2 (#1)"
    output: relay_2
    on_turn_on:
      - output.turn_on: led_status_2
    on_turn_off:
      - output.turn_off: led_status_2
  - platform: restart
    id: reboot_switch
    name: "Reboot Me"

Detailed information on the APE is available here

Manufacturing the PCB

This PCB was manufactured at PCBWAY. The Gerber files and BOM, as well as all the schematics, will soon be available as a shared project on their website. If you would like to have PCBWAY manufacture one of your own, designs, or even this particular PCB, you need to do the following…
1) Click on this link
2) Create an account if you have not already got one of your own.
If you use the link above, you will also instantly receive a $5USD coupon, which you can use on your first or any other order later. (Disclaimer: I will earn a small referral fee from PCBWay. This referral fee will not affect the cost of your order, nor will you pay any part thereof.)
3) Once you have gone to their website, and created an account, or login with your existing account,

4) Click on PCB Instant Quote

5) If you do not have any very special requirements for your PCB, click on Quick-order PCB

6) Click on Add Gerber File, and select your Gerber file(s) from your computer. Most of your PCB details will now be automatically selected, leaving you to only select the solder mask and silk-screen colour, as well as to remove the order number or not. You can of course fine-tune everything exactly as you want as well.

7) You can also select whether you want an SMD stencil, or have the board assembled after manufacturing. Please note that the assembly service, as well as the cost of your components, ARE NOT included in the initial quoted price. ( The quote will update depending on what options you select ).

8) When you are happy with the options that you have selected, you can click on the Save to Cart Button. From here on, you can go to the top of the screen, click on Cart, make any payment(s) or use any coupons that you have in your account.

Then just sit back and wait for your new PCB to be delivered to your door via the shipping company that you have selected during checkout.

Design and build an ESP8266 IoT Controller, Part 3

Welcome to Part 3 of this build. If you are new to this series, Part1 and Part2 can be found by clicking on the respective links. Today, we will look at the completed PCB for our IoT Controller. Full disclosure, There are some issues, ranging from components that have still (15 days after being ordered, not been delivered), as well as 3 minor errors on the PCB ( That is entirely my fault ). We will look at how I have overcome the problems to still end up with a functionals PCB. Please note that the errors in the PCB Artwork have BEEN CORRECTED and that the version for public download does not contain any errors. You can thus order it with confidence.

Let us get started

Errors on the PCB
Powering on the PCB
Integrating and Testing with Home Assistant
Tasmota
Order this PCB for yourself
Conclusion and Further steps

Errors on the PCB

Ground Error on C10, C11 and U2

During the design phase, I have forgotten to add a ground to the 5v regulator, and its supporting smoothing capacitors. These components were not initially included in my design, but, while added in later after I decided that since I will be designing the PCB to operate from many different voltage inputs, a reliable 5v source that is not dependent on USB power should be added… The components were added to the schematic, and I forgot to add the ground. It went undetected on the PCB design, as the Ground plane is a copper area…

In the picture above, you can see that I have temporarily fixed it with two wire links from the ground of C1, to the grounds of C10 and C11 respectively. These grounds connect back to U2.

C1 is another issue. Originally designed as a 100uf Electrolytic capacitor, I had to settle for a 10uf Tantalum. The reason being that the ordered capacitors are still floating in logistics space… with no definite ETA.

Error on I2C labelling, as well as I2C Pins at IC2

The following error was not so easy to spot. It gave me quite a headache to find. As I normally use netlabels on all the pins of any IC that I use, I have correctly labelled ESP12-E GPIO5 as SCL and GPIO4 as SDA. These netlabels were then transferred onto the PFC8574’s pins but in reverse! Note to self: Always re-read the pinout in the datasheet! To make matters worse, I flipped the SCL and SDA labels on the pin header…

How to fix:
I am fortunate that the ESP12-E, like all other ESP Modules, does not have fixed I2C pins. If this was an Atmega based project, the boards would have been useless if tracks could not be cut and reconnected!
On the ESP12-E, I2C is however software allocated to any desired GPIO pin. It was thus easily fixed by just swapping the two pins in software.

The third problem encountered is another logistics issue. This is in the process of being resolved, but, as you will soon see, is not actually a problem at all…

I have added support for an onboard USB to Serial converter, via a CH340G chip. The chip requires a 12Mhz resonator or crystal. My dear supplier accidentally sent me an 8 Mhz version. I have thus decided to depopulate the entire USB to Serial circuit, leaving just the USB Port and protection diode on the board. (To allow for powering via USB).

This does mean that programming the board becomes a little more complicated, connecting an external USB to Serial Adapter, and pressing and holding the flash button while pressing and releasing reset for each upload, followed by a manual reset afterwards. This is a pain, but, as I will be using these boards with ESPHome, only required once. All future uploads will be OTA anyway, and the correct components can be retrofitted when they arrive at a later stage.

Powering on the PCB

The PCB was first powered on with an external USB to serial converter and using the Arduino IDE, a simple sketch testing the I2C addressing of the chip, as well as the functioning of all onboard relays and LEDs.

The board was then flashed with ESPHome, using the procedure described in Part 1.
I then proceeded to measure the current required by the board, to make sure that it is as designed.

