EV-Controller

This project is an ESP8266/ESP32-based exhaust valve controller for motorcycles. It offers real-time monitoring and configuration through a web interface, utilizing WebSockets for live data communication. The core functionality is to control the motorcycle's exhaust valve based on configurable RPM thresholds.

Features

• RPM-based exhaust valve control with configurable opening and closing thresholds.
• Web interface for real-time RPM monitoring and settings adjustment.
• WiFi Access Point (AP) mode for initial setup and configuration.
• WiFi Station (STA) mode to connect to an existing wireless network.
• Secure Over-the-Air (OTA) updates for both firmware and filesystem.
• Manual override for valve control directly from the web interface.

Hardware Construction

To build the hardware, you will need to manufacture the PCB and source the electronic components.

1. PCB Manufacturing

The Gerber files required for PCB production are located in the pcb/production/gerber.zip archive. You can upload this file to any PCB manufacturer of your choice.

2. Component Sourcing

The list of all necessary components (Bill of Materials) is available in the pcb/production/bom.csv file. This file can be used to order parts from electronic component distributors.

3. Assembly

Solder the components onto the manufactured PCB. For component placement and orientation, please refer to the following files:

• Schematic: pcb/schema.pdf
• KiCad Project: pcb/Rave-Controller.kicad_pro (can be opened with KiCad)

For automated pick-and-place assembly, the pcb/production/positions.csv file is also provided.

Firmware Installation

The firmware is built using PlatformIO.

Prerequisites

• Visual Studio Code
• PlatformIO IDE extension for VS Code

Build and Upload

1. Clone this repository to your local machine.
2. Open the cloned repository folder in Visual Studio Code.
3. PlatformIO will automatically detect the platformio.ini file and prompt you to install the required project dependencies.
4. Once dependencies are installed, select the correct environment for your board (e.g., d1_mini).
5. Use the PlatformIO "Upload" task to build and flash the firmware to your device. Alternatively, you can run the following command from the integrated terminal:

   pio run -e d1_mini --target upload

Initial Setup

1. On the first boot, the device will create a Wi-Fi Access Point. The default SSID and password can be found in the source code (data/config.json).
2. Connect your computer or smartphone to this Wi-Fi network.
3. Open a web browser and navigate to the device's default IP address, which is 42.42.42.42.
4. From the web interface, you can configure your home Wi-Fi credentials (SSID and password) and set the desired RPM thresholds for the exhaust valve operation.
5. After saving the new settings, the device will restart, connect to your specified Wi-Fi network, and begin normal operation.