generated from CubeCraft-Creations/Tracehound
feat: add 3D printable case design (OpenSCAD) and hardware assembly guide
- GoPro Hero 3 sleeve with lens/screen/USB cutouts - ESP32 D1 Mini electronics compartment (vented) - LiPo battery compartment with velcro strap slots - Bill of materials (~0 per camera node) - Wiring diagram (LiPo → dual buck converters → ESP32 + GoPro) - Field deployment workflow OpenSCAD model in hardware/case/remoterig-case.scad Assembly guide in hardware/README.md
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# RemoteRig — Camera Node Hardware Design
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> **Version:** 0.1.0 | **Status:** Draft
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> **Target:** GoPro Hero 3 Black/Silver + ESP32 D1 Mini + 1000mAh LiPo
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## Overview
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Each camera node is a self-contained unit clipped onto a GoPro Hero 3. It provides:
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- Camera control (start/stop recording) via Wi-Fi
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- Status monitoring (battery, storage, recording state)
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- MQTT communication to the central Pi Zero 2 W hub
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- Battery power for both the ESP32 and GoPro
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## Physical Assembly
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```
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┌─────────────────────────────────┐
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│ GoPro Hero 3 │
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│ ┌─────────────────────────┐ │
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│ │ Lens (front) │ │
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│ └─────────────────────────┘ │
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│ ┌─────────────────────────┐ │
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│ │ Screen │ │
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│ └─────────────────────────┘ │
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│ ┌──────────┐ │
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│ 3D Sleeve ─────→│ ESP32 │ │ ← clips onto back/bottom
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│ │ D1 Mini │ │
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│ └──────────┘ │
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│ ┌──────────┐ │
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│ │ LiPo │ │ ← slides under GoPro
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│ │ 1000mAh │ │
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│ └──────────┘ │
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└─────────────────────────────────┘
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```
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## Bill of Materials
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| Item | Qty | Cost | Notes |
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|------|-----|------|-------|
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| GoPro Hero 3 Black/Silver | 1 | Already owned | Target camera |
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| ESP32 D1 Mini | 1 | ~$4 | Or NodeMCU-32S (~$5) |
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| LiPo 3.7V 1000mAh | 1 | ~$8 | 50x34x8mm typical |
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| 5V/3A buck converter | 1 | ~$2 | LiPo → GoPro USB |
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| 3.3V buck converter | 1 | ~$1 | LiPo → ESP32 VIN |
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| JST-XH 2-pin connectors | 2 | ~$1 | Battery quick-disconnect |
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| Micro-USB right-angle cable | 1 | ~$2 | Buck → GoPro |
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| Velcro strap (20cm) | 1 | ~$0.50 | Secure to GoPro |
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| PETG filament | ~30g | ~$0.60 | 3D printed case |
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**Total per node:** ~$20
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## 3D Printed Case
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The case consists of three parts (see `hardware/case/remoterig-case.scad`):
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### Part 1: GoPro Sleeve
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Wraps around the GoPro body with cutouts for:
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- Lens (front)
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- Screen/viewfinder (back)
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- USB port (side)
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- Bottom mounting fingers
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- Mounting ears for electronics compartment
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### Part 2: Electronics Compartment
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Clips onto the sleeve's mounting ears. Holds:
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- ESP32 D1 Mini board (recessed fit)
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- USB cable routing (in → ESP32, out → GoPro)
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- Ventilation slots (top)
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- LED visibility window
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### Part 3: Battery Compartment
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Slides under the GoPro. Contains:
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- LiPo battery cavity
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- Cable exits (to ESP32, to GoPro buck converter)
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- Velcro strap slots
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### Print Settings
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- **Material:** PETG (outdoor/heat resistant) or PLA+
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- **Layer height:** 0.2mm
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- **Infill:** 20% gyroid
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- **Supports:** Yes (for cable channels)
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- **Bed adhesion:** Brim (5mm) for sleeve
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- **Orientation:** Print sleeve on its back, compartments flat
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## Wiring
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```
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LiPo 3.7V
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├── JST-XH connector
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│
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├──→ 5V/3A Buck Converter → Micro-USB right-angle → GoPro USB port
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│ (power only — no data over USB)
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│
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└──→ 3.3V Buck Converter → ESP32 VIN + GND
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(or ESP32 D1 Mini has built-in regulator — connect directly to 5V pin)
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```
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**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:
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```
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LiPo → 5V Buck → ├── ESP32 5V pin
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└── GoPro USB port
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```
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## Wi-Fi Topology (No Cables for Camera Control)
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```
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GoPro Hero 3 ──(Wi-Fi AP @ 10.5.5.1)──→ ESP32 STA #1
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│
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Travel Router ──(Wi-Fi AP)─────────────────→ ESP32 STA #2
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(192.168.4.1) │
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│
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└──→ MQTT → Pi Hub (192.168.4.10)
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```
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The ESP32 has **no wired data connection** to the GoPro. All camera control is over Wi-Fi. The USB cable is **power only**.
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## Enclosure Dimensions
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| Component | W × H × D (mm) |
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|-----------|-----------------|
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| GoPro Hero 3 | 60 × 42 × 30 |
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| ESP32 D1 Mini | 34 × 26 × 5 |
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| LiPo 1000mAh | 50 × 34 × 8 |
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| Full assembly | ~70 × 60 × 55 |
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## Usage in the Field
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1. **Pre-show:** Charge LiPos, flash ESP32 firmware, verify MQTT connectivity
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2. **At venue:** Mount cameras, power on ESP32s (they auto-connect to travel router)
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3. **Monitoring:** Open `http://192.168.4.10:8080` on laptop/kiosk
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4. **Control:** Start/stop recording from dashboard
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5. **Post-show:** Stop recording, power down, swap batteries for next session
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## Future Improvements
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- **Hot-swap battery:** Quick-release battery tray with spring contacts
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- **Weather sealing:** O-ring groove in sleeve for outdoor rain protection
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- **Lens hood:** Integrated sun shield for outdoor daytime recording
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- **Mount adapter:** 1/4"-20 tripod mount thread on bottom
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- **Antenna routing:** External antenna connector for improved Wi-Fi range in stadiums
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