Current Requirements
Powered from 9V to 12V DC via the DC Barrel Connector

Standby, Wifi Connected to Home Assistant, All relays and LEDs off 75mA
All relays energised, status LEDs all on 255mA

Integrating and Testing with EspHome and Home Assistant

The configuration for ESPHome was updated and uploaded to the device OTA. I decided to add a monitor for the VCC input of the ESP12-E, a remote Restart button, and an external DHT11 Temperature and Humidity sensor.
The updated code is available below

esphome:
  name: iot-controller-8266-01
  platform: ESP8266
  board: nodemcuv2

# Enable logging
logger:

# Enable Home Assistant API
api:

ota:
  password: "2f8a73f47f1893f3f7baa391c4d0ba96"

wifi:
  ssid: "<your ssid>"
  password: "<your password>"

  # Enable fallback hotspot (captive portal) in case wifi connection fails
  ap:
    ssid: "Iot-Controller-8266-01"
    password: "y4aaH7vMITsC"

captive_portal:
#--- DO NOT COPY ANYTHING ABOVE THIS LINE ---

# when using this, you need to reassign the status LED to another GPIO
#deep_sleep:
#  run_duration: 5min
#  sleep_duration: 2min

i2c:
  sda: GPIO5
  scl: GPIO4
  scan: true
  id: i2c_bus_a
  
pcf8574:
  - id: 'pcf8574_hub'
    address: 0x22
    pcf8575: false

status_led:
    pin: 
      number: GPIO16
      inverted: true
# Reassign this LED to another GPIO when using deep sleep mode !

sensor:
# Monitor VCC on the ESP12-E
  - platform: adc
    pin: VCC
    name: "Device Input Voltage"
    unit_of_measurement: "V"
# Monitor the WiFi Signal Strength at the device
  - platform: wifi_signal
    name: "WiFi Signal Sensor"
    unit_of_measurement: "dBm"
    update_interval: 240s
# Add Temperature and Humidity Sensor
  - platform: dht
    pin: GPIO2
    temperature:
      name: "Room Temperature"
      unit_of_measurement: "°C"
      icon: "mdi:temperature"
      device_class: "temperature"
      state_class: "measurement"
      accuracy_decimals: 2
      
    humidity:
      name: "Room Humidity"
      unit_of_measurement: "%"
      icon: "mdi:water-percent"
      device_class: "humidity"
      state_class: "measurement"
      accuracy_decimals: 2
    update_interval: 60s

# Outputs to control relays and led's

output:
 - platform: gpio
   id: relay_1
   pin: 
      pcf8574: pcf8574_hub
      number: 0
      mode: OUTPUT
      inverted: true
 - platform: gpio
   id: relay_2
   pin: 
      pcf8574: pcf8574_hub
      number: 1
      mode: OUTPUT
      inverted: true
 - platform: gpio
   id: led_status_1
   pin: 
      pcf8574: pcf8574_hub
      number: 2
      mode: OUTPUT
      inverted: true
 - platform: gpio
   id: led_status_2
   pin: 
      pcf8574: pcf8574_hub
      number: 3
      mode: OUTPUT
      inverted: true
# Monitor the two local control pushbuttons on the device  
binary_sensor:
  -  platform: gpio
     id: push_button_1
     name: 'Relay1 Pushbutton'
     device_class: ''
     pin:
        pcf8574:  pcf8574_hub
        number: 4
        mode: INPUT
        inverted: true
     on_press:
      then:
        - switch.toggle: switch_relay1
     filters:
       -  delayed_on_off: 50ms
       
  -  platform: gpio
     id: push_button_2
     name: 'Relay2 Pushbutton'
     device_class: ''
     pin:
        pcf8574:  pcf8574_hub
        number: 5
        mode: INPUT
        inverted: true
     on_press:
      #min_length: 50ms
      #max_length: 500ms
      then:
        - switch.toggle: switch_relay2
     filters:
       -  delayed_on_off: 50ms

# Allow control from inside Home Assistant
     
switch:
  - platform: output 
    id: switch_relay1
    name: "Relay No. 1 (#0)"
    output: relay_1
    on_turn_on:
    - output.turn_on: led_status_1
    on_turn_off:
    - output.turn_off: led_status_1
  - platform: output 
    id: switch_relay2
    name: "Relay No. 2 (#1)"
    output: relay_2
    on_turn_on:
    - output.turn_on: led_status_2
    on_turn_off:
    - output.turn_off: led_status_2
 # Add a remote Reboot switch 
  - platform: restart
    name: "Reboot Me"

After uploading this configuration, Home Assistant was configured to reflect the changes.

Home Assistant showing the IoT Controller status ( EE Lab Area ) as well as Admin stats (Master Control Panel)

I have decided to split the different status and control outputs from the device into two cards, One in the EE Lab Area, which will later be moved into the actual room(s) where the device will be deployed, as well as on a Master Control Panel. From here, I can reboot individual devices, see their voltages and WiFi Status

Tasmota

As promised before, I did test the device with Tasmota. I had to do a custom compile to get support for the PCF8574. Performance was however VERY poor. ESPHome is snappy and quick, even in local mode. Tasmota seemed to have at least a one-second delay on doing anything.
I thus abandoned it, and won’t be making use of it in this project anymore. The flexibility of ESPHome to do what I want, how I want it, is definitely missing in Tasmota. Hopefully, that will change in the future?

Order this PCB for yourself

You can order this PCB from PCBWay as a shared Project, by clicking here.
New users will get a $5 USD coupon for use with their first order if they follow the link below to sign up for an account.

I would also like to thank Wendy at PCBWay for once again being a star. The project went smoothly and was very well produced. Make sure to consider using PCBWay for your next PCB order.

Conclusion and further steps

I am in the process of building and assembling another 2 of these devices. I have also ordered and received PolyCarbonate enclosures to mount them in. As this is an ongoing project, I still plan to add I2C temperature measurement chips to each, to measure the temperature inside the enclosure. An Air quality sensor, as well as a CO2 sensor, is also planned, with a possible Display Shield to provide test output locally at the device. This display, at the moment at least, is planned as an I2C Oled or similar. There are also plans to do an option to directly power the unit from 220V AC via an additional base-board for now, or a complete redesign, incorporating everything on one board.
Thank you for following along, I hope that you found it educational and entertaining.
Please consider joining us on Patreon. We are in the process of creating exclusive content for that platform, as well as for http://144.126.248.244. Most of the content will also remain free for all as usual.

