LEDDs

PCB and enclosure design of a trailing edge light bulbs dimmer

Fabrication of v1.0

The fabricated board from release v1.0 worked, but has some minor problems.

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Features

Suitable for dimmable LED bulbs

Uses MOSFETs to switch off the voltage on the trailing edge.

Rotary encoder for direct control

Fully usable as a standalone device.

Default rotary encoder functions:

• rotate for brightness adjustment
• press to turn ON/OFF
• press and rotate to cycle through the effects

Runs ESPHome firmware

Example configuration in fw/example/.

Enclosure

The enclosure consists of a 3D printed open-box chassis and a PCB top cover.

3D printed chassis

Located in enclosure/chassis.

PCB top plate

Located in enclosure/top_plate/.

Specifications

• input voltage: ~230 V
• maximum output power: 100 W
• idle power draw: 0.5 W
• dimensions:
  • width: 100 mm
  • depth: 51 mm
  • height: 25 mm

Making the project

1. Ordering the parts

1.1. PCB and top plate

Download the PCB gerbers and the top plate gerbers.

Or download the combined gerbers. These include the PCB and the top plate on a single PCB.

1.2. 3D printed chassis

Download the chassis STL file.

Tested printing parameters: JLC3DP:

• technology: FDM (plastic)
• material: PLA
• color: white
• surface finish: no

1.3. Components

Download the BOM.

Download the enclosure's BOM.

2. PCB assembly

Use the interactive BOM.

3. Firmware upload

Note

A USB-to-UART adapter module is required.

1. Download the provided ESPHome example configuration.
2. Follow ESPHome's getting started guide to compile and upload the firmware.

4. Enclosure

1. Melt the threaded inserts into the enclosure.

2. Insert the PCB into the enclosure and screw in the cables.

3. Insert the screws in the top plate and place the spacers around the screws.

4. Screw the top plate through the PCB into the enclosure.

Contributing

Every type of contribution is welcome, like improvements or corrections on the:

• documentation
• schematic/PCB design
• enclosure (chassis and top panel) design
• ESPHome configuration

Contributions can be made as improvements or as variants (e.g. different enclosure design, ESPHome configuration, etc.).

The procedure is:

• fork
• branch
• commit
• pull request

You're welcome to post photos in Discussions: Show and tell.