remote-rig/hardware/README.md

# RemoteRig — Camera Node Hardware Design

> **Version:** 0.1.0 | **Status:** Draft
> **Target:** GoPro Hero 3 Black/Silver + ESP32 D1 Mini + 1000mAh LiPo

## Overview

Each camera node is a self-contained unit clipped onto a GoPro Hero 3. It provides:
- Camera control (start/stop recording) via Wi-Fi
- Status monitoring (battery, storage, recording state)
- MQTT communication to the central Pi Zero 2 W hub
- Battery power for both the ESP32 and GoPro

## Physical Assembly

```
┌─────────────────────────────────┐
│         GoPro Hero 3            │
│  ┌─────────────────────────┐    │
│  │      Lens (front)       │    │
│  └─────────────────────────┘    │
│  ┌─────────────────────────┐    │
│  │        Screen           │    │
│  └─────────────────────────┘    │
│                    ┌──────────┐ │
│    3D Sleeve ─────→│ ESP32    │ │ ← clips onto back/bottom
│                    │ D1 Mini  │ │
│                    └──────────┘ │
│                    ┌──────────┐ │
│                    │ LiPo     │ │ ← slides under GoPro
│                    │ 1000mAh  │ │
│                    └──────────┘ │
└─────────────────────────────────┘
```

## Bill of Materials

| Item | Qty | Cost | Notes |
|------|-----|------|-------|
| GoPro Hero 3 Black/Silver | 1 | Already owned | Target camera |
| ESP32 D1 Mini | 1 | ~$4 | Or NodeMCU-32S (~$5) |
| LiPo 3.7V 1000mAh | 1 | ~$8 | 50x34x8mm typical |
| 5V/3A buck converter | 1 | ~$2 | LiPo → GoPro USB |
| 3.3V buck converter | 1 | ~$1 | LiPo → ESP32 VIN |
| JST-XH 2-pin connectors | 2 | ~$1 | Battery quick-disconnect |
| Micro-USB right-angle cable | 1 | ~$2 | Buck → GoPro |
| Velcro strap (20cm) | 1 | ~$0.50 | Secure to GoPro |
| PETG filament | ~30g | ~$0.60 | 3D printed case |

**Total per node:** ~$20

## 3D Printed Case

The case consists of three parts (see `hardware/case/remoterig-case.scad`):

### Part 1: GoPro Sleeve
Wraps around the GoPro body with cutouts for:
- Lens (front)
- Screen/viewfinder (back)
- USB port (side)
- Bottom mounting fingers
- Mounting ears for electronics compartment

### Part 2: Electronics Compartment
Clips onto the sleeve's mounting ears. Holds:
- ESP32 D1 Mini board (recessed fit)
- USB cable routing (in → ESP32, out → GoPro)
- Ventilation slots (top)
- LED visibility window

### Part 3: Battery Compartment
Slides under the GoPro. Contains:
- LiPo battery cavity
- Cable exits (to ESP32, to GoPro buck converter)
- Velcro strap slots

### Print Settings
- **Material:** PETG (outdoor/heat resistant) or PLA+
- **Layer height:** 0.2mm
- **Infill:** 20% gyroid
- **Supports:** Yes (for cable channels)
- **Bed adhesion:** Brim (5mm) for sleeve
- **Orientation:** Print sleeve on its back, compartments flat

## Wiring

```
LiPo 3.7V
  ├── JST-XH connector
  │
  ├──→ 5V/3A Buck Converter → Micro-USB right-angle → GoPro USB port
  │    (power only — no data over USB)
  │
  └──→ 3.3V Buck Converter → ESP32 VIN + GND
       (or ESP32 D1 Mini has built-in regulator — connect directly to 5V pin)
```

**Note:** ESP32 D1 Mini has an onboard 3.3V regulator. You can feed it 5V directly to the 5V pin if using a single 5V buck converter. This simplifies wiring:
```
LiPo → 5V Buck → ├── ESP32 5V pin
                  └── GoPro USB port
```

## Wi-Fi Topology (No Cables for Camera Control)

```
GoPro Hero 3 ──(Wi-Fi AP @ 10.5.5.1)──→ ESP32 STA #1
                                            │
Travel Router ──(Wi-Fi AP)─────────────────→ ESP32 STA #2
(192.168.4.1)                               │
                                            │
                                            └──→ MQTT → Pi Hub (192.168.4.10)
```

The ESP32 has **no wired data connection** to the GoPro. All camera control is over Wi-Fi. The USB cable is **power only**.

## Enclosure Dimensions

| Component | W × H × D (mm) |
|-----------|-----------------|
| GoPro Hero 3 | 60 × 42 × 30 |
| ESP32 D1 Mini | 34 × 26 × 5 |
| LiPo 1000mAh | 50 × 34 × 8 |
| Full assembly | ~70 × 60 × 55 |

## Usage in the Field

1. **Pre-show:** Charge LiPos, flash ESP32 firmware, verify MQTT connectivity
2. **At venue:** Mount cameras, power on ESP32s (they auto-connect to travel router)
3. **Monitoring:** Open `http://192.168.4.10:8080` on laptop/kiosk
4. **Control:** Start/stop recording from dashboard
5. **Post-show:** Stop recording, power down, swap batteries for next session

## Future Improvements

- **Hot-swap battery:** Quick-release battery tray with spring contacts
- **Weather sealing:** O-ring groove in sleeve for outdoor rain protection
- **Lens hood:** Integrated sun shield for outdoor daytime recording
- **Mount adapter:** 1/4"-20 tripod mount thread on bottom
- **Antenna routing:** External antenna connector for improved Wi-Fi range in stadiums