What is SPI? Serial Peripheral Interface – Part 1

Introduction

The Serial Peripheral Interface is a synchronous serial communication interface for short-distance communication, it is typically used in embedded systems. The interface was developed by Motorola in the mid 1980’s and has become a very popular standard.

It is used with many kinds of sensors, LCD’s and also SD-Cards. SPI operates in a Master-Slave model, with a possibility of multiple slave devices, each selected in turn by a SS (slave select) or CS (chip select) pin that is usually pulled low by the master.

Typical connection between two SPI devices

Typical configuration

SPI is a four-wire interface, with the different lines being
– MOSI [Master Out Slave In]
-MISO [Master In Slave Out]
-SCLK [Serial Clock OUT – generated by the master]
-SS/CS [Slave Select or Chip Select, sometimes also labelled CE – Chip Enable]

SPI is a FULL DUPLEX interface, where the master initiates the communication frames between the various slave devices. This is usually done by pulling the particular device’s SS/CS pin low. Data is then shifted simultaneously into and out of the devices by means of the MOSI and MISO lines on the bus. The frequency of the serially shifted data is controlled by the SCLK line. This clock signal is generated by the master device.

It is important to note that MOST of the slave devices have a tri-state (HIGH IMPEDANCE) mode on their MISO pins. This electrically disconnects the MISO pin from the bus when the device is not selected via the SS/CS pin.

You should also note the SPI slave devices that do not have a tri-state mode on their MISO pins, should not be used on the same bus as devices that have without using an external tri-state buffer circuit between the non-tristate device and the rest of the devices on the MISO bus.

Typical connection between an SPI Master and three Slave devices


It is possible to connect multiple SPI slave devices to on Master device if you remember that each slave device will need its own dedicated SS/CS pin on the master. This can however quickly use a lot of IO pins on a microcontroller, thus being one of the disadvantages of SPI versus I2C. SPI is however quite a bit faster than I2C.

Data Transmission

To begin communication, the bus master configures the clock, using a frequency supported by the slave device, typically up to a few MHz. The master then selects the slave device with a logic level 0 on the select line. If a waiting period is required, such as for an analog-to-digital conversion, the master must wait for at least that period of time before issuing clock cycles.

During each SPI clock cycle, full-duplex data transmission occurs. The master sends a bit on the MOSI line and the slave reads it, while the slave sends a bit on the MISO line and the master reads it. This sequence is maintained even when only one-directional data transfer is intended.

A typical hardware setup using two shift registers to form an inter-chip circular buffer

Transmissions normally involve two shift registers of some given word-size, such as eight bits, one in the master and one in the slave; they are connected in a virtual ring topology. Data is usually shifted out with the most significant bit first. On the clock edge, both master and slave shift out a bit and output it on the transmission line to the counterpart. On the next clock edge, at each receiver the bit is sampled from the transmission line and set as a new least-significant bit of the shift register. After the register bits have been shifted out and in, the master and slave have exchanged register values. If more data needs to be exchanged, the shift registers are reloaded and the process repeats. Transmission may continue for any number of clock cycles. When complete, the master stops toggling the clock signal, and typically deselects the slave.

Transmissions often consist of eight-bit words. However, other word-sizes are also common, for example, sixteen-bit words for touch-screen controllers or audio codecs, such as the TSC2101 by Texas Instruments, or twelve-bit words for many digital-to-analogue or analogue-to-digital converters.

Every slave on the bus that has not been activated using its chip select line must disregard the input clock and MOSI signals and should not drive MISO (I.E. must have a tri-state output) although some devices need external tri-state buffers to implement this.

Clock polarity and phasing

In addition to setting the clock frequency, the master must also configure the clock polarity and phase with respect to the data. Motorola SPI Block Guide names these two options as CPOL and CPHA (for clock polarity and phase) respectively, a convention most vendors have also adopted.

The timing diagram is shown below. The timing is further described below and applies to both the master and the slave device.

  • CPOL determines the polarity of the clock. The polarities can be converted with a simple inverter.
  • CPOL=0 is a clock which idles at 0, and each cycle consists of a pulse of 1. That is, the leading edge is a rising edge, and the trailing edge is a falling edge.
  • CPOL=1 is a clock which idles at 1, and each cycle consists of a pulse of 0. That is, the leading edge is a falling edge, and the trailing edge is a rising edge.
  • CPHA determines the timing (i.e. phase) of the data bits relative to the clock pulses. Conversion between these two forms is non-trivial.
  • For CPHA=0, the “out” side changes the data on the trailing edge of the preceding clock cycle, while the “in” side captures the data on (or shortly after) the leading edge of the clock cycle. The out-side holds the data valid until the trailing edge of the current clock cycle. For the first cycle, the first bit must be on the MOSI line before the leading clock edge.
  • An alternative way of considering it is to say that a CPHA=0 cycle consists of a half cycle with the clock idle, followed by a half cycle with the clock asserted.
  • For CPHA=1, the “out” side changes the data on the leading edge of the current clock cycle, while the “in” side captures the data on (or shortly after) the trailing edge of the clock cycle. The out-side holds the data valid until the leading edge of the following clock cycle. For the last cycle, the slave holds the MISO line valid until slave select is de-selected.
  • An alternative way of considering it is to say that a CPHA=1 cycle consists of a half cycle with the clock asserted, followed by a half cycle with the clock idle.
A timing diagram showing clock polarity and phase. Red lines denote clock leading edges, and blue lines, trailing edges.

The MOSI and MISO signals are usually stable (at their reception points) for the half cycle until the next clock transition. SPI master and slave devices may well sample data at different points in that half cycle.

