ESP32 Wearable Vibration Alert PCB Design
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Found 3 results for Find a through-hole 4 pin connector header or module connector with pins suitable for wiring an external MT3608 boost module: VIN+ VIN- VOUT+ VOUT-. Beginner friendly 2.54mm pitch header or terminal block..
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The MT3608 part I found includes its own detailed converter PCB geometry, which is creating manufacturing-rule conflicts inside the layout. For a beginner build like your protoboard, the better PCB approach is to use a 4-position through-hole connector labeled for the external MT3608 module: IN+, IN-, OUT+, OUT-. I’m switching to that cleaner, solder-friendly footprint now.
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Read layout.
Read schematic.
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Board check: 1 issue(s) found
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Auto-routing your board.
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Completed 5 design checks — found 19 issues.
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Routing complete!
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Completed 5 design checks — found 8 issues.
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Yes, it changes the PCB. I updated the design to use an external MT3608 boost module connection instead of the previous Adafruit boost module.
What changed:
- Replaced the boost converter section with J2, a 4-pin through-hole terminal block for the MT3608.
- J2 wiring is:
- Pin 1: MT3608 IN+ -> switched protected LiPo battery rail
- Pin 2: MT3608 IN- -> GND
- Pin 3: MT3608 OUT+ -> 5V rail to ESP32 and relay
- Pin 4: MT3608 OUT- -> GND
- Re-placed J2 on the PCB for easy wiring.
- Re-routed the PCB.
- Final check shows no airwire, dangling-trace, overlapping-copper, missing-footprint, or invalid-layer issues.
I did not add the 220 ohm resistor because the MT3608 itself does not need a 220 ohm resistor for power conversion. If that resistor was only for the LED, it is no longer needed because the LED was removed. If you used the 220 ohm resistor somewhere else on your protoboard, tell me where it was connected and I’ll match it exactly.
LED series resistor
Relay input resistor
Add MT3608 test points
Run ERC/DRC
Add pinout labels
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Project Specification — ESP32 Wearable Vibration Alert
Project Overview
- Status: Draft
- Compact wearable prototype for construction worker safety monitoring.
- ESP32 DevKit controls a relay module, and the relay directly switches a 3V coin vibration motor.
- No MOSFET or transistor motor driver is used for the motor path.
Intended Use
- University engineering prototype for worker alerting in construction environments.
- Battery-powered wearable PCB with simple solderable connections and clear labels.
What the Device Should Do
- Power an ESP32 DevKit from a Li-Po battery through a charger/protection and regulator/boost stage.
- Drive a relay input from one ESP32 GPIO.
- Relay contacts switch battery/motor power to the vibration motor.
- Provide a status LED and optional push button.
Main Features
- ESP32-WROOM-32 DevKit controller.
- Li-Po battery input via JST connector.
- TP4056 charger/protection module connection.
- Relay-module motor switching.
- 3V coin vibration motor output.
- Power switch, status LED, optional push button.
- Beginner-friendly through-hole headers/connectors where possible.
System Architecture
Diagram
Hardware Subsystems
- Power: Li-Po battery, TP4056 protection/charger module, power switch, boost/regulator rail sized for ESP32 peak current and relay coil/module current.
- Compute: ESP32 DevKit with ESP32-WROOM-32 module.
- Actuation: Relay module input controlled by ESP32 GPIO; relay contacts directly switch vibration motor power.
- User interface: Status LED and optional push button.
- Mechanical: Rounded compact wearable PCB, mounting holes, silk labels.
Interfaces and Connections
- JST battery connector: BAT+ and BAT-.
- TP4056 module header: B+/B-, OUT+/OUT- or protected battery output depending on module pinout.
- ESP32 DevKit: VIN/5V, GND, GPIO relay control, GPIO LED, GPIO button.
- Relay module: VCC, GND, IN, COM, NO, NC.
- Motor connector: MOTOR+ and MOTOR-.
Power and Runtime Expectations
- Battery nominal voltage: 3.7V Li-Po, minimum assumed about 3.0V, full charge 4.2V.
- ESP32 WiFi peak current can be high; regulator/boost should support at least 700mA output margin.
- Relay module adds coil/input current; selected module must be compatible with ESP32 GPIO logic.
- Motor current path should use wider traces than logic signals.
Power Tree and Power Budget
Table
| Rail | Load | Typical | Peak/Design |
|---|---|---|---|
| 5V/VIN | ESP32 DevKit | 150-250mA | 500mA WiFi bursts |
| 5V or 3.3V | Relay module | 30-80mA typical module-dependent | 100mA design allowance |
| Battery switched | 3V coin vibration motor | 60-100mA | 150mA startup allowance |
| 3.3V GPIO | LED/button logic | <10mA | 10mA |
Design allowance: boost/regulator output should support at least 600mA continuous and 700mA+ transient for ESP32 plus relay. Motor trace should be sized for at least 250mA for margin.
Manufacturing and Assembly Expectations
- Prototype-focused PCB, not production safety-certified hardware.
- Through-hole headers/connectors preferred for beginner soldering.
- Modules may be mounted on female headers for replacement.
- Ground plane required.
Firmware-Relevant Hardware Requirements
- Relay control GPIO drives the relay input.
- Status LED GPIO indicates alert/power state.
- Optional button GPIO may trigger test vibration.
- Firmware must avoid GPIO6-GPIO11 on ESP32-WROOM-32.
Physical Design Expectations
- Compact wearable PCB with rounded corners.
- ESP32 antenna should face a board edge with copper keepout.
- Mounting holes in corners.
- Clear silkscreen labels for battery, TP4056, relay, motor, switch, GPIOs, and polarity.
Important Design Decisions
- User explicitly requires relay-module direct motor switching and forbids MOSFET/transistor motor driver.
- Use module-based TP4056 and relay to simplify beginner assembly.
- Use common ground across ESP32, relay, charger/protection, and motor battery return.
Assumptions
- The relay module input is opto/transistor-buffered on the module and GPIO-compatible; otherwise a bare relay coil cannot be driven directly by ESP32.
- The TP4056 board includes battery protection, as requested.
- The motor is a small 3V coin vibration motor with current below 150mA startup.
- Exact enclosure dimensions are not specified; board will be compact but sized for beginner soldering.
Change Notes
- Initial specification created from user requirements.
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