remote-rig/hardware/README.md

# RemoteRig — Camera Node Hardware Design

> **Version:** 0.3.0 | **Status:** v4 CAD prototype ready for measurement/print validation
> **Target:** GoPro Hero 3 Black/Silver + ESP32-C3 Super Mini + ESP-01S + USB power bank

## Overview

Each camera node is two ESP boards in a small stand-mounted case. The case **does not attach to the camera**; it straps to a tripod/lighting stand with reusable cloth zip ties / Velcro straps. Powered by a standard USB power bank.

```
     ┌─────────────────┐
     │  USB Power Bank │── USB ──→ GoPro (power only)
     │  (off-the-shelf)│── USB ──→ Camera Node Case
     └─────────────────┘
              │
     ┌────────┴────────────────────────────┐
     │  Camera Node Case v4                │ ← Velcro/cloth straps to stand
     │  ┌──────────────────────────────┐   │
     │  │ Flush/recessed service lid   │   │
     │  │ 1.3 OLED: CAM/REC/BAT/LINK   │   │
     │  │ PWR LED + RGB STAT LED       │   │
     │  │ Small rocker power switch    │   │
     │  └──────────────────────────────┘   │
     │  ESP-01S camera bridge ↔ ESP32-C3   │
     └─────────────────────────────────────┘
```

## Bill of Materials

| Item | Qty | Cost | Notes |
|------|-----|------|-------|
| ESP32-C3 Super Mini | 1 | ~$4–$6 | MQTT / hub-side bridge; known board envelope 22.5 × 18 mm |
| ESP-01S / ESP8266 module | 1 | ~$2–$3 | Camera-side GoPro Wi-Fi bridge; known envelope ~24.7 × 14.3 × 12 mm |
| 1.3-inch OLED/status screen | 1 | ~$4–$8 | Prototype CAD assumes ~31 × 16 mm visible window / ~35 × 19 mm panel clearance; confirm exact module |
| 3 mm power LED | 1 | <$1 | Separate always-power/5V indicator |
| 3 mm RGB status LED | 1 | <$1 | Replaces separate red/green status LEDs; firmware can map node states to color |
| Small rocker switch | 1 | ~$1–$3 | On/off switch; prototype CAD assumes 13 × 19 mm snap-in opening |
| USB power bank (5000 mAh+) | 1 | ~$10 | Powers camera node and GoPro |
| Short USB cables / wiring | as needed | ~$2–$5 | Power bank → node + GoPro; internal power/signal wiring |
| M2 or small self-tapping screws | 4 | <$1 | Front service lid screws; pilot holes are parametric |
| PETG filament | ~35–50 g | ~$1 | 3D printed case body + lid |
| Reusable cloth zip ties / Velcro straps | 2 | ~$1 | Primary stand mount through rear strap channels |

**Total per node:** roughly ~$25–$35 plus GoPro and power bank, depending on display/switch choice.

## 3D Printed Case

**Current source:** `hardware/case/camera-node-case-v4.scad`
**Pipeline:** `hardware/DESIGN_PIPELINE.md`

The v4 case replaces the v3 clamp/dovetail concept with a simpler strap-mounted field enclosure:

1. **Case body** — shell sized around ESP32-C3 Super Mini + ESP-01S with service/wiring clearance.
2. **Flush/recessed front service lid** — screw-on front status panel with locating lip.
3. **Front panel controls/indicators**:
   - 1.3-inch OLED/status screen window.
   - 3 mm **PWR** LED.
   - single 3 mm **RGB STAT** LED for state-dependent colors.
   - small rectangular rocker switch cutout.
   - lower vent/style slots.
4. **Rear strap channels** — two raised horizontal cloth zip-tie / Velcro strap paths to reduce rotation on a tripod/stand.
5. **Bottom cable exit** — cable/strain-relief notch for USB/power wiring.

