remote-rig/hardware

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