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# SuperSensor v2.x # SuperSensor v2.x
**NOTICE**: The Supersensor v2.x is still under development! Parts and configurations
may change until the design is finalized.
The SuperSensor is an all-in-one voice, motion, presence, temperature/humidity/air The SuperSensor is an all-in-one voice, motion, presence, temperature/humidity/air
quality, and light sensor, built on an ESP32 with ESPHome, and inspired quality, and light sensor, built on an ESP32 with ESPHome, and inspired
heavily by the EverythingSmartHome Everything Presence One sensor and the heavily by the EverythingSmartHome Everything Presence One sensor and the
@@ -13,8 +10,8 @@ interfaces with wake word detection, as well as other sensor detection options
as you want them. as you want them.
Assist feedback is provided by a pair of common-cathode RGB LED. No speakers Assist feedback is provided by a pair of common-cathode RGB LED. No speakers
or annoying TTS feedback here! With an optional 3D Printed case and a clear or annoying TTS feedback here! With [an optional 3D Printed case and a clear
diffuser cover, the LEDs can be turned into a sleek light bar on the bottom diffuser cover](/case), the LEDs can be turned into a sleek light bar on the bottom
of the unit for quick and easy confirmation of voice actions, or just use of the unit for quick and easy confirmation of voice actions, or just use
it bare if you like the "PCB on a wall" aesthetic. it bare if you like the "PCB on a wall" aesthetic.
@@ -46,12 +43,12 @@ and [my update post on version 2.0](https://www.boniface.me/posts/the-supersenso
2. Replaced the SR602 PIR sensor with the AM312 PIR sensor. 2. Replaced the SR602 PIR sensor with the AM312 PIR sensor.
The SR602 was, in my experience, prone to constant false misfirings even in completely empty rooms. In addition its orientation requirements The SR602 was, in my experience, prone to constant false misfirings and hard to enclose due to its shape. In addition its orientation is
are awkward (pins on the left or right side). While it's possible I just had a bad batch, this soured me significantly to these sensors, awkward (pins on the left or right side) which made building around it difficult. Thus, this sensor has been replaced with the nicer,
especially after reading many other similar reports around the internet. more straight AM312 PIR design. This does add vertical height to the sensor but I consider this a good tradeoff, and think it looks neat.
Thus, this sensor has been replaced with the more reliable AM312. While the form factor fo the AM312 leaves a bit to be desired (sticking Note that like all cheap PIRs, the AM312 is prone to misfiring if exposed. For this reason, [the case](/case) is recommended for any serious
up by about 1cm more from the board), and in the end this sensor misfires just as much as the SR602, I've committed to the change. PIR use-cases.
3. Completely redesigned the custom PCB around the above sensor changes, which is now more compact in a 50x55mm almost-square configuration. 3. Completely redesigned the custom PCB around the above sensor changes, which is now more compact in a 50x55mm almost-square configuration.