This adds more flexibility to the communication channel between the master and slave.

Mode numbers

The combinations of polarity and phases are often referred to as modes which are commonly numbered according to the following convention, with CPOL as the high order bit and CPHA as the low order bit:

For “Microchip PIC” / “ARM-based” microcontrollers (note that NCPHA is the inversion of CPHA):

SPI modeClock polarity
(CPOL/CKP)
Clock phase
(CPHA)
Clock edge
(CKE/NCPHA)
0001
1010
2101
3110
For PIC32MX: SPI mode configure CKP, CKE and SMP bits. Set SMP bit and CKP, CKE two bits configured as above table.
ModeCPOLCPHA
000
101
210
311
For other microcontrollers:

Another commonly used notation represents the mode as a (CPOL, CPHA) tuple; e.g., the value ‘(0, 1)’ would indicate CPOL=0 and CPHA=1.

Note that in Full Duplex operation, the Master device could transmit and receive with different modes. For instance, it could transmit in Mode 0 and be receiving in Mode 1 at the same time.

Independent Slave Configuration

In the independent slave configuration, there is an independent chip select line for each slave. This is the way SPI is normally used. The master asserts only one chip select at a time.

Pull-up resistors between the power source and chip select lines are recommended for systems where the master’s chip select pins may default to an undefined state. When separate software routines initialize each chip select and communicate with its slave, pull-up resistors prevent other uninitialized slaves from responding.

Since the MISO pins of the slaves are connected together, they are required to be tri-state pins (high, low or high-impedance), where the high-impedance output must be applied when the slave is not selected. Slave devices not supporting tri-state may be used in independent slave configuration by adding a tri-state buffer chip controlled by the chip select signal. (Since only a single signal line needs to be tri-stated per slave, one typical standard logic chip that contains four tristate buffers with independent gate inputs can be used to interface up to four slave devices to an SPI bus.)

Typical SPI configuration

Daisy chain configuration

Some products that implement SPI may be connected in a daisy chain configuration, the first slave output being connected to the second slave input, etc. The SPI port of each slave is designed to send out during the second group of clock pulses an exact copy of the data it received during the first group of clock pulses. The whole chain acts as a communication shift register; daisy chaining is often done with shift registers to provide a bank of inputs or outputs through SPI. Each slave copies input to output in the next clock cycle until the active low SS line goes high. Such a feature only requires a single SS line from the master, rather than a separate SS line for each slave.

Note that not all SPI devices support this. You should thus check your datasheet before using this configuration!

SPI Daisy Chain configuration

Valid Communications

Some slave devices are designed to ignore any SPI communications in which the number of clock pulses is greater than specified. Others do not care, ignoring extra inputs and continuing to shift the same output bit. It is common for different devices to use SPI communications with different lengths, as, for example, when SPI is used to access the scan chain of a digital IC by issuing a command word of one size (perhaps 32 bits) and then getting a response of a different size (perhaps 153 bits, one for each pin in that scan chain).

Interrupts

SPI devices sometimes use another signal line to send an interrupt signal to a host CPU. Examples include pen-down interrupts from touchscreen sensors, thermal limit alerts from temperature sensors, alarms issued by real-time clock chips, SDIO, and headset jack insertions from the sound codec in a cell phone. Interrupts are not covered by the SPI standard; their usage is neither forbidden nor specified by the standard. In other words, interrupts are outside the scope of the SPI standard and are optionally implemented independently from it.

Bit Banging a SPI Master – Example code

Below is an example of bit-banging the SPI protocol as an SPI master with CPOL=0, CPHA=0, and eight bits per transfer. The example is written in the C programming language. Because this is CPOL=0 the clock must be pulled low before the chip select is activated. The chip select line must be activated, which normally means being toggled low, for the peripheral before the start of the transfer, and then deactivated afterwards. Most peripherals allow or require several transfers while the select line is low; this routine might be called several times before deselecting the chip.

/*
 * Simultaneously transmit and receive a byte on the SPI.
 *
 * Polarity and phase are assumed to be both 0, i.e.:
 *   - input data is captured on rising edge of SCLK.
 *   - output data is propagated on falling edge of SCLK.
 *
 * Returns the received byte.
 */
uint8_t SPI_transfer_byte(uint8_t byte_out)
{
    uint8_t byte_in = 0;
    uint8_t bit;

    for (bit = 0x80; bit; bit >>= 1) {
        /* Shift-out a bit to the MOSI line */
        write_MOSI((byte_out & bit) ? HIGH : LOW);

        /* Delay for at least the peer's setup time */
        delay(SPI_SCLK_LOW_TIME);

        /* Pull the clock line high */
        write_SCLK(HIGH);

        /* Shift-in a bit from the MISO line */
        if (read_MISO() == HIGH)
            byte_in |= bit;

        /* Delay for at least the peer's hold time */
        delay(SPI_SCLK_HIGH_TIME);

        /* Pull the clock line low */
        write_SCLK(LOW);
    }

    return byte_in;
}

This concludes part 1 of my series on SPI. I hope you found it interesting and useful.

Multiple I2C Devices on the same Bus, I2C Part 3

Today I will continue my series on I2C by showing you how to use multiple devices on the I2C bus. This will be an extremely short post, as it builds on skills that we have already covered.

I will connect the following

1 x 16×2 I2C LCD Screen address 0x27
1x 128×32 I2C OLED Display address 0x3C
2x PCF8574 I2C Io Extenders address 0x20 and 0x21

All of these devices will be controlled from Arduino Uno, using the following libraries


LiquidCrystal_I2C.h to control the LCD screen,
Wire.h and PCF8574.h to control the I2C IO extenders and
Adafruit_GFX, Adafruit_SSD1306.h and SPI.h to control the SSD1306 128×32 OLED display.

