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ESP32 Remote Schematic
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flux

Built the complete schematic foundation for the ESP-NOW Smart Paddle Remote:
  • Two separate, fully wired blocks: rechargeable remote and USB-powered gateway
  • 59 components and 46 nets
  • ESP32-C3-MINI-1 modules with native USB
  • MCP73831 500 mA LiPo charging
  • TPS63802 low-quiescent-current buck-boost for the remote
  • AP63203 2 A buck regulator for the gateway
  • USB-C, ESD protection, BOOT/RESET controls, paddle input, battery ADC, and status LEDs
  • ERC verification returned no unresolved warnings or errors
  • Calculated six-month requirement with margin is about 308 mAh; a 1000 mAh cell is projected to provide substantial margin at 15 presses/day, subject to prototype measurements
Project files:
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  • Confirm whether the firmware/bring-up files from the final executor run were created and review their contents.
  • Arrange the electrically correct but spatially scattered schematic symbols into two compact visual blocks.
  • Measure real sleep current, transmission energy, and latency on the prototype.
  • Split the design into physical remote and gateway boards, then proceed through placement, routing, and enclosure design.
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flux

The executor output cannot be inspected or reconciled further in this turn. Based on the completed work already reported, the project contains the wired remote and gateway schematic with clean ERC; remaining work includes confirming the firmware/bring-up documents, organizing the schematic visually, and proceeding to separate PCB layouts and enclosure design.
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Files

Schematic

Layout

3D View

Board Bring-Up Plan
Remote Board
  1. With no battery or USB, inspect for shorts between REM_USB_5V, REM_BAT, REM_3V3, and REM_GND.
  2. Connect a current-limited bench supply at J2: start at 3.7 V and 100 mA limit. Confirm REM_3V3 rises to approximately 3.3 V; then increase the limit for radio testing.
  3. Verify U3 power-good is high and check startup across 3.0–4.2 V battery input.
  4. Confirm reset behavior at EN and download mode using BOOT held low during reset.
  5. Program through native USB; if necessary use J3 UART/BOOT/EN.
  6. Confirm the status LED is off at reset and only lights under firmware control.
  7. Confirm paddle idle is high and press pulls GPIO3 low; verify wake from deep sleep.
  8. Measure REM_BAT_ADC against a DMM at several battery voltages and store calibration constants.
  9. Connect a protected LiPo, then USB-C. Confirm charge current direction, charger temperature, charge LED, and final 4.2 V regulation. Expect thermal current reduction when the cell is low; stop if the package/board temperature is abnormal.
  10. Measure deep-sleep battery current. Pass target: preferably below 30 µA assembled; investigate above 50 µA.
  11. Send repeated ESP-NOW events and verify acknowledgement and normal event latency below 300 ms.
Gateway Board
  1. Inspect GW_USB_5V/GW_3V3/GW_GND for shorts.
  2. Power from a current-limited 5 V source. Verify 3.3 V output and clean startup.
  3. Check AP63203 SW/BST only with an appropriate short-ground-spring oscilloscope probe; do not probe the switching node with a long ground lead.
  4. Verify RESET and BOOT controls, native USB programming, and UART header operation.
  5. Confirm continuous Wi-Fi operation and ESP-NOW reception while monitoring 3.3 V droop and regulator/inductor temperature.
  6. Exercise worst-case radio traffic for at least 30 minutes. Pass if the 3.3 V rail remains within the ESP32 module operating range and no component approaches its thermal limit.
  7. Verify Home Assistant event publication, duplicate suppression, and battery-state updates.
Separation Check
  • REM_* and GW_* rails are intentionally independent. Before assembly, confirm there is no PCB copper or connector pin that bridges the two devices.

  • Remote Board

  • Gateway Board

  • Separation Check