@@ -63,7 +60,7 @@ and [my update post on version 2.0](https://www.boniface.me/posts/the-supersenso
|-------|--------------------|----------------------------------|-------| |-------|--------------------|----------------------------------|-------|
| 1 | GY-SGP41 | $11.08 | [AliExpress](https://www.aliexpress.com/item/1005006746827606.html) | | 1 | GY-SGP41 | $11.08 | [AliExpress](https://www.aliexpress.com/item/1005006746827606.html) |
| 1 | GY-SHT45 | $5.67 | [AliExpress](https://www.aliexpress.com/item/1005008175340220.html)* | | 1 | GY-SHT45 | $5.67 | [AliExpress](https://www.aliexpress.com/item/1005008175340220.html)* |
| 1 | SR602 | $0.81 | [AliExpress](https://www.aliexpress.com/item/1005001572550300.html) | | 1 | AM312 | $0.81 | [AliExpress](https://www.aliexpress.com/item/1005001572550300.html) |
| 1 | TSL2591 | $4.59 | [AliExpress](https://www.aliexpress.com/item/1005008619462097.html) | | 1 | TSL2591 | $4.59 | [AliExpress](https://www.aliexpress.com/item/1005008619462097.html) |
| 1 | HL-LD2510C | $4.79 | [AliExpress](https://www.aliexpress.com/item/1005006000579211.html)* | | 1 | HL-LD2510C | $4.79 | [AliExpress](https://www.aliexpress.com/item/1005006000579211.html)* |
| 1 | INMP441 | $2.93 | [AliExpress](https://www.aliexpress.com/item/1005002902615623.html) | | 1 | INMP441 | $2.93 | [AliExpress](https://www.aliexpress.com/item/1005002902615623.html) |
@@ -80,17 +77,14 @@ and [my update post on version 2.0](https://www.boniface.me/posts/the-supersenso
### To Solder or Not To Solder ### To Solder or Not To Solder
Personally, for my Supersensor 1.x's and the initial batch of Supersensor 2.x's, I directly soldered I strongly encourage anyone building one of these units to leverage sockets for all components. First,
all the non-ESP components to the board. This proved to be a major mistake when I later decided this provides good spacing between components which can help with general better performance. It can
to switch from SGP30's to SGP41's after some testing and I had to desolder all of them, ruining also allow for quick swapping if any turn out to be defective or if future changes are warranted.
several PCBs in the process. It was also a hassle to desolder the existing sensors for reuse
during the 1.x to 2.x conversion.
As a result, I actually strongly encourage anyone building one of these units to leverage sockets **If you use the [case](/case), it is sized assuming socketed components!** So for case users you
for all components, to allow for quick swapping if any turn out to be defective or if future changes must socket all components.
are warranted.
Note that due to the PCB design, you *must* socket at least one set of components - either the ESP32 Note that due to the PCB design, you *must socket at least one* set of components - either the ESP32
or the sensors on the front. Due to the positioning and overlap, it would be impossible to solder or the sensors on the front. Due to the positioning and overlap, it would be impossible to solder
everything directly to the board, as the ESP covers several of the solder points of the front everything directly to the board, as the ESP covers several of the solder points of the front
sensors and vice versa. sensors and vice versa.
@@ -285,6 +279,7 @@ for VOCs via AirGradient.
Note however that like all MOx sensors, the SGP41 does not differentiate gasses, and as Note however that like all MOx sensors, the SGP41 does not differentiate gasses, and as
such cannot tell the difference between normal, everyday natural VOCs like those in such cannot tell the difference between normal, everyday natural VOCs like those in
breath or from e.g. ripening fruit, and dangerous VOCs from e.g. construction materials. breath or from e.g. ripening fruit, and dangerous VOCs from e.g. construction materials.
It also reacts strongly to heavy humidity, resulting in higher values in such environments.
These should be used only as a general indication of air quality over short periods, rather These should be used only as a general indication of air quality over short periods, rather
than an absolute reference over long periods (much to my own frustration but inevitable than an absolute reference over long periods (much to my own frustration but inevitable
begruding acceptance). begruding acceptance).

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case/README.md Normal file
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# SuperSensor 2.x Case
This is a 3D-printable case for the SuperSensor 2.x all-in-one voice, motion,
presence, temperature/humidity/air quality, and light sensor.
This case provides a convenient way to cover up the SuperSensor's PCB, either
for aesthetics or to help protect it from harsh environments.
You can [tinker the design on TinkerCAD here](https://www.tinkercad.com/things/1HT3fyNbln0-supersensor-case).
## Printing
Provided here are 5 `.obj` CAD files designed for slicing and printing with
any slicer software and 3D printer.
### `body.obj`
This is the main body of the case which houses the PCB. It includes an opening
for the insertion of a USB-C cable of "normal" size, which should fit most cables.
This part should be printed in a solid, durable material of any colour you wish.
### `face.obj`
This is the front face of the case. It clips into the body with 4 triangular
grip clips, and has 5 openings:
* A large rectangle for the insert below.
* A large circle for the PIR and am312 extension tube below.
* A small flush hole for the TSL2591 light sensor.
