Internet Radio Project (Prototype)

An internet radio inspired by other models here on printables, and around the internet, but this model and circuit diagrams are all my own work. 

This should still be classed as a prototype since I haven't ironed out all the issues with the casing as yet. It slots together but doesn''t fasten but that can be solved with some carefully applied CA or hot melt glue.

A rotary encoder with button into the top of the radio is used for volume and option selection. There will also be the ability to control the radio via infrared remote.

It uses an ESP32 microcontroller breakout board and VS1053 audio decoder board.

The firmware for this radio was written by Ed Smallenburg and can be found on his github here.

Stripboard layout files were designed by me in DIYLC by bancika

This is NOT a kit, or a tutorial that can be built.  It is currently an experimental prototype so I cannot provide advice on proper assembly, parts, etc. at this time.

You WILL need to modify the source FreeCAD file, since the speakers I am using were taken out of a dead DAB radio. It should be relatively easy to alter the sketches in the speaker_stage body to accommodate speakers with slightly differing dimensions or screw holes, the buck boost circuit and DAC.

Updates:

06.08.2024:

Project prototype is complete. I have uploaded the current FreeCAD source and exported STL parts. The project works well enough for my purposes so I've not spent the time to fully optimise the design - the casing has insufficient fastening between the two halves so I have currently resorted to hot melt glue to fix them. There are also some problems with the power section design which have resulted in the design of a small bezel which houses the power connector and specific switch that I used. I had to cut the protruding section off the power section so it would fit inside the casing and the original switch mounting broke off.

Please feel free to remix the files as you see fit.

14.07.2024: 

I've changed to using a wiring harness to link the VS1053, ESP32, OLED and IR sensor which will make it a lot easier to assemble without soldering. 
The radio will still require a PCB for the amplifier and isolation transformers. Stripboard patterns for the prototype have been uploaded.

03.07.2024: 

Uploaded a picture of the prototype in operation and stripboard layouts prior to design and manufacture of actual PCB boards for the internals.

28.06.2024: 

More CAD file updates and upload of DIY Layout Creator board layouts for the prototype on stripboard before the PCBs are designed.

The original display didn't play well with the rest of the electronics so I have opted for an SSD1306 0.96" 128x64 display for now.

03.07.2024:

Uploaded a photo of the prototype in operation including stripboard layouts for the ESP32 and amp sections prior to PCB design and manufacture.

08.06.2024:

The speaker housing has been uploaded as a separate FreeCAD file. It was designed to house a specific type of speaker I scavenged from an old stereo but can be modified to suit other types of round speakers. This has been tested with the integrated amplifier module using my Fire Tablet and the amplifier and speakers work together properly.

I am hoping to eventually release board files for the CPU module if/when I get around to finishing the design and getting them produced but for now the prototype is on perfboard.

03.05.2024: 

The skeleton of the radio is starting to look a lot more like I originally intended. It'll probably take a few more revisions before I could actually class this as a buildable project for almost anyone. It looks like one of the decoder boards I bought is busted but the old one seems to work fine on the breadboard while I'm testing and working out wiring. There's still the power supply module to complete, and the display module. I've not even checked if either of the displays I bought work yet! :/

Part List:

• SSD1306 OLED
• Rotary encoder
• ESP32 development board (or equivalent)
• VS10xx Codec board
• 2x 8ohm 3W speakers
• 2x 600:600 audio transformers
• 1 PAM8408 amplifier breakout
• Stranded 22AWG hookup wire, multiple colours.
• Dupont connector set with crimp sockets and pins.

You will also need stripboard if you are attempt to build the prototype amplifier board.

I already have a crimping tool for the dupont connectors. It is a relatively cheap one but does the job nicely.