### Export wrappers

Simple per-part OpenSCAD wrappers are included:

- `hardware/case/camera-node-case-v4-body.scad`
- `hardware/case/camera-node-case-v4-lid.scad`
- `hardware/case/camera-node-case-v4-preview.scad`

Example CLI exports, if OpenSCAD is installed:

```bash
openscad -o hardware/case/camera-node-case-v4-body.stl hardware/case/camera-node-case-v4-body.scad
openscad -o hardware/case/camera-node-case-v4-lid.stl hardware/case/camera-node-case-v4-lid.scad
openscad -o hardware/case/camera-node-case-v4-preview.stl hardware/case/camera-node-case-v4-preview.scad
```

Or render the main file directly:

```bash
openscad -D 'part="body"' -o hardware/case/camera-node-case-v4-body.stl hardware/case/camera-node-case-v4.scad
openscad -D 'part="lid"' -o hardware/case/camera-node-case-v4-lid.stl hardware/case/camera-node-case-v4.scad
openscad -D 'part="preview"' -o hardware/case/camera-node-case-v4-preview.stl hardware/case/camera-node-case-v4.scad
```

### Print Settings

- **Material:** PETG preferred for heat/outdoor use and strap-tab durability.
- **Layer:** 0.2 mm typical.
- **Infill:** 20% gyroid minimum; 30%+ recommended around rear strap bridges.
- **Supports:** likely minimal/none depending on orientation; verify rear strap bridge spans and cable notch in slicer.
- **Post-processing:** fit 4 lid screws; deburr OLED/LED/switch cutouts; soften strap-channel edges if the printed radius is too sharp for cloth ties.

## Expected Status Screen Content

Preferred 1.3-inch OLED layout/content style:

```text
CAM 03   REC ●
BAT 87%  LINK OK
00:12:34
```

Suggested fields:

- `CAM` / node ID.
- `REC` state with a clear recording indicator.
- Battery percentage or supply estimate.
- `LINK OK` / degraded / disconnected state.
- Recording/session timer.

## Wiring

```text
USB Power Bank
  ├── USB-A → Camera Node Case
  │       ├── rocker switch → node power rail
  │       ├── PWR LED indicator
  │       ├── ESP32-C3 Super Mini
  │       ├── ESP-01S / ESP8266
  │       ├── 1.3-inch OLED display
  │       └── RGB status LED
  │
  └── USB-A → GoPro USB port
          (power only — no data)

UART / control inside case:
  ESP-01S TX  ──→ ESP32-C3 RX
  ESP-01S RX  ←── ESP32-C3 TX
  ESP-01S GND ─── ESP32-C3 GND
```

**Power note:** exact wiring depends on the regulator/power board used. Confirm OLED voltage, LED current limiting, and whether the rocker switches USB 5 V input or a regulated node rail.

## Wi-Fi Topology

```text
GoPro Hero 3 ──(AP @ 10.5.5.1)──→ ESP-01S / ESP8266 camera bridge
                                             │
                                        UART │ (inside case)
                                             │
Travel Router ──(AP)────────────────────→ ESP32-C3 MQTT bridge
(10.60.1.1)                                │
                                             │
                                        MQTT │
                                             ▼
                                   Pi Hub (10.60.1.56)
```

The ESP8266/ESP-01S and GoPro talk over Wi-Fi. The only cable to the GoPro is USB power from the battery pack.

## Field Setup

1. Mount GoPro on tripod/stand.
2. Route two reusable cloth zip ties / Velcro straps through the rear v4 case channels.
3. Strap the case to a tripod/stand leg; use both strap paths to resist rotation.
4. Connect power bank to case and GoPro.
5. Toggle rocker switch on.
6. Verify PWR LED, RGB status LED, and OLED status: camera ID, REC state, battery, link, timer.
7. Monitor from `http://10.60.1.56:8080`.

## Case Dimensions

Prototype v4 nominal CAD dimensions:

| Part / feature | W × D × H (mm) |
|---|---|
| Case shell external | ~68 × 42 × 32 |
| Case with rear strap bridges | ~68 × 45.2 × 32 |
| Front recessed lid | visible panel ~60 × 2 × 26; total with locating lip ~60 × 3 × 26 |
| OLED visible window assumption | ~31 × 16 |
| Rocker cutout assumption | ~13 × 19 |
| Rear strap channels | two horizontal pass-through paths, ~48 mm usable slot width, ~4.2 mm strap-thickness clearance |
| Board clearance targets | ESP32-C3 22.5 × 18 mm + ESP-01S 24.7 × 14.3 × 12 mm plus wiring/service clearance |

These dimensions are placeholders for the first CAD prototype. Measure the actual OLED module, rocker switch, LEDs, screws, USB cable bend radius, and strap width/thickness before committing to production prints.