* A small funneled hole for the SGP41 air quality sensor.
* A small funneled hole for the SHT45 temperature/humidity sensor.
**NOTE**: This design can affect the baseline readings of these sensors!
Specifically, the TSL will report much lower ambient light levels (up to 30 lux)
unless light is directly facing it; and the SHT45 will hover about 6 degrees
higher than the exposed PCB would from my testing. Take these into account in
your usage!
This part should be printed in a solid, durable material of any colour you wish.
### `insert.obj`
This insert fits into the large rectangle in the face, and provides a diffuser
for the feedback/status LEDs, including an opening for the INA microphone. It
is inserted into the face separately during assembly, though a multi-material
printer could concievably print it into the face during printing.
This part should be printed in a solid, durable material in **a natural or transluscent** colour (it must let light through).
### `am312-tube.obj`
This round tube provides additional buffering for the AM312 over the face, extending
it by 8mm to completely cover the AM312 body. It attaches to the face over the large
circular hol separately during assembly.
This part should be printed in a solid, durable material in any colour you wish.
### `usb-extension.obj` (optional)
This square tube provides additional coverage of the USB cable opening for situations
where that may be needed, either for "weatherproofing", cable management, or mounting.
It attaches over the opening in the body and should fit most cables. Note that USB
insertion may be harder with this on so consider that carefully during cable selection;
a long boot cable is a plus here.
This part should be printed in a solid, durable material in any colour you wish.
## Assembly
To begin, print the parts above as indicated; default slicer settings should be sufficient.
We will exclude the USB cable opening extension for this assembly, but its installation
is straightforward.
1. Lay out the parts; you will need:
* The body, face, insert, and AM312 tube parts.
* Superglue
* A toothpick (if not using a precision superglue applicator)
* A hard, flat surface (I use a vice)
![Parts](.images/parts.jpg)
2. Place the face face-down (clips up), and place dabs of superglue at the corners of the
insert openings.
![Face Assembly 1](.images/face-assembly-1.jpg)
3. Spread the superglue along the inner edges with the toothpick; or, combine 2+3 by using
a precision superglue applicator. You need very little glue here; avoid extra ooze!
![Face Assembly 2](.images/face-assembly-2.jpg)
4. Firmly place the insert face-down into the hole; the overlap edges should match.
![Face Assembly 3](.images/face-assembly-3.jpg)
5. Apply firm pressure to both sides of the insert with your thumbs, a vice, or another
pressing object, until the glue can set up (15-30 seconds).
![Face Assembly 4](.images/face-assembly-4.jpg)
6. Flip over the face; the insert should now be solidly affixed. Clean up any oozing superglue
with a paper towel or lint-free rag.
![Face Assembly 5](.images/face-assembly-5.jpg)
7. Place a small amount of superglue on your toothpick tip; if using a precision superglue
applicator, skip this step.
![Face Assembly 6](.images/face-assembly-6.jpg)
8. Gently spread the superglue around the circular opening (or apply using a precision superglue
applicator); you want the bead to be no more than 1mm wide to avoid ooze.
![Face Assembly 7](.images/face-assembly-7.jpg)
9. Line up the AM312 tube, and firmly press it down to seal. Clean up any oozing superglue
with a paper towel or lint-free rag.
![Assmbly 8](.images/face-assembly-8.jpg)
You will now have a completed face assembly and are ready to install the actual SuperSensor.
![Completed Face](.images/completed-face.jpg)
10. Gently insert the SuperSensor board into the case body, lining it up with the four standoffs.
Gently press down until the ESP32 is firmly sitting on the bottom (it should require no force).
![Body Assembly 1](.images/body-assembly-1.jpg)
You can verify that the USB plug is sitting flush on the base.