With DuPont wires and breadboards being the reliable things they are, I decided that, after initial testing, I will not show you how to do button inputs on the PCF8574 at this stage. The amount of stray capacitance floating around on the breadboards, and small momentary push-button switches, made for a very impressive but unreliable mess of wires, with no real learning value to it 😉 Maybe some more on that later when I do a decent real-world example using these technologies 🙂

As the total distance between the devices is relatively short, it was not necessary to use pull-up resistors on the I2C bus in my setup. I suspect that that is due to the fact that they may already be included on some of my devices.

The circuit is quite straight forward.

  1. Connect all SDA pins on the I2C devices together serially, and connect that to the Arduino SDA pin ( That is usually A4)
  2. Connect all SCL pins on the I2C devices together serially, and connect that to the Arduino SCL pin ( That is usually A5)

    A note: On my Uno clone, there is an additional I2C breakout at the top of the device, near the USB adapter. I chose to use that as well as A4 and A5, as the bus hung itself up when connected to the breadboard. Your mileage may vary on this one 🙂
  3. Connect all 5v (Vcc) lines to 5v on the Arduino, and all Ground (GND) lines to GND on the Arduino.
  4. Now connect 4 LEDs, through a suitable resistor ( 640 ohms up to 1k ohm ) to pin P0 and P1 on both of the PCF8574 IO extenders. Also, connect the other leg of the LED to ground.
  5. I have powered my Uno from an external 5v power supply, as I did not want to pull too much current from the regulator on the actual Uno clone.

That should complete your hardware setup. Double check all your connections, and then load the i2c scanner sketch in the Arduino IDE, you may find it under the examples for the Wire.h library.

Power up the circuit, and upload the sketch to the Uno. Open the Serial Monitor.

You should see 4 I2C devices being detected. Note their addresses. If you dont see 4 devices, check your wiring and addresses. You may have a device with a conflicting address or a bad connection. If you used the breadboard to connect the bus, chances are very good that you will not see all the devices.

Good, if all of that is working, copy paste the following code into a new Arduino IDE window.
I will explain the code in the section below:

/*
  Multiple devices on the I2C bus
  Maker and Iot Ideas, MakerIoT2020
*/
// Include the libraries that we will need
#include <SPI.h> // needed for OLED display. 
#include <PCF8574.h> // PCF8574
#include <Wire.h> // Generic I2C library
#include <Adafruit_GFX.h> // for OLED display
#include <Adafruit_SSD1306.h> // for OLED display
#include <LiquidCrystal_I2C.h> // For I2C LCD display

// we need to define the size of the OLED screen

#define OLED_WIDTH 128
#define OLED_HEIGHT 32

// mine does not have an onboard reset pin. If yours do, specify the 
// pin that it is connected to on the Arduino here. To use the 
// Arduino reset pin, specify -1 as below

#define OLED_RESET -1

// Define the OLED display, width,hight protocol and reset pin
Adafruit_SSD1306 oled(OLED_WIDTH,OLED_HEIGHT, &Wire, OLED_RESET);

// Define the I2C LCD screen address and pin configuration
LiquidCrystal_I2C lcd(0x27,2,1,0,4,5,6,7,3,POSITIVE);

// Define the PCF8574 devices ( you can have up to 8 on a bus )
// but in this case, my LCD uses address 0x27, so I will have a 
// conflicting address if I were to use 8 of them together with the
// LCD

PCF8574 Remote_1(0x20); 
PCF8574 Remote_2(0x21);

// Note the I2C addresses. You can obtain them from the i2c_scanner

void setup() {
  // serial debugging if needed
  Serial.begin(115200);
  // Start OLED Display Init

  if (!oled.begin(SSD1306_SWITCHCAPVCC,0x3C)) { // Init the OLED 
    Serial.println(F("OLED INIT FAILED"));
    for(;;); // Dont proceed ... loop forever
  }
  oled.display();
  delay(2000); // This delay is required to give display time to 
  // initialise properly
  oled.clearDisplay();
  oled.setTextSize(0);
  oled.setTextColor(SSD1306_WHITE);
  oled.setCursor(0,0);
  oled.println("TEST SCREEN");
  oled.display();
  delay(2000);
  oled.clearDisplay();
  oled.setCursor(1,0);
  oled.println("OLED SCREEN ON");
  oled.display();

  // Start the LCD

  lcd.begin(16,2);
  
  // Set the initial state of the pins on the PCF8574 devices
  // I found that the PCF8574 library sometimes does funny things
  // This is also an example of how to use native i2c to set the 
  // status of the pins
  
  Wire.begin();
  Wire.beginTransmission(0x20); // device 1
  Wire.write(0x00); // all ports off
  Wire.endTransmission();
  Wire.begin();
  Wire.beginTransmission(0x21); // device 2
  Wire.write(0x00); // all ports off
  Wire.endTransmission();
  // Set pinModes for PCF8574 devices
  // Note that there are two of them

  Remote_1.pinMode(P0,OUTPUT);
  Remote_1.pinMode(P1,OUTPUT);
  Remote_2.pinMode(P0,OUTPUT);
  Remote_2.pinMode(P1,OUTPUT);
  
  // Start both IO extenders

  Remote_1.begin();
  Remote_2.begin();

  // and set ports to low on both
  // you may find that if you ommit this step, they come up in an
  // unstable state.

