The start:

The challenges:

Documentation:

Use of AI:

01| Ideation and Sketching

02| Electronic Production

02|01| Selecting the components

02|02| PCB

02|02|01| PCB Design
Create a new project in KiCad → open the schematic editor → add the components and make sure each has a footprint → if not, download the files and add them to the library → connect the ports and mark the unused ones as "no connect" → run the Electrical Rules Check (ERC) → solve errors and make sure I understand the warnings → switch to the PCB Editor and import the components with their connections → customize the track width to 0.5 mm, which gave me the best results when cutting the PCB (see Week 08 for details) → rearrange the components → change the unconnected SMD pads' copper layer to B.Cu to avoid affecting the tracks → route the tracks → run the Design Rules Check (DRC) → fix any errors and review the warnings → align the components on my laptop screen to match the spacing on the PCB — this is critical when using components that aren't available in the KiCad footprint libraries → plot and export the Gerber file after 4 versions and tweaks for better results, especially given the shortage of PCB stock — I had to fit this PCB into a 71 mm length design.

02|02|02| PCB Milling
Import the Gerber file into FlatCAM → align the PCB design to the (0,0) origin → add an external buffer of 0.4 mm → make sure the tracks and routes are clear and don't overlap with the cutting routes or buffer → export the G-code file → in Easel, import the file → set up the CNC as documented in Week 08 → start milling → use a multimeter to check the routes

02|02|03| Soldering the components
I prepared my soldering station, keeping the main components close to me and following safety measures → I used the microscope to get better visibility on the PCB and the SMD components I'm using → first I applied solder flux paste (RMA-223) on the pads → I added a little solder (Flux Solder 0.8mm/100g, ProsKit 8PK-033A-L) on the pads → make sure the components' legs match the spaces on the PCB → I review my PCB design and confirm the correct ends are matched to avoid short circuits; I try to keep the legs fixed in place → heat the previously soldered pads → once I feel the component has settled onto its pads, I remove the solder tip → repeat this process until all the parts are soldered and fixed → I run a multimeter test to confirm which routes are connected and which are isolated → Done.

03| Coding and Programing

03|01| Microcontroller Programing

I selected Thonny IDE to start coding in MicroPython → I connected the XIAO via USB cable → first, set the microcontroller name to FBL_R and advertise it so it can be discovered by the interface app we will develop this code → test the connection with each component → blink the LED first this code → vary the vibration motor strength this code → wake up the MPU sensor and read the X, Y, Z values this code

# Advertise device Bluetooth Name
import bluetooth
import time

# 1. Initialize BLE
ble = bluetooth.BLE()
ble.active(True)

# 2. Define the name
DEVICE_NAME = "FBL_R"

def advertise():
    # BLE Advertisement format: [Length, Type, Data]
    # Type 0x09 is the 'Complete Local Name'
    name_bytes = DEVICE_NAME.encode('utf-8')
    # Payload = [Len of name + 1, Type 0x09, The Name]
    payload = bytearray([len(name_bytes) + 1, 0x09]) + name_bytes
    
    # gap_advertise(interval_us, payload)
    # 100000 us = 100ms interval
    ble.gap_advertise(100000, payload)
    print("FBL_R is now advertising...")

# 3. Start advertising
advertise()

# 4. Keep the program running
while True:
    time.sleep(1)
					

# LED light blinking 

from machine import Pin
import time

# Replace 'X' with the GPIO number from your PCB design
led = Pin(X, Pin.OUT)

while True:
    led.value(0)  # Logic 0 = LED ON (Common Anode)
    print("LED is ON")
    time.sleep(0.5)
    
    led.value(1)  # Logic 1 = LED OFF
    print("LED is OFF")
    time.sleep(0.5)
					

# Vibrator change strength 
from machine import Pin

# D6 corresponds to GPIO 21 on the ESP32-C3
motor = Pin(21, Pin.OUT)

# Set it to 0 (Stopped)
motor.value(0)
print("Motor on D6 (GPIO 21) is now set to 0")
					

# MPU sensor and reading
import machine
import time
import struct

# Initialize I2C
i2c = machine.I2C(0, sda=machine.Pin(6), scl=machine.Pin(7))
addr = 0x68

# IMPORTANT: Wake up the MPU-6050 inside this script
try:
    i2c.writeto_mem(addr, 0x6B, b'\x00')
    print("MPU-6050 Woken Up Successfully")
except:
    print("Could not find sensor. Check wires!")

def read_accel():
    try:
        # Read 6 bytes starting from 0x3B
        data = i2c.readfrom_mem(addr, 0x3B, 6)
        # Unpack high and low bytes into 3 signed integers (x, y, z)
        return struct.unpack('>hhh', data)
    except:
        return None

while True:
    vals = read_accel()
    if vals:
        ax, ay, az = vals
        print("X: {:6d} | Y: {:6d} | Z: {:6d}".format(ax, ay, az))
    else:
        print("Sensor disconnected!")
        break # Exit the loop if the sensor is lost
        
    time.sleep(0.2)
					

03|02| App Interfce

I created my app using MIT App Inventor platform. First screen will contant instrution of how to use the clips → I designed the two clips, left and right → I added list view to search for Buletooth devices → a battery level indicators → a number of text labels to update the status of the connection → adding Calibration button to set the acceptable degree within the thrishhold define on the clips → Sliders for the user preference for the acceptable angle threshhold → the acceptable angle and time before awaken the vibrator → vibration strength.

App inventor provide block prograimng functionaliy that easies the use of syntax coding. here I dublicated the same comands for the left and righ clips, calling on the bluetooth connection and senting some paramerters to the ESP32 C3 microcontroller.

03|03| integrating clips with App

04| Packaging

04|01| Clip Case

04|01|01| 3D deisgn-FreeCAD
create new file on KiCAD → Open Schematics design → add the components and make sure they have a footprint →

04|01|02| 3D printing
create new file on KiCAD → Open Schematics design → add the components and make sure they have a footprint →

04|01|03| Assembly
create new file on KiCAD → Open Schematics design → add the components and make sure they have a footprint →

04|01|04| Evaluation
create new file on KiCAD → Open Schematics design → add the components and make sure they have a footprint →

04|01|05| Cover Molding
create new file on KiCAD → Open Schematics design → add the components and make sure they have a footprint →

04|02| Wooden Case

04|02|01| CAD Design
create new file on KiCAD → Open Schematics design → add the components and make sure they have a footprint →

04|02|02| Laser Cut
create new file on KiCAD → Open Schematics design → add the components and make sure they have a footprint →

04|02|03| Assembly evalaution
create new file on KiCAD → Open Schematics design → add the components and make sure they have a footprint →

05| Spiral Development

conyinue working on this project, I would like to make the wooden cae wireless chargeing case for the both clips and to also have it indicate when a clip is missing.