![Body Assembly 2](.images/body-assembly-2.jpg)
11. Remove the top cap of the AM312.
12. Place the face over the AM312.
![Body Assembly 3](.images/body-assembly-3.jpg)
13. Line up the clips on one side (I prefer the left). Then using a gentle squeezing motion, apply
pressur eto the sides of the case on the right side while also applying lateral pressure on
the face towards the inserted clips. This picture is a one-handed demonstration, applying a
squeezing pressure between my thumb and middle finger and a downwards pressure with my index
finger to provide force; using two hands is advised.
![Body Assembly 4](.images/body-assembly-4.jpg)
14. While doing the previous step, ensure that the 3 sensor holes are lined up with their corresponding sensors.
![Body Assembly 5](.images/body-assembly-5.jpg)
15. Press the face into the body so that all 4 clips are making contact.
![Body Assembly 6](.images/body-assembly-6.jpg)
16. Reinstall the top cap of the AM312; it should have a snug fit against the tube.
You now have an assembled case!
![Completed Case](.images/completed-case.jpg)
As a further step, consider placing a line of tape around the face-body joint. The locking clip
design was made with printing in mind, and does have some play here.

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f 46 38 37
f 155 149 181
f 181 173 155
f 175 91 118
f 91 67 84
f 91 84 99
f 151 154 148
f 151 148 145
f 131 126 122
f 131 122 132
f 190 191 137
f 178 182 156
f 183 181 142
f 149 142 181
f 99 84 96
f 99 96 108
f 169 49 164
f 120 118 91
f 118 49 175
f 65 164 49
f 157 160 154
f 157 154 151
f 75 69 33
f 33 24 75
f 69 60 1
f 60 55 1
f 55 42 2
f 11 8 42
f 42 39 11
f 18 11 39
f 108 96 27
f 108 27 26
f 126 119 116
f 126 116 122
f 124 28 53
f 81 74 160
f 81 160 157
f 53 105 124
f 128 124 105
f 116 119 111
f 112 111 119
f 138 144 63
f 144 148 63
f 63 187 138
f 137 138 187
f 187 190 137
f 150 182 143
f 134 128 105
f 52 31 145
f 62 52 145
f 62 139 133
f 142 192 185
f 185 183 142
f 185 192 135
f 188 135 192
f 94 147 88
f 100 136 94
f 106 136 100
f 88 147 83
f 83 153 159
f 162 73 159
f 65 73 164
f 162 164 73
f 73 78 159
f 83 159 78
f 45 29 167
f 45 167 172
f 105 98 134
f 98 92 134
f 140 134 92
f 127 109 166
f 121 127 166
f 166 171 121
f 177 121 171
f 180 107 177
f 123 117 176
f 176 170 123
f 170 165 123
f 129 123 165
f 4 129 165
f 4 165 66
f 172 167 173
f 172 173 178
f 62 133 189
f 189 135 188
f 114 58 109
f 59 166 109
f 161 72 163
f 143 186 191
f 186 137 191
f 111 112 32
f 31 32 112
f 38 57 10
f 57 58 10
f 178 173 181
f 178 181 182
f 51 79 156
f 168 163 47
f 174 168 47
f 47 102 174
f 67 174 102
f 51 48 80
f 51 80 79
f 182 181 183
f 182 183 184
f 48 17 21
f 48 21 80
f 64 47 163
f 158 72 161
f 87 82 146
f 146 140 92
f 92 87 146
f 152 146 82
f 158 152 82
f 82 76 158
f 72 158 76
f 64 163 72
f 184 183 185
f 184 185 186