  Remote_1.digitalWrite(P0,LOW);
  Remote_1.digitalWrite(P1,LOW);
  Remote_2.digitalWrite(P0,LOW);
  Remote_2.digitalWrite(P1,LOW);
  
}

void loop() {
  // Draw a character map on the OLED display.
  // This function is borrowed from the Adafruit library

  testdrawchar();

  // Write to the IO extenders

  Remote_1.digitalWrite(P0,HIGH);
  Remote_1.digitalWrite(P1,LOW);
  Remote_2.digitalWrite(P0,HIGH);
  Remote_2.digitalWrite(P1,LOW);
  
  // Display their status on the LCD
  lcd.setCursor(0,0);
  lcd.print(" R1 P0=1 P1=0");
  lcd.setCursor(0,1);
  lcd.print(" R2 P0=1 P1=0");
  delay(500);

  // Change status
  Remote_1.digitalWrite(P1,HIGH);
  Remote_1.digitalWrite(P0,LOW);
  Remote_2.digitalWrite(P1,HIGH);
  Remote_2.digitalWrite(P0,LOW);

  // Update LCD
  lcd.setCursor(0,0);
  lcd.print(" R1 P0=0 P1=1");
  lcd.setCursor(0,1);
  lcd.print(" R2 P0=0 P1=1");
  delay(500);
  // Do some graphics on the OLED display
  // Function borrowed from Adafruit
  testdrawrect();
  oled.clearDisplay();
  delay(500);
  // repeat indefinitely

}

void testdrawrect(void) {
  oled.clearDisplay();

  for(int16_t i=0; i<oled.height()/2; i+=2) {
    oled.drawRect(i, i, oled.width()-2*i, oled.height()-2*i, SSD1306_WHITE);
    oled.display(); // Update screen with each newly-drawn rectangle
    delay(1);
  }

  delay(500);
}

void testdrawchar(void) {
  oled.clearDisplay();

  oled.setTextSize(1);      // Normal 1:1 pixel scale
  oled.setTextColor(SSD1306_WHITE); // Draw white text
  oled.setCursor(0, 0);     // Start at top-left corner
  oled.cp437(true);         // Use full 256 char 'Code Page 437' font

  // Not all the characters will fit on the display. This is normal.
  // Library will draw what it can and the rest will be clipped.
  for(int16_t i=0; i<256; i++) {
    if(i == '\n') oled.write(' ');
    else          oled.write(i);
  }

  oled.display();
  delay(500);
}

This concludes a quick and dirty show and tell… I hope that it will stimulate questions and ideas for a lot of people.

Thank you

I2C between Maker Nano and Kid-Bright32 (Esp32)

In our last post, we started looking at the workings of the I2C protocol. In case you missed that, you can read about that here. Today, I will continue with I2C by showing you how to implement the protocol between an Maker Nano (a Arduino Nano Clone) and Kid-Bright32 (a ESP32 based development and Education device).

This project will eventually be turned into an IoT device, with Google Assistant voice control. The Kid-Bright have very limited IO pins, and the Maker Nano has no Network Connectivity unless we use an Ethernet Shield. Enough of that for now, let us start with today’s tutorial, we will get back to this project later…

The Code for the Master

/* I2C Master Code - Kid Bright 32 v 1.3
   Can be adapted to Arduino or NodeMCU or STM32
   As it uses no special libraries, only the standard Wire.h
   that is already included with the Arduino IDE
*/

#include <Wire.h>

#define button1 16 // Button 1
#define button2 14 // Button 2
#define led_blue 17 // Led 1
#define led_red 2 // Led 2
#define led_yellow 15 // Led 3


void setup() {
  Wire.begin(); // Start I2C, join bus as a Master
  pinMode(button1,INPUT_PULLUP); // Set as input
  pinMode(button2,INPUT_PULLUP); 
  pinMode(led_blue,OUTPUT); // Set as output
  pinMode(led_red,OUTPUT);
  pinMode(led_yellow,OUTPUT);
  digitalWrite(led_blue,HIGH); // LED is Active Low
  digitalWrite(led_red,HIGH); // LED is Active Low
  digitalWrite(led_yellow,HIGH); // LED is Active Low
  Serial.begin(115200); // Start Serial for debugging
}

byte Data = 0; // Variable for sending data to the slave
int SlaveData = 0; // Variable for receiving data from the slave

void loop() {
  Wire.beginTransmission(4); // Send data to Slave at address #4
  Wire.write(Data); // Transmit one byte ( 8 bits)
  Wire.endTransmission(); // End Transmission
  Wire.requestFrom(4,1); // Request one (1) byte of data from the      //slave at address$
  while (Wire.available()) { // If data received
    SlaveData = Wire.read(); // Save it into a variable
  }

// We will implement a simple latch in software, where a single 
// button latches or releases a bit with every press and release.  
// This code should ideally include debouncing as well. It was left
// out for clarity.

  if (digitalRead(button1) == LOW) { // If button 1 pressed
    if (bitRead(Data,0) == HIGH) { // test if bit 0 in variable is set
      bitClear(Data,0); // clear it if it is set
    } else {
      bitSet(Data,0) == HIGH; // set bit to high
    }
  } 
// Do the same for the second button

  if (digitalRead(button2) == LOW) {
    if (bitRead(Data,1) == HIGH) {
      bitClear(Data,1);
    } else {
      bitSet(Data,1) == HIGH;
    }
  } 
 
// We will test for a set bit in the transmitted byte, and invert it, 
// as the LED's are active LOW

  digitalWrite(led_blue,!bitRead(Data,0)); // Toggle Led 1
  digitalWrite(led_red,!bitRead(Data,1)); // Toggle Led 2

// Same with the data received from the slave

  digitalWrite(led_yellow,!bitRead(SlaveData,0)); // Toggle Led 3
  
// Print Debug info on serial port
  
  Serial.print("Send to Slave 0xb");
  Serial.println(Data,BIN);
  Serial.print("Received from Slave 0xb");
  Serial.println(SlaveData,BIN);
  
