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:

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:

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:

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

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

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.