Table
| Process Step | Potential Failure Mode | Potential Failure Effect | Severity (S) | Occurrence (O) | Detectability (D) | Risk Priority Number (RPN) | Action Recommended |
|---|---|---|---|---|---|---|---|
| Power Supply (+5V, +3V3) | Voltage regulator failure | System power loss | 9 | 6 | 4 | 216 | Use voltage regulators with overcurrent and thermal protection |
| ESP32-CAM | Communication failure | Loss of image/data transmission | 8 | 5 | 3 | 120 | Implement robust error-handling and retry logic |
| HC-SR501 | False trigger or no detection | Erratic camera activation | 7 | 4 | 3 | 84 | Calibrate PIR sensor; add filtering in software |
| Transistor Q1 (S8050) | Short circuit or open circuit | Inability to control current | 7 | 4 | 4 | 112 | Add current limiting resistors; consider a different transistor |
| Resistor R3 (1k) | Increased resistance | Reduced current flow | 5 | 3 | 5 | 75 | Use precision resistors with low temperature coefficients |
| Resistor R4 (10k) | Decreased resistance | Excessive current flow | 6 | 3 | 5 | 90 | Inspect and select quality-controlled resistors |
| Connector J1/J2 | Poor connection | Intermittent functionality | 8 | 4 | 4 | 128 | Ensure proper connector assembly and use locking connectors |
| Net Connections | Signal loss or noise | Degraded performance | 7 | 3 | 3 | 63 | Use shielding and maintain good routing practices |
Table
| Step | Description | Expected Result |
|---|---|---|
| 1 | Power Supply Verification | Ensure the module is supplied with 5V and 3.3V power as required. |
| 2 | Check Connections | Verify connections for GND (common ground) and VCC to avoid any loose or incorrect connections. |
| 3 | Flash Test Firmware | Flash a test firmware using an appropriate IDE (Arduino IDE or ESP-IDF) and USB-TTL converter. |
| 4 | Open Serial Monitor | Open the serial monitor to check and confirm the module's boot log and any debug messages. |
| 5 | Configure WiFi Settings | In the test firmware, configure and input the SSID and password for your Wi-Fi network. |
| 6 | Upload Code | Upload the code and check for any upload errors. The module should boot up with the firmware. |
| 7 | Scan for WiFi Access Points | Allow the module to scan and print available WiFi access points to verify WiFi functionality. |
| 8 | Connect to WiFi Network | Connect the ESP32-CAM to the preset WiFi network and check for successful connection via serial monitor. |
| 9 | Ping Test | Ping an external server (such as google.com) to verify connectivity and response time. |
| 10 | Capture Camera Feed | Access camera feed using the IP address shown in the serial monitor in a web browser. It should display a video stream. |
| 11 | Verify Camera Quality | Observe the camera feed and verify the image quality and resolution settings. |
| 12 | Validate Additional Pin Functions | Test additional GPIO pins using simple LED blink or I/O operations to ensure they function correctly. |
| 13 | Test Reset Functionality | Press the reset button on the module and observe the reboot sequence for any errors or issues. |
| 14 | Check for Heat and Stability | Observe the module for any overheating or stability issues during extended use. |
WiFi Camera with Motion Detection Reference Design
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