Manual Técnico do Projeto ESP32 para Controle de

Gerador

1. Estrutura do Projeto
- MCU principal: ESP32-WROOM-32
- Multiplexador I²C: TCA9548A
- ADC’s: ADS1115 para medições de tensão, corrente e sensores do motor
- Fonte: Step-down LM2596 (12V → 5V) + AMS1117 (5V → 3.3V)
- Isolação: Optoacoplador H11AA1 para detecção de cruzamento por zero na rede AC
- Drivers auxiliares: Transistores 2N2222 para chaveamento
- Interconexão: Header fêmea para encaixe de módulos já existentes
- Conexões externas: Bornes de 2P/3P para alimentação, relés e sensores

2. Layout de Conectividade
- Entradas: 12V DC em borne de 2 pinos (J1)
- Saídas: até 4 bornes de 3 pinos (J2…J5) para relés/sensores
- Headers fêmea: alinhados para encaixar módulos ESP32 e expansões
- Camadas: sugerido 2 layers para custo baixo, com plano de GND contínuo

3. Boas Práticas de Projeto

- Separar trilhas de alta corrente das trilhas de sinal (I²C, ADC).
- Deixar ilhas térmicas para reguladores.
- Incluir resistores pull-up em barramento I²C.
- Incluir LEDs indicadores (Power, Status Wi-Fi, Relés).
- Test-points para depuração de sinais críticos (Vcc 3.3V, I²C SDA/SCL, Reset).

4. Melhorias Futuras
- Suporte para expansão com conectores adicionais.
- Migrar para 4 camadas se houver ruído em medições analógicas.
- Inserção de fusível resetável (PTC) na entrada 12V.
- Inclusão de TVS diodes para proteção contra surtos.

Bill of Materials (BOM)

