Week 1 - Hardware Assembly & Connections

🚀 Week 1 - Hardware Assembly & Connections

📅 Date: 2025-01-27 – 2025-02-02
🏷️ Tags: Year 2 Project, ESP32-S3, Smart Knob, Hardware Setup, Motor Wiring

🎯 This Week's Goals

  1. Familiarize with all hardware components used in the project.
  2. Assemble the Smart Knob hardware, including screen, motor, and control board.
  3. Connect the ESP32-S3 development board with the motor driver and screen driver.
  4. Verify basic hardware functionality, ensuring proper power and signal transmission

📌 Hardware Materials

This week, we begin assembling the SuperDial Smart Knob. Since we are using a pre-assembled ESP32-S3 development board, we do not need to solder the main control board, but we still need to properly connect the motor driver board, screen driver board, and complete the full hardware assembly.

 Hardware Components Overview 

🔹Additional Components

ComponentPurpose
MT6701 Magnetic EncoderReads the rotation angle and direction of the knob
EG2133 Motor Driver ChipControls the speed and direction of the brushless motor
WS2812 RGB LEDUsed for status indication with multi-color lighting effects
MT3608 DC-DC Boost Module  Converts 5V to 4.7V for stable power supply
AMS1117 3.3V Voltage ModuleConverts 5V to 3.3V to power ESP32-S3
3.3V/5V LCD screenDisplay for the smart knob

🔹 Main Components（Additional components have been integrated on three PCB boards）

ESP32-S3 Development Board




Motor Driver Board



Screen Driver Board

Motor



🔧 1️⃣ Hardware Assembly

🔹 Step 1: Screen Installation

📌 Screen Mounting

  1. Insert an M2.5×5 screw, ensuring center alignment.
  2. Align the hexagonal edges with the white guide lines, then secure the screen using copper pillars.

📌 Screen Connection

  1. Connect the 8P display cable, ensuring the correct orientation.
  2. Route the cable through the PCB slot, avoiding any stress or bending.
  3. Fix the screen with double-sided tape, ensuring stability.



🔹 Step 2: Motor Installation

📌 Motor Alignment

  1. Align the 3D-printed motor rotor component with the four motor holes.
  2. Insert and tighten M2×3 screws, but do not overtighten, as this may damage the motor coil.

📌 Motor Wiring

  1. Connect the 3P motor cable, ensuring proper polarity.
  2. Route and secure the motor cable to prevent interference.
  3. Place the motor driver board on the motor adapter, then secure it using M2×12 screws.


🔹 Step 3: Connecting the Main Control Board

📌 Screen Connection

  1. Use an 8P connector cable to connect the screen driver board & ESP32-S3.
  2. Ensure the cable is correctly aligned to avoid damaging the interface.

📌 Mounting the Main Control Board

  1. Insert M2×12 screws through the four mounting holes on the main control board.
  2. Place M2×6.6 anti-vibration rubber dampers onto the screws.
  3. Tighten until the dampers just make contact with the PCB, ensuring stability.


📌 Power Connection and Finished

  1. Solder a 2P power wire to connect the main board & motor driver board (Left = VCC, Right = GND).
  2. Use an 8P dual-head straight cable to connect the main board & motor driver board.
  3. ⚠️ Ensure correct polarity! If the cable is difficult to insert, it may be reversed.
  4. Finished picture

🔥 Troubleshooting & Debugging

IssueSolution
Screen flickering or not turning onCheck SPI connections and ensure proper backlight power
Motor not rotatingVerify PWM signal and motor driver power
Magnetic encoder giving incorrect dataEnsure stable I²C communication and check pull-up resistors

📌 Next Week's Plan

  1. Implement Bluetooth connection and HID basic control through ESP32-S3
  2. Debug motor control and try to use FOC to optimize the feel
  3. Design 3D printed housing to improve structural integrity

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