 // Small delay, should change to millis in production code

  delay(200);
       
}
The Master Device. Connections are +5v (red) SCL (brown) SDA (orange) Ground (blue)

Code for the Slave

/*
     I2C Slave
     Arduino Nano or Compatible, can be used with ESP32 or STM32
     as well as no special libraries used, only standard Wire.h
*/

#include <Wire.h>

#define button 2 // A user button
#define led1 3 // Led 1
#define led2 4 // Led 2

byte Data = 0; // Variable for sending data to the Master

void setup() 
{
  pinMode(button,INPUT_PULLUP); // Set as Input
  pinMode(led1,OUTPUT);
  pinMode(led2,OUTPUT);
  digitalWrite(led1,LOW); // Led is Active High, so switch it off
  digitalWrite(led2,LOW);
  Wire.begin(4); // Join I2C Bus as device #4
  Wire.onReceive(receiveEvent); // Register receive Event
  Wire.onRequest(requestEvent); // Register request event
  Serial.begin(115200); // start serial debugging
  
}

void loop() {
// implement a software bit latch, on bit 0 of the Data variable
// the latch is toggled by pressing and releasing the button
// should ideally be debounced as well

 if (digitalRead(button) == LOW) {
  if (bitRead(Data,0) == HIGH) {
    bitClear(Data,0);
  } else {
    bitSet(Data,0) == HIGH;
  }
 }
 delay(200); // small delay
}

// This event will be triggered when the master requests data

void requestEvent() 
{
  Wire.write(Data); // Send data to the master
  Serial.print("Sending to Master 0xb");
  Serial.println(Data,BIN);
}
// This event gets triggered when the master sends data

void receiveEvent(int Quantity)
{
  int x = Wire.read(); // read the data ( one byte in this case)
  digitalWrite(led1,bitRead(x,0)); // Toggle LED 1 on Bit 0 state
  digitalWrite(led2,bitRead(x,1)); // Toggle LED 2 on Bit 1 state
  Serial.print("Received from Master 0xb"); // Debugginh
  Serial.println(x,BIN);

}
Maker Nano on an IO Shield, Connections are +5v (red) SCL (brown) SDA (orange) Ground (blue)

How does this work.

After uploading the code to the two boards, and connecting the boards to the I2C bus, we may power everything up. Please note that the boards MUST have a common ground. I have also powered both from the same supply. also make sure the SDA goes to SDA, and SCL to SCL… On a short distance like this, pull-up resistors are not required ( your milage may vary )

When we first power it up, is will seem as if nothing happened, but if you press and release one of the switches, the LED’s will light up, and stay lit until you press the switch again.

What next ?

In further parts of this, we will expand on this device, turning it into an IoT device, by combining many different skills that I have presented in previous tutorials.

What exactly is I2C?

In this post, I will tell you all the basics of the I2C protocol. What it is, where it comes from and also how it is configured and setup. We will also look at how data is transferred and received

Table of contents
1. Introduction
2. The Features of I2C
3. The Hardware
3.1 The physical I2C Bus
3.2 The Master and Slave devices on the bus
4. The data transfer protocol
4.1 The Start Condition
4.2 The Address Block
4.3 The Read/Write Bit
4.4 The ACK/NACK Bit
4.5 The Data Block
4.6 The Stop Condition
5. How does I2C work in practice
5.1 Sending data to a Slave Device
5.2 Reading data from a Slave Device
5.3 The Clock stretching concept

Introduction

I2C communication is the short form name for inter-integrated circuit protocol. It is a communication protocol developed by Philips Semiconductors for the transfer of data between a central processor and multiple integrated circuits on the same circuit board by using just two common wires.

Due to its simplicity, it is widely adopted for communication between microcontrollers and sensor arrays, displays, IoT devices, EEPROMs etc.

This is a synchronous serial communication protocol. It means that data bits are transferred one by one at regular intervals of time set by a reference clock line.

The Features of I2C

The I2C protocol has the following important features

  • Only two common bus lines (wires) are required to control any device/IC on the I2C network.
  • There is no need for a prior agreement on data transfer rate like in UART communications. The data transfer speed can thus be adjusted whenever it is required.
  • It has a simple mechanism for validating the transferred data.
  • It uses a 7-bit addressing system to target a specific device/IC on the I2C bus.
  • I2C networks are extremely easy to scale. New devices can simply be connected to the two common I2C bus lines.

The Hardware

The physical I2C Bus

The I2C Bus (Interface wires) consists of just two wires and are named Serial Clock Line (SCL) and Serial Data Line (SDA). The data to be transferred is sent through the SDA wire and is synchronized with the clock signal from SCL. All the devices/ICs on the I2C network are connected to the same SCL and SDA lines as shown in the image below:

The physical I2C Bus. All devices are connected to the same 2 wired on the bus, namely SDA and SCL

Both the I2C bus lines (SDA, SCL) are operated as in open-drain driver mode. It means that any device/IC on the I2C network can drive(pull) SDA and SCL low, but they cannot drive them high. So, a pull-up resistor is used on each bus line, to keep them high (at positive voltage) by default.

This is to prevent the bus from shorting, which might happen when one device tries to pull the line high and some other device tries to pull the line low.

The Master and Slave Devices on the I2C Bus

The devices connected to the I2C bus are categorized as either masters or slaves. At any instant of time, only a single master stays active on the I2C bus. It controls the SCL clock line and decides what operation is to be done on the SDA data line.

All the devices that respond to instructions from this master device are slaves. For differentiating between multiple slave devices connected to the same I2C bus, each slave device is physically assigned a permanent 7-bit address.

When a master device wants to transfer data to or from a slave device, it specifies this particular slave device address on the SDA line and then proceeds with the transfer. So effectively communication takes place between the master device and a particular slave device.

