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Dummy Tux edited this page Dec 2, 2024 · 11 revisions

The STS equipment is to provide an IP based emergency stop system for entertainment show laser display systems. Module design as each setup is different and can be scaled up and down depending on requirements.

All equipment is being used in a live production environment subject to varying temperature ranges, humidity and vibrations. All designs should take this into account and provide backup and resilience to harsh environments in design.

The system is to be designated STS - SafeT System.

Notes for PCB Design and Fabrication

Property Value
Color Black
Silkscreen Color White
Silkscreen Text Board name, revision, and "Made in ..."
Extra processing Conformal coating
Mounting holes minimum 4 x M3 mounting holes, or more

PCBs to Design

Board Master Control STS E-Stop STS External Receiver etherCON Mod
Controller Raspberry CM5 ESP32 ESP32 N/A
Display 4.3inch touch 1.3inch N/A N/A
Connectivity 1Gb Ethernet 100M Ethernet 100M Eth 1Gb Ethernet
Programming interface USB Type-C USB Type-C USB Type-C N/A
Power supply PSU PoE PoE PoE

Master Control Board

  • Capacitive Display on front pannel via connector or direct mounting
  • Connect up other modules via MConnector, up to 6 modules
    • Connect to internal UPS to feedback voltages, battery percentage, etc.
    • Connect to power input module to read voltage and current draw
    • Connect to rackcase control module controlling LEDs, fans, etc.
  • Firmware update via USB Type-C or web server
  • Host a embedded webpage to display information remotely
  • Dual RJ45 port for network connections
  • Ability to chain the secondary control board

(component selection table is coming soon ...)

(block diagram is coming soon ...)

STS E-Stop Board

STS E-Stop is for remote input from user, to emergency stop system, push to start display information on TFT (or OLED) screen. Powered via PoE with optional DC input from local power supply.

  • Mechanical requirements
    • PTS (push-to-start) momentary button with RGB LED
    • Screw terminal block for DC power input
    • "I-conn" JST connector for internal connection for power, LED, and relay control
  • Functional requirements
    • State 1: E-stopped
      • Plunger LED is solid on
      • PTS Button is solid RED
      • Screen displays an icon and description, e.g. "#name E-Stop has #state" in RED color
    • State 2: Restart
      • Plunger LED pulsing on/off
      • PTS button pulsing ORANGE
      • Screen displays push-to-start info.
    • State 3: Active
      • Plunger LED is off
      • PTS button is solid GREEN
      • Screen displays an icon and description, e.g. "Laser system active", in GREEN color
   stateDiagram
   direction LR

   accTitle: This is the accessible title
   accDescr: This is an accessible description

   classDef S_stopped fill:red,color:white,font-style:italic
   classDef S_restart fill:orange,color:black,font-style:italic
   classDef S_active fill:green,color:white,font-weight:bold,stroke-width:2px,stroke:yellow

   [*]--> Stopped
   Stopped --> Restart
   Restart --> Active
   Active --> Stopped

   class Stopped S_stopped
   class Restart S_restart
   class Active S_active
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From the given requirement, the following architecture can be used.

Board STS External Receiver
Controller Espressif ESP32-S3 Microcontroller
Display Waveshare 1.68in LCD via SPI or Waveshare 1.3in LCD via SPI
Connectivity Wiznet W5500 10/100M Ethernet PHY controller
Programming interface USB Type-C
Power supply SDAPO DP9900(M) 9W PoE module 
flowchart LR
    rj45(((RJ45))) <--> magnet["RJ45 isolation
        Transformer"]
    magnet --> poe["DP9900M
        PoE module"]
    magnet <--(Ethernet)--> phy{"Wiznet W5500
    PHY interface"}

    usb((("USB
        Type-C"))) --> mcu{"Espressif ESP32-S3
        Microcontroller"}

    subgraph core[Digital circuit]
        phy <--(SPI)--> mcu
    end

    mcu --(SPI)--> display[["Waveshare
        1.3inch or 1.68inch
        LCD Module"]]
    poe --> mcu
    poe --> phy

    mcu --(GPIOI)--> iconn(((IConnector)))
    mcu --(GPIOI)--> mconn(((MConnector)))
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STS External Receiver Board

STS External Receiver is the external interface to provide emergency stop signal to lasers.

  • Mechanical requirements
    • metal housing like Neutrik NE8FF
    • 1 x Neutrik etherCON RJ45 connector
    • 1 x XLR 3P circular cable connector
  • Functional requirements
    • PoE
    • 10/100M Ethernet
    • 1 x NC relay
    • Electrical isolation between RJ45 and XLR connector, using optic or magnetic isolation

From the given requirement, the following architecture can be used.

Board STS External Receiver
Controller Espressif ESP32-S3 Microcontroller
Display N/A
Connectivity Wiznet W5500 10/100M Ethernet PHY controller
Programming interface USB Type-C
Power supply SDAPO DP9900(M) 9W PoE module 
flowchart LR
    rj45(((RJ45))) <--> magnet["RJ45 isolation
        Transformer"]
    magnet --> poe["DP9900M
        PoE module"]
    magnet <--(Ethernet)--> phy{"Wiznet W5500
    PHY interface"}

    usb((("USB
        Type-C"))) --> mcu{"Espressif ESP32-S3
        Microcontroller"}

    subgraph core[Digital circuit]
        phy <--(SPI)--> mcu
        mcu --(GPIO)--> relay[Relay]
    end

    relay --> xlr(((3p XLR)))
    poe --> mcu
    poe --> phy
    poe --> relay
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etherCON Mod PCB

(withdrawn due to 1Gb Ethernet switching by using relays)

Reference

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