Part Number Supplier Supplier Part Unit Price USD Extended Price USD Description
ESP32-WROOM-32 LCSC C82899 $3.50 $3.50 WiFi+BT Microcontroller Module ht
TCA9548APWR LCSC C130026 $1.80 $1.80 I2C Multiplexer 1-to-8
ADS1115IDGSR LCSC C37593 $2.20 $2.20 16-bit ADC I2C
ADS1115IDGSR LCSC C37593 $2.20 $2.20 16-bit ADC I2C
ADS1115IDGSR LCSC C37593 $2.20 $2.20 16-bit ADC I2C
ADS1115IDGSR LCSC C37593 $2.20 $2.20 16-bit ADC I2C
 Part Number Supplier Supplier Part Unit Price USD Extended Price USD Description
INA219BIDR LCSC C57593 $1.50 $1.50 Current/Power Monitor I2C
H11AA1 LCSC C506919 $0.80 $0.80 Optocoupler AC Input
MAX485ESA+ LCSC C12075 $1.20 $1.20 RS485 Transceiver
AO3400A LCSC C20917 $0.15 $0.15 N-Channel MOSFET 30V 5.7A
HLK-5M05 LCSC C209900 $4.50 $4.50 AC-DC Converter 5V 1A
MKDS-1.5/2-5.08 LCSC C395880 $0.80 $0.80 Terminal Block 2 Position
MKDS-1.5/2-5.08 LCSC C395880 $0.80 $0.80 Terminal Block 2 Position
MKDS-1.5/2-5.08 LCSC C395880 $0.80 $0.80 Terminal Block 2 Position
MKDS-1.5/2-5.08 LCSC C395880 $0.80 $0.80 Terminal Block 2 Position
MKDS-1.5/2-5.08 LCSC C395880 $0.80 $0.80 Terminal Block 2 Position
MKDS-1.5/2-5.08 LCSC C395880 $0.80 $0.80 Terminal Block 2 Position
MKDS-1.5/2-5.08 LCSC C395880 $0.80 $0.80 Terminal Block 2 Position
Header_1x06_P2.54mm LCSC C124375 $0.10 $0.10 Pin Header Male 6 Position
P11A-MASA-B-A-EMU2 LCSC C86580 $0.50 $0.50 RJ45 Connector 8P8C
Header_1x06_P2.54mm LCSC C124375 $0.10 $0.10 Pin Header Male 6 Position
Header_1x04_P2.54mm LCSC C124374 $0.08 $0.08 Pin Header Male 4 Position
Header_1x04_P2.54mm LCSC C124374 $0.08 $0.08 Pin Header Male 4 Position
RC1206FR-07150KL LCSC C144481 $0.02 $0.04 Resistor 150kΩ ±1% 1/4W
RC0603FR-0747KL LCSC C25819 $0.01 $0.01 Resistor 47kΩ ±1% 1/10W
RC0603FR-071KL LCSC C21190 $0.01 $0.01 Resistor 1kΩ ±1% 1/10W
RC0603FR-074K7L LCSC C23162 $0.01 $0.02 Resistor 4.7kΩ ±1% 1/10W
RC0603FR-0710KL LCSC C25804 $0.01 $0.06 Resistor 10kΩ ±1% 1/10W
RC1206FR-07120RL LCSC C144177 $0.02 $0.02 Resistor 120Ω ±1% 1/4W
RC0603FR-07100RL LCSC C22775 $0.01 $0.01 Resistor 100Ω ±1% 1/10W
RC0603FR-07100KL LCSC C25803 $0.01 $0.01 Resistor 100kΩ ±1% 1/10W
RC0603FR-0751KL LCSC C23197 $0.01 $0.01 Resistor 51kΩ ±1% 1/10W
WSL25120L000FEA LCSC C163067 $0.50 $0.50 Shunt Resistor 0.1Ω ±1% 1W
M31CR71C106KA12L LCSC C13585 $0.05 $0.30 Capacitor 10µF 16V X7R
M188R71H104KA93D LCSC C14663 $0.01 $0.04 Capacitor 100nF 50V X7R
M31CR71C105KA88L LCSC C13551 $0.03 $0.06 Capacitor 1µF 50V X7R
EEU-FR1E101 LCSC C59339 $0.15 $0.15 Electrolytic 100µF 25V
EEU-FR1C101 LCSC C59338 $0.12 $0.12 Electrolytic 100µF 16V
SRN6045-220M LCSC C167317 $0.35 $0.35 Inductor 22µH 4A Shielded
BLM18PG121SN1D LCSC C1621 $0.02 $0.06 Ferrite Bead 120Ω@100MHz
SMBJ15A LCSC C347363 $0.25 $0.25 TVS 15V 600W
SMBJ5.0A LCSC C347359 $0.25 $0.25 TVS 5V 600W
SS54-E3/57T LCSC C204492 $0.15 $0.15 Schottky 5A 40V
 Part Number Supplier Supplier Part Unit Price USD Extended Price USD Description
SS34-E3/57T LCSC C204489 $0.12 $0.12 Schottky 3A 40V
APT1608MGC LCSC C72043 $0.03 $0.03 LED Verde 570nm
APT1608SYCK LCSC C72038 $0.03 $0.03 LED Amarelo 590nm
APT1608QBC/D LCSC C72041 $0.03 $0.03 LED Azul 465nm
APT1608SRCPRV LCSC C72037 $0.03 $0.03 LED Vermelho 640nm
V275LA20AP LCSC C7428 $0.80 $0.80 MOV 275V AC 20J
[Link] LCSC C182082 $0.12 $0.12 Fusível 2A 250V
[Link] LCSC C182081 $0.12 $0.12 Fusível 1A 32V
0466.500NR LCSC C182080 $0.12 $0.12 Fusível 500mA 32V
ABS07-32.768KHZ-T LCSC C32346 $0.25 $0.25 Crystal 32.768kHz
SW_PUSH_6mm LCSC C318884 $0.15 $0.15 Push Button Emergency
Buzzer_12mm LCSC C94599 $0.80 $0.80 Buzzer 5V 85dB
TestPoint_D2mm LCSC C238825 $0.05 $0.05 Test Point 2mm
TestPoint_D2mm LCSC C238825 $0.05 $0.05 Test Point 2mm
TestPoint_D2mm LCSC C238825 $0.05 $0.05 Test Point 2mm
TestPoint_D2mm LCSC C238825 $0.05 $0.05 Test Point 2mm
TestPoint_D2mm LCSC C238825 $0.05 $0.05 Test Point 2mm
TestPoint_D2mm LCSC C238825 $0.05 $0.05 Test Point 2mm
TestPoint_D2mm LCSC C238825 $0.05 $0.05 Test Point 2mm
TestPoint_D2mm LCSC C238825 $0.05 $0.05 Test Point 2mm
nan nan nan nan $35.45 nan
nan JLCPCB nan $8.00 $8.00 PCB FR4 1.6mm Green HASL
nan JLCPCB nan $15.00 $15.00 SMT Assembly Service
nan Manual nan $8.00 $8.00 Through-hole Assembly
nan Manual nan $5.00 $5.00 Complete Functional Test
nan Manual nan $3.00 $3.00 ESP32 Firmware Flash
nan Included nan $2.00 $2.00 Technical Documentation
nan nan nan nan $76.45 nan
nan nan nan nan $15.29 nan
nan nan nan nan $12.50 nan
nan nan nan nan $8.75 nan
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