All the other slave devices don’t respond unless their address is specified by the master device on the SDA line.

The Master and Slave Devices on the I2C Bus. Note that each Slave device has it’s own address.

The Data Transfer Protocol

The protocol (set of rules) that is followed by the master device and slave devices for the transfer of data between them works as follows:

Data is transferred between the master device and slave devices through the SDA data line, via patterned sequences of 0’s and 1’s (bits). Each sequence of 0’s and 1’s is called a transaction and each data transaction is structured as in the image below:

The structure of an I2C Data transaction

The Start Condition

Whenever a master device/IC decides to start a transaction, it switches the SDA line from a high level to a low level before the SCL line switches from high to low.

Once a start condition is sent by the master device, all the slave devices get active even if they were in sleep mode, and wait for the address bits to see which device should respond.

The I2C Start Condition. Note that SDA Switches LOW before SCL. All slave devices on the bus will now listen for an address bit to decide which device should respond.

The Address Block

The Address block is comprised of 7 bits and are filled with the address of slave device (in binary) to/from which the master device needs to send/receive data. All the slave devices on the I2C bus will compare these address bits with their own address.

The Read/Write Bit

This bit specifies the direction that the data must be transferred in. If the master device/IC needs to send data to a slave device, this bit is set to ‘0’. If the master device/IC needs to receive data from the slave device, it is set to ‘1’.

The ACK/NACK Bit

This is the Acknowledged/Not-Acknowledged bit. If the physical address of any slave device is the same as the address that was broadcasted by the master device, that slave device will set the value of this bit to ‘0’ . If there are no slave device(s) with the broadcasted address, this bit will remain at logic ‘1’ (default). This will tell the master that the data/command has been received and/or acknowledged by a slave device.

The Data Block

The data block is comprised of 8 bits and they are set by the transmitter,wheather this be the master or the slave, depending on wheather a read or a write operation was requested, with the data bits that needs to transfered to the receiver. This block is followed by an ACK/NACK bit that is set to ‘0’ by the receiver if it successfully receives data. Otherwise it stays at logic ‘1’.

This combination of data blocks followed by an ACK/NACK bit is repeated until all the data is completely transferred.

The Stop Condition

After all the required data blocks are transferred through the SDA line, the master device switches the SDA line from low to high before the SCL line switches back from high to low.

The I2C Stop condition. This signals the end of a transaction. Note SDA returns to High BEFORE the SCL line is pulled High.

How does I2C work in practice

When an I2C transaction is initiated by a master device either to send or receive data to/from a slave device, all of the processes mentioned above will happen at least one.
Let us look at a typical scenario for each of the different type of scenarios.

Sending Data to a Slave Device

The following sequence of operations will take place when a master device tries to send data to a particular slave device through I2C bus:

  • The master device sends a start condition
  • The master device sends the 7 address bits which correspond to the slave device to be targeted
  • The master device sets the Read/Write bit to ‘0’, which signifies a write
  • Now two scenarios are possible:
    • If no slave device matches with the address sent by the master device, the next ACK/NACK bit stays at ‘1’ (default). This signals the master device that the slave device identification is unsuccessful. The master clock will end the current transaction by sending a Stop condition or a new Start condition
    • If a slave device exists with the same address as the one specified by the master device, the slave device sets the ACK/NACK bit to ‘0’, which signals the master device that a slave device is successfully targeted
  • If a slave device is successfully targeted, the master device now sends 8 bits of data which is only considered and received by the targeted slave device. This data means nothing to the remaining slave devices
  • If the data is successfully received by the slave device, it sets the ACK/NACK bit to ‘0’, which signals the master device to continue
  • The previous two steps are repeated until all the data is transferred
  • After all the data is sent to the slave device, the master device sends the Stop condition which signals all the slave devices that the current transaction has ended

The image below represents the transaction with the data bits sent on the SDA line and the device that controls each of them:

I2C Master sending data to a slave device

Reading Data from a Slave Device

The sequence of operations remain the same as in previous scenario except for the following:

  • The master device sets the Read/Write bit to ‘1’ instead of ‘0’ which signals the targeted slave device that the master device is expecting data from it
  • The 8 bits corresponding to the data block are sent by the slave device and the ACK/NACK bit is set by the master device
  • Once the required data is received by the master device, it sends a NACK bit. Then the slave device stops sending data and releases the SDA line

If the master device to read data from specific internal location of a slave device, it first sends the location data to the slave device using the steps in previous scenario. It then starts the process of reading data with a repeated start condition.

The below figure represents the overall data bits sent on the SDA line and the device that controls each of them:

Reading data from a Slave device on the I2C bus

The Clock Stretching concept

Let say the master device started a transaction and sent address bits of a particular slave device followed by a Read bit of ‘1’. The specific slave device needs to send an ACK bit, immediately followed by data.

But if the slave device needs some time to fetch and send data to master device, during this gap, the master device will think that the slave device is sending some data.

To prevent this, the slave device holds the SCL clock line low until it is ready to transfer data bits. By doing this, the slave device signals the master device to wait for data bits until the clock line is released

Conclusion

This concludes this tutorial. In a future post, I will show you how to use I2C to transfer data between two micro-controllers.



A glance back in History – Manufacturing your own transistors – At home!

We are living in an industrial age, electronics components are easily available. They are dirt cheap. I would like to share a few pages from an old book that I have recently found on a book-archive site on the internet. It is freely available for download, so I thought I would add a bit of history and share it with my fellow electronics enthusiasts…

The Book is called “Practical Transistors and Transistor Circuits” by JS Kendal.
It was first published in August 1954…

This is chapter 1, which I find the most interesting, I sincerely hope you will find it interesting too.

I hope that you have enjoyed the journey back in time… Thank you