f 186 185 135
f 186 135 137
f 190 188 192
f 190 192 191
f 63 62 187
f 189 187 62
f 188 190 187
f 188 187 189
# 384 faces
#end of obj_0

2953
case/body.obj Normal file

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1133
case/face.obj Normal file

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361
case/insert.obj Normal file
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@@ -0,0 +1,361 @@
# Object Export From Tinkercad Server 2015
mtllib obj.mtl
o obj_0
v 35.425 -3.7 0.32
v 35.425 -3.7 0
v 35.425 -14.1 0
v 35.425 -14.1 0.32
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v 62.0396 -10.3146 1.32
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v 84.625 -4.9 1.32
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v 60.7711 -10.0114 0
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v 60.915 -9.9828 0
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v 62.5571 -8.3825 1.32
v 59.7354 -8.2175 0
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v 59.5422 -9.19 0
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v 59.5892 -9.3289 0
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v 59.8322 -9.6928 0
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v 62.0396 -7.4854 1.32
v 61.3075 -8.0104 0
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v 61.0539 -7.8642 0
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v 60.915 -7.8172 0
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v 60.625 -7.7791 0
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v 60.335 -7.8172 0
v 60.8857 -6.917 1.32
v 60.625 -6.9 1.32
v 60.3643 -6.917 1.32
v 60.1075 -6.9679 1.32
v 59.8598 -7.0518 1.32
v 59.625 -7.1677 1.32
v 59.4072 -7.3126 1.32
v 62.628 -4.9 1.32
v 59.2104 -7.4854 1.32
v 59.0376 -7.6822 1.32
v 58.8927 -7.9 1.32
v 58.7768 -8.1348 1.32
v 60.8857 -10.883 1.32
v 60.625 -10.901 1.32
v 58.6929 -8.3825 1.32
v 58.642 -8.6393 1.32
v 58.625 -8.9 1.32
v 58.642 -9.1607 1.32
v 58.6929 -9.4175 1.32
v 58.7768 -9.6652 1.32
v 58.8927 -9.9 1.32
v 59.0376 -10.1178 1.32
v 59.2104 -10.3146 1.32
v 59.4072 -10.4874 1.32
v 59.625 -10.6323 1.32
v 59.8598 -10.7482 1.32
v 60.1075 -10.8321 1.32
v 60.3643 -10.883 1.32
v 61.1425 -10.8321 1.32
v 61.3902 -10.7482 1.32
v 61.625 -10.6323 1.32
# 115 vertices
g group_0_15277357
usemtl color_15277357
s 0
f 1 2 3
f 1 3 4
f 4 8 1
f 8 10 1
f 6 3 5
f 37 3 17
f 70 3 68
f 14 10 8
f 14 8 20
f 21 22 23
f 21 23 25
f 112 19 17
f 21 25 27
f 26 27 25
f 19 112 24
f 9 2 7
f 11 2 9
f 32 26 31
f 32 27 26
f 34 30 32
f 30 29 32
f 71 23 66
f 73 28 71
f 23 71 28
f 22 55 23
f 52 50 34
f 33 34 32
f 46 22 37
f 3 37 22
f 34 33 52
f 53 52 33
f 28 15 2
f 6 17 3
f 24 37 19
f 35 37 24
f 39 37 35
f 17 19 37
f 2 56 3
f 21 4 3
f 21 3 22
f 25 28 1
f 53 33 55
f 36 55 33
f 28 25 23
f 42 37 40
f 28 2 1
f 39 41 37
f 55 36 38
f 43 37 42
f 41 40 37
f 45 2 11
f 97 35 24
f 22 46 47
