OpneHab, esp8266 And MQTT - Smart Lighting Project

Hello everyone,
Today I wanted to talk about a old project of mine. I am talking about it just now because like every hardware project of mine, it gets delayed because many design issues.. but the important thing is that I don't give up!
I mean smart lighting is not really new, and not really creative.. you can probably find this title in other blog, but it's really cool in my opinion.
Let's get started:
Why smart lighting? basically.. because I am lazy..
Why not using already retail product? because it's expensive and not challenging.

Actually the real reason for me was my eyes sensitivity to light. In the last years I started walking more and more with sunglasses. In time, my eyes became really sensitive to light (yeah I know, I sound like a basement nerd), which requires changing my light brightness in the room (it was too bright). I got a regular fluorescent lamp, which cannot be dimmed.

Regular incandescent bulb can be dimmed but are really inefficient and the light is yellowish and not nice and natural white. At this point I said let's build some LED based one. At this time the LED strips are really popular, I can use them to light my room.
I used 8 RGB strips of 2.5M

Two 12V 12A power supplies with modified cooling.
This design was tested and I was really disappointed. Those LED strips has afoul efficiency, at 250W they were still less bright than two 32W T8 fluorescent. Each LED got its own resistor, making the entire consumption go to heating the resistors. Even more, for some reason RGB led making white color is much less efficient than just white LED. Also, the cheap LED strips has horrible color uniformly. Each batch is different, and some strips has slightly different colors :(

Knowing the RGB and LED strips are really inefficient, I decided to separate the main white lighting and the RGB one, and of course not using LED strips.  I bought simple 10W RGB LED, and some 220v 15W LED plate.
I will control the brightness with esp2866 PWM connected to MOSFET regulating the 220V.
The first try didnt work because of the LED 220v driver is sensitive to the PWM for some reason.
Second try was a 24W LED plate X4 connected in series, meaning no driver is needed.

The result:

(You may or may not see the thermistor)
Electronics:

From the bottom to up:
PCA9685 - PWM Controller
ESP8266 - Wifi controller based on LUA/Arduino

The GPIO transformer created some problems, it got replaced by optocoupler (made much more sense).

Software
Arduino:

