0240020cd2
- KiCad schematic and PCB layout (45x35mm board) - Full BOM with JLCPCB part numbers - ESPHome firmware configuration - 3D-printable wall-mount enclosure (OpenSCAD + STL) - Pin mapping and power budget documentation
114 lines
3.4 KiB
Markdown
114 lines
3.4 KiB
Markdown
# ESP32-S3 Presence Sensor
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Compact wall-mount presence sensor with camera, mmWave radar, PIR, temperature/humidity, and ambient light sensing. Designed for Home Assistant via ESPHome.
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## Features
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- **5MP Camera** (OV5640, 120° wide-angle) - video stream to HA
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- **24GHz mmWave Radar** (LD2410C) - presence detection even when still
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- **PIR Sensor** (AM312) - instant motion trigger
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- **Temp/Humidity** (SHT41) - ±0.2°C accuracy
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- **Light Sensor** (BH1750) - 1-65535 lux
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- **USB-C powered** - any 1A+ charger
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- **~45x35mm PCB** - wall mountable
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## How Detection Works
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```
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Motion event:
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PIR (AM312) ──→ instant trigger (ms response)
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│
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▼
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mmWave (LD2410C) ──→ sustained presence tracking
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│ (detects breathing/typing)
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▼
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Combined "Occupancy" ──→ true if either sensor active
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30s delay before "unoccupied"
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```
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PIR catches fast motion immediately. mmWave confirms someone is still in the room even when sitting perfectly still. The combined sensor gives zero false-offs.
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## Project Files
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| File | Description |
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|------|-------------|
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| `presence-sensor.kicad_pro` | KiCad project file |
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| `presence-sensor.kicad_sch` | Schematic |
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| `PIN_MAPPING.md` | GPIO assignments and power budget |
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| `BOM.csv` | Bill of materials with JLCPCB part numbers |
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| `esphome-presence-sensor.yaml` | ESPHome firmware config |
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## Build Instructions
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### 1. Order PCBs
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- Open project in KiCad 8+
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- Complete PCB layout (place components, route traces)
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- Generate Gerbers: File → Plot → Gerber
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- Upload to [JLCPCB](https://jlcpcb.com)
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- Enable SMD assembly, upload BOM.csv
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### 2. Order Modules (plug-in, not soldered by JLCPCB)
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- OV5640 camera module (24-pin 0.5mm FPC, wide-angle 120°)
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- HLK-LD2410C mmWave radar module
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- AM312 mini PIR sensor
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### 3. Assembly
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- Solder LD2410C to 1.27mm header
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- Solder AM312 to 2.54mm header
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- Connect OV5640 via FPC cable
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### 4. Flash Firmware
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```bash
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# Install ESPHome
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pip install esphome
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# Create secrets.yaml
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cat > secrets.yaml << EOF
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wifi_ssid: "your-wifi"
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wifi_password: "your-password"
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api_key: "generate-a-key"
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ota_password: "your-ota-password"
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fallback_password: "your-fallback"
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EOF
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# Flash via USB-C (hold BOOT, press RESET, release BOOT)
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esphome run esphome-presence-sensor.yaml
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```
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### 5. Add to Home Assistant
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- ESPHome auto-discovers the device
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- Settings → Devices & Services → ESPHome → Configure
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## Cost Per Board
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| Item | Cost |
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|------|------|
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| PCB fabrication (5pcs) | ~$8 total |
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| SMD assembly | ~$12/board |
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| Components on PCB | ~$5.50/board |
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| OV5640 camera module | ~$3.50 |
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| LD2410C radar | ~$2.50 |
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| AM312 PIR | ~$0.50 |
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| **Total per board** | **~$32** |
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## Design Notes
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### Antenna Clearance
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- ESP32-S3 antenna extends past board edge
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- No copper pour under antenna area (top or bottom)
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- Keep antenna away from LD2410C radar module
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### Thermal
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- SHT41 placed on board edge, away from ESP32 heat
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- -1.5°C offset in ESPHome config (calibrate after testing)
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- Enclosure should have ventilation slots near SHT41
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### mmWave Orientation
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- LD2410C mounted perpendicular to wall for widest room coverage
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- Detection cone is ~60° in each direction
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- Optimal height: 1.2-1.5m from floor
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### Camera
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- OV5640 connects via 24-pin FPC flex cable
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- Camera module sits at top of enclosure, angled slightly down
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- 120° wide-angle lens covers most of a room from wall mount
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