f 49 2 48
f 48 2 45
f 50 22 47
f 51 2 49
f 52 22 50
f 39 113 41
f 53 22 52
f 54 2 51
f 55 22 53
f 114 115 41
f 56 2 54
f 57 23 55
f 37 43 46
f 59 23 57
f 62 23 59
f 64 3 61
f 65 23 62
f 65 62 63
f 66 23 65
f 67 3 64
f 61 3 58
f 69 66 63
f 12 3 70
f 58 3 56
f 5 3 12
f 68 3 67
f 36 31 38
f 101 56 54
f 78 28 76
f 76 28 74
f 101 58 56
f 38 31 44
f 79 28 78
f 81 28 79
f 58 102 61
f 82 28 81
f 73 74 28
f 84 28 82
f 61 103 64
f 15 28 84
f 63 60 31
f 114 41 113
f 7 2 15
f 81 79 86
f 67 105 68
f 87 82 86
f 107 70 68
f 107 68 106
f 40 115 42
f 70 107 12
f 16 13 42
f 43 42 13
f 75 72 92
f 77 75 92
f 18 46 13
f 43 13 46
f 20 27 32
f 27 20 8
f 83 80 92
f 85 83 92
f 18 29 46
f 47 46 29
f 10 26 1
f 25 1 26
f 47 29 50
f 30 50 29
f 92 10 14
f 7 15 90
f 89 90 15
f 30 34 50
f 91 9 90
f 7 90 9
f 89 14 90
f 9 91 93
f 9 93 11
f 90 14 91
f 48 45 95
f 93 91 14
f 38 57 55
f 95 94 14
f 94 93 14
f 94 45 93
f 45 11 93
f 96 95 14
f 44 59 38
f 57 38 59
f 10 92 26
f 31 26 92
f 60 62 44
f 59 44 62
f 89 88 14
f 92 14 88
f 87 92 88
f 87 86 92
f 86 85 92
f 60 63 62
f 24 98 97
f 20 32 98
f 80 77 92
f 69 31 72
f 63 31 69
f 92 72 31
f 60 44 31
f 36 33 32
f 31 36 32
f 39 35 97
f 99 96 14
f 97 98 32
f 98 112 20
f 100 99 14
f 65 63 66
f 94 95 45
f 101 100 14
f 111 110 20
f 20 105 104
f 103 102 20
f 14 20 101
f 104 103 20
f 102 101 20
f 8 4 27
f 4 21 27
f 69 72 66
f 71 66 72
f 96 49 95
f 48 95 49
f 75 73 72
f 71 72 73
f 96 99 49
f 51 49 99
f 77 74 73
f 77 73 75
f 106 105 20
f 99 100 51
f 54 51 100
f 74 77 76
f 80 76 77
f 107 106 20
f 108 107 20
f 83 78 76
f 83 76 80
f 101 54 100
f 109 108 20
f 110 109 20
f 83 85 78
f 79 78 85
f 111 20 112
f 102 58 101
f 85 86 79
f 103 61 102
f 97 32 113
f 81 86 82
f 64 103 104
f 114 113 32
f 82 87 84
f 88 84 87
f 114 32 115
f 104 105 64
f 67 64 105
f 89 15 88
f 84 88 15
f 115 32 16
f 106 68 105
f 16 32 13
f 13 32 18
f 12 107 108
f 29 18 32
f 109 5 12
f 109 12 108
f 5 109 6
f 110 6 109
f 111 17 6
f 111 6 110
f 17 111 112
f 24 112 98
f 113 39 97
f 40 41 115
f 16 42 115
# 230 faces
#end of obj_0

64
case/usb-extension.obj Normal file
View File

@@ -0,0 +1,64 @@
# Object Export From Tinkercad Server 2015
mtllib obj.mtl
o obj_0
v 22.378 -32.248 0
v 15.373 -32.248 0
v 15.373 -45.253 0
v 22.378 -45.253 0
v 13.375 -47.25 0
v 13.375 -30.25 0
v 24.375 -47.25 0
v 24.375 -30.25 0
v 22.378 -45.253 20
v 15.373 -45.253 20
v 15.373 -32.248 20
v 22.378 -32.248 20
v 24.375 -30.25 20
v 24.375 -47.25 20
v 13.375 -47.25 20
v 13.375 -30.25 20
# 16 vertices
g group_0_15277357
usemtl color_15277357
s 0
f 6 8 2
f 4 7 3
f 3 5 2
f 5 6 2
f 5 3 7
f 7 4 1
f 1 2 8
f 7 1 8
f 12 13 11
f 10 14 9
f 8 13 14
f 8 14 7
f 5 15 16
f 5 16 6
f 5 14 15
f 16 15 11
f 10 11 15
f 14 10 15
f 5 7 14
f 16 11 13
f 9 14 12
f 13 12 14
f 9 4 3
f 9 3 10
f 10 3 2
f 10 2 11
f 16 13 6
f 8 6 13
f 12 1 4
f 12 4 9
f 1 12 11
f 1 11 2
# 32 faces
#end of obj_0