SmartDB v2 — permanent compact project

The compact redesign is now the main v2 project in smart_db/. Open smart_db/smart_db.kicad_pro in KiCad 10. The former compact_wip/ folder has been moved here with its local libraries, editing scripts, review outputs and saved history.

Current revision

  • 95 × 78 mm four-layer PCB with an ESP32-S3-WROOM-1-N16R8 module.

  • Standard construction assumption: 1.6 mm FR-4, 1 oz outer / 0.5 oz inner copper.

  • AP63203 buck supply, ADC supply filter, decoupling and test points.

  • Accessible I²C and USB connectors, front/back pin labels and a SmartDB logo.

  • Two camera connections: J3 for the MLX90640 thermal module, and J6 USB-A for ESP32-CAM-MB power through a USB-A to micro-USB cable. J6 uses SMD contacts, is fused and locally decoupled, and has no data connection. The two-target firmware provides Wi-Fi JPEG capture and S3 thermal fusion. See the power budget.

  • Fully routed board, including the buck converter, ADC, relay, USB/UART and control signals; routing and trace-width review.

  • Preferred widths: 0.30 mm signals, 0.60 mm power, 0.75 mm 5 V/coil supply, and 1.00 mm load paths, with narrower local escapes where required.

  • Regulated 5 V logic input; provisional 5–24 V DC, up-to-1 A resistive relay test load.

Routing complete: 0 unconnected items. Engineering review remains before fabrication. KiCad 10.0.6 reports 0 ERC violations, 0 DRC violations and 0 schematic/PCB mismatches. See the project notes for the remaining hardware and stackup validation.

Firmware and setup

Open esp_idf/smartdb_fusion in VS Code and run SmartDB: Setup, or launch ./setup.sh from that directory. Set up the separate esp32cam board first, then the smartdb_s3 main board. The menu handles firmware installation, Wi-Fi, camera address, protection limits and status. Connection settings persist on each board without subsequent reflashing.

Use J4 USB-C for main-board programming and connect the camera base directly to the computer for camera programming. J6 is camera power only. The selected SCT-013 firmware monitors isolated low-voltage AC; the logic supply remains DC, and the earlier provisional DC relay load target is not a verified AC contact rating. Firmware builds/host tests pass; physical sensor, relay, power and camera-alignment validation remain pending.

Files and previews

Download the complete current v2 CAD package. It includes the PCB, schematic, project-local libraries and 3D models, pin map, review PDFs and validation record. Documentation builds verify every recorded source hash before packaging; editor lock files, user preferences and historical work directories are excluded. The bundle is generated by docs/build.sh or docs/prepare_vercel.py.

Current routed v2 front view

Current connector and 3D preview

File

Purpose

Schematic

Editable schematic

PCB

Editable, fully routed compact board

STEP assembly

Current 3D preview; approximate connector models are not enclosure-fit references

Copper PDF

All four copper layers

Schematic PDF

Current schematic export

Placement PDF / PNG

Front assembly and logo preview

Bottom labels PDF

Connector pin labels

Pin map

MCU signals and power connections

Validation record

Source hashes and checks

Keep SmartDB.kicad_sym, SmartDB.pretty/, sym-lib-table and fp-lib-table and SmartDB.3dshapes/ beside the project. The library paths are project-relative. The USB 3D model is an approximate visualization, not an enclosure-fit model.

Previous revision

The previous routed bench board, its schematic PDF, STEP export, review reports, project history and documentation are preserved in archive/bench_before_compact_2026-10-08/. Its routing and validation results apply only to that archived board.

The current system requirements remain in the architecture.