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Battery-Powered ESP32 Environmental Sensor Node

Overview

This project is a compact, battery-powered environmental monitoring device built around the ESP32. It is designed to measure temperature, humidity, and atmospheric pressure, and transmit data wirelessly over Wi-Fi.

The system integrates power management, battery charging, sensing, and communication into a single PCB, making it suitable for IoT applications and embedded product prototyping.


Features

  • ESP32-based Wi-Fi connectivity
  • Environmental sensing (temperature, humidity, pressure)
  • Battery-powered operation (Li-Po)
  • USB-C power input and charging
  • Integrated battery protection
  • Low-power design (deep sleep capable)
  • UART interface for programming and debugging

Hardware Architecture

The system is composed of the following main subsystems:

Power Subsystem

  • USB-C 5V input
  • Li-Po battery charging IC
  • Battery protection circuit
  • 3.3V regulation stage
  • Bulk and decoupling capacitors

Processing Unit

  • ESP32-WROOM-32 module
  • Boot configuration and reset circuitry
  • UART programming interface

Sensor Subsystem

  • BME280 environmental sensor (I2C interface)
  • Pull-up resistors for I2C communication

Block Diagram

USB-C → Charger → Battery → Regulator → ESP32 → Sensor (I2C)

Design Highlights

  • Modular schematic organization (power / MCU / sensor)
  • Proper decoupling and power distribution
  • ESP32 antenna keep-out respected
  • I2C bus design with pull-up resistors
  • Battery protection and safe charging design

Key Engineering Decisions

  • ESP32 Module Selection Used a pre-certified ESP32 module to simplify RF design and ensure reliable Wi-Fi performance.

  • Battery-Powered Architecture Designed around a single-cell Li-Po battery for portability and real-world IoT use cases.

  • Power Regulation Strategy Implemented a regulated 3.3V rail to ensure stable operation during ESP32 current spikes.

  • USB-C Power-Only Configuration USB-C connector used strictly for power input, avoiding unnecessary USB data complexity.

  • I2C Sensor Interface Selected a digital sensor with I2C to minimize pin usage and simplify routing.


PCB Design

  • 2-layer PCB
  • Ground plane for signal integrity
  • Compact component placement
  • Standard SMD components (0603 passives)
  • Connector placement optimized for usability

Files Included

Design Files

  • Schematic files
  • PCB layout files

Manufacturing Files

  • Gerbers
  • Drill files
  • Bill of Materials (BOM)
  • Pick-and-place files

Documentation

  • Block diagram
  • Rendered board images

Applications

  • IoT environmental monitoring
  • Smart home systems
  • Remote sensing nodes
  • Battery-powered embedded systems

Future Improvements

  • Power path optimization (load sharing / advanced charger IC)
  • Lower power consumption tuning
  • OTA firmware update support
  • Enclosure design integration
  • Additional sensor support

Author

Hardware design and layout by Abdelwahed Eloued


License

This project is open-source and available under the MIT License.

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