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PowerRGB/README.md

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WiFi-Controlled RGB Power Lamp

This repository documents the design and implementation of a WiFi-controlled RGB lamp using discrete power electronics and embedded systems. The lamp is based on 3× 5W LEDs (RGB), driven by LM3404 constant-current drivers, monitored by INA226 current sensors, and controlled by an ESP8266 microcontroller via a custom web interface.

Overview

  • Microcontroller: ESP8266 (ESP-12E)
  • LED Drivers: LM3404, one per color channel
  • Current Sensors: INA226 (I²C), one per channel
  • Power Supply: 24V DC input, regulated to 5V and 3.3V
  • User Interface: Web application hosted on ESP8266 for RGB control and power monitoring

System Architecture

Block Diagram:

Block Diagram

Web Interface

  • RGB control using Vue-based color picker
  • Adjustable brightness slider (mapped to PWM)
  • Real-time current monitoring (INA226)
  • Basic animation mode (rainbow sequence)

Web UI Screenshot:

Web UI

PCB Design

  • 2-layer FR4 PCB with thermal copper pours and via stitching
  • Test points for PWM, switch nodes, and sense lines
  • FFC interface for external programmer
  • Custom CH340C programming board (USB → UART)

gerber View:

PCB gerber

3D Render:

3D PCB Render

3D Render:

PCB

Testing and Analysis

Thermal Imaging

  • Thermal images captured using Fluke thermal camera
  • Red LED remains coolest; green and blue require better cooling
  • Thermal deviation from calculated values due to PCB/slug bonding

Thermal Measurement Example:

Thermal Image

Oscilloscope Measurements

  • Switching ripple observed and confirmed within expected range
  • DCM ringing noted at switch nodes; no impact on operation

Known Issues & Improvements

  • DIM Pin Fix: Initial circuit caused full brightness during MCU boot. Fixed with pulldown resistor.
  • I²C Line Reversal: SDA/SCL reversed in layout; resolved via software GPIO reassignment.
  • Thermal Solution: Future revisions should consider external heatsink or aluminum-core PCB.

Full Report

All design calculations, schematics, measurements, and references are available in the final report:

📄 Project_RubenSchoonbaert.pdf