	#define PCA9685_SERIAL_DEBUG 0
	#include "Arduino.h"
	#include <ESP8266WiFi.h>
	#include <ArduinoOTA.h>
	#include <PCA9685.h>
	#include <Wire.h>
	#include <PubSubClient.h>
	// Update these with values suitable for your network.
	const char* ssid = "yaron";
	const char* password = "********";
	const char* mqtt_server = "10.0.0.2";
	unsigned long start, finished;
	WiFiClient espClient;
	PubSubClient client(espClient, "10.0.0.2");
	PCA9685 driver = PCA9685(0x0, PCA9685_MODE_P_DRIVER, 800.0);
	long lastMsg = 0;
	char msg[50];
	int value = 0;
	int brightness_rgb = 4095;
	int gpio0_interrupt = 0, gpio0_interrupt_previous = 0;
	void setup_wifi() {
	delay(10);
	WiFi.begin(ssid, password);
	while (WiFi.status() != WL_CONNECTED) {
	delay(500);
	}
	}
	void callback(const MQTT::Publish& pub) {
	if (String(pub.topic()) == "/YSHome/YaronRoom/Lighting/MainWhite") {
	driver.getPin(PCA9685_LED0).setValueAndWrite(pub.payload_string().toInt());
	}
	if (String(pub.topic()) == "/YSHome/YaronRoom/Lighting/RGB") {
	String payload = pub.payload_string();
	int c1 = payload.indexOf(',');
	int c2 = payload.indexOf(',',c1+1);
	int red = int(payload.substring(0,c1).toFloat());
	int green = int(payload.substring(c1+1,c2).toFloat());
	int blue = int(payload.substring(c2+1).toFloat());
	driver.getPin(PCA9685_LED2).setValueAndWrite(red);
	driver.getPin(PCA9685_LED1).setValueAndWrite(green);
	driver.getPin(PCA9685_LED3).setValueAndWrite(blue);
	}
	if (String(pub.topic()) == "/YSHome/YaronRoom/Lighting/RGB/Brightness") {
	brightness_rgb = pub.payload_string().toInt();
	}
	}
	void reconnect() {
	// Loop until we're reconnected
	while (!client.connected()) {
	if (client.connect("ESP8266Client")) {
	client.subscribe("/YSHome/YaronRoom/Lighting/MainWhite");
	client.subscribe("/YSHome/YaronRoom/Lighting/RGB");
	client.subscribe("/YSHome/YaronRoom/Lighting/RGB/Brightness");
	} else {
	// Wait 5 seconds before retrying
	delay(5000);
	}
	}
	}
	void setup_ote()
	{
	ArduinoOTA.onStart([]() {
	});
	ArduinoOTA.onEnd([]() {
	});
	ArduinoOTA.onProgress([](unsigned int progress, unsigned int total) {
	});
	ArduinoOTA.onError([](ota_error_t error) {
	if (error == OTA_AUTH_ERROR) Serial.println("Auth Failed");
	else if (error == OTA_BEGIN_ERROR) Serial.println("Begin Failed");
	else if (error == OTA_CONNECT_ERROR) Serial.println("Connect Failed");
	else if (error == OTA_RECEIVE_ERROR) Serial.println("Receive Failed");
	else if (error == OTA_END_ERROR) Serial.println("End Failed");
	});
	ArduinoOTA.begin();
	}
	void setup_leds()
	{
	Wire.begin(2,14); // Wire must be started!
	// setup the PCA9685
	driver.setup();
	driver.getPin(PCA9685_LED0).setValueAndWrite(0xff);
	}
	void callback_publish()
	{
	client.publish("/YSHome/YaronRoom/Lighting/Temperature", String(analogRead(A0)));
	}
	void gpio_transformer_interrupt()
	{
	gpio0_interrupt=1;
	}
	void setup() {
	pinMode(BUILTIN_LED, OUTPUT); // Initialize the BUILTIN_LED pin as an output
	//Serial.begin(115200);
	setup_wifi();
	setup_ote();
	setup_leds();
	start=millis();
	pinMode(5, INPUT);
	attachInterrupt(5, gpio_transformer_interrupt, CHANGE);
	client.set_callback(callback);
	}
	void loop() {
	ArduinoOTA.handle();
	if (!client.connected()) {
	reconnect();
	}
	client.loop();
	finished=millis();
	if (finished - start > 2000) {
	start=millis();
	callback_publish();
	}
	if(gpio0_interrupt) {
	gpio0_interrupt=0;
	if(gpio0_interrupt_previous != digitalRead(5)) {
	client.publish("/YSHome/YaronRoom/Lighting/gpio0",String((int)digitalRead(5)));
	gpio0_interrupt_previous=digitalRead(5);
	}
	}
	}

view raw mqtt.cpp hosted with ❤ by GitHub

As you can see we are supporting OTA!
The openhab side is really easy except the gamma correction.  You can read about it here.
Simple gamma correction code:

	// Generate an LED gamma-correction table for Arduino sketches.
	// Written in Processing (www.processing.org), NOT for Arduino!
	// Copy-and-paste the program's output into an Arduino sketch.
	float gamma = 2.8; // Correction factor
	int max_in = 255, // Top end of INPUT range
	max_out = 255; // Top end of OUTPUT range
	void setup() {
	print("const uint8_t PROGMEM gamma[] = {");
	for(int i=0; i<=max_in; i++) {
	if(i > 0) print(',');
	if((i & 15) == 0) print("\n ");
	System.out.format("%3d",
	(int)(pow((float)i / (float)max_in, gamma) * max_out + 0.5));
	}
	println(" };");
	exit();
	}

view raw gama.c hosted with ❤ by GitHub