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STD ESP32-based Precision Wattmeter

ESP32-based Precision Wattmeter

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License

CC BY-SA 3.0

License: CC BY-SA 3.0

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Update time: 2024-03-01 21:41:08
Creation time: 2023-09-23 01:13:51
Description

Description

I was looking for something to build with an ESP32 microcontroller and a little bit of analog electronics twist for fun. I came up with the idea to build a digital watt-meter, like one of those cheap RC hobby ones, but with three improvements - 1. High precision (and accuracy), 2. Datalogging, 3. WiFi connectivity so that multiple of these devices can talk together and calculate efficiency of power supplies.
That means if you hook up one of these at the input and the output of your DC-DC converter and have them connected to the same WiFi network, you will have live feed of efficiency and be able to log the data over time without any manual fiddling in spreadsheet softwares.

For precision measurement, I have chosen the ADS1256 24-bit op amp and paired it with B grade ADR4525 voltage reference. Voltage divider and current shunt resistors are low ppm as well (10 and 20ppm/C respectively). Right now I have a complete schematic and PCB design waiting for a education sponsorship from a PCB manufacturing company. I wish to share all the resources publicly and hopefully turn it into a community project where more people join in and help improve the design.

Design Drawing

Design Drawing

schematic diagram
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PCB
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ID Name Designator Footprint Quantity spiceSymbolName
1 TESTPAD 1,2,3,4,5,6,7 TESTPAD 7 TESTPAD
2 4000Hz BUZZER1 BUZ-SMD_L5.0-W5.5-P4.60 1 MLT-5020
3 100nF C1,C2,C3,C9,C14,C17,C19,C23 C0805 8 CC0805KRX7R9BB104
4 1uF C4,C5,C8,C12 C0805 4 CL21B105KBFNNNE
5 47uF C6,C15 C1206 2 CL31A476MPHNNNE
6 100uF C7 CAP-SMD_L6.0-W3.2-R-RD 1 CA45-C-10V-100μF-K
7 100nF C10,C20,C21,C22 C1206 4 GRM31C5C1H104JA01L
8 18pF C11,C13 C0603 2 CL10C180JB8NNNC
9 10uF C16,C18 CAP-SMD_L3.5-W2.8-R-RD 2 TC212B106M016B
10 XT60PW-M CN1 CONN-TH_XT60PW-M 1 XT60PW-M
11 XT60PW-F CN2 CONN-TH_XT60PW-M 1 XT60PW-M
12 9V In CN3 CONN-TH_XH-2AW_C2908611 1 XH-2AW_C2908611
13 SMF54CA_C353274 D1 SOD-123FL_L2.8-W1.8-LS3.7-BI 1 SMF54CA_C353274
14 MTF185-104SY1 H1 HDR-TH_4P-P2.54-V-F 1 MTF185-104SY1
15 NX3008NBKW Q1,Q3 SOT-323-3_L2.0-W1.3-P1.30-LS2.1-BR 2 NX3008NBKW,115
16 AOD2610E Q2 TO-252-2_L6.5-W6.1-P4.58-LS10.0-BR 1 AOD2610E
17 10kΩ R1,R4,R5,R17 R0805 4 0805W8F1002T5E
18 10kΩ R2,R6,R7,R8,R9 R0603 5 0603WAF1002T5E
19 270Ω R3,R10 R0603 2 0603WAF2700T5E
20 270Ω R11,R14,R15,R16,R22,R23 R0805 6 PTFR0805B270RN9
21 100kΩ 10ppm R12 R0805 1 PTFR0805B100KN9
22 100mΩ R13 R2512 1 VMS-R100-1.0-U
23 4.7kΩ 10ppm R19 R0805 1 PTFR0805B4K70N9
24 10mΩ R20,R21 R2512 2 VMS-R010-1.0-U
25 100Ω R24,R25,R26,R27 R0805 4 0805W8F1000T5E
26 470kΩ R28 R0805 1 0805W8F3303T5E
27 100kΩ R29 R0805 1 0805W8F1003T5E_C149504
28 47Ω R30 R0805 1 0805W8F470JT5E
29 Shorting SH1,SH2,SH3,SH4 SHORTING 4 Shorting
30 JUMPER-PAD-2 SJ1,SJ2 PAD-JUMPER-2 2 JUMPER-PAD-2
31 TS-1037-A4B3-D2 SW1,SW2,SW3 KEY-SMD_2P-L7.1-W7.1-P4.00-LS9.0 3 TS-1037-A4B3-D2
32 SK12D07VG4 SW4 SW-TH_SK12D07VG4 1 SK12D07VG4
33 OPA350UA U1 SOIC-8_L5.0-W4.0-P1.27-LS6.0-BL 1 OPA350UA
34 ADR4525BRZ-R7 U2 SOIC-8_L4.9-W3.9-P1.27-LS6.0-BL 1 ADR4525BRZ-R7
35 AD8628 U3 SOT-23-5_L3.0-W1.7-P0.95-LS2.8-BR 1 AD8628ARTZ-REEL7
36 AGND-DGND U4 AGND-DGND 1 AGND-DGND
37 XC6206P332MR_C347376 U5 SOT-23-3_L3.0-W1.7-P0.95-LS2.9-BR 1 XC6206P332MR_C347376
38 ESP32-S2-Mini U6 ESP32-S2-MINI 1 ESP32-S2-Mini
39 ADS1256IDBR U7 SSOP-28_L10.2-W5.3-P0.65-LS7.8-BL 1 ADS1256IDBR
40 CJ7805 3% U8 TO-252-2_L6.6-W6.1-P4.58-LS10.1-BR-CW 1 CJ7805 3%
41 7.68MHz X1 CRYSTAL:CRYSTAL_HC49-U_VERTICAL 1 S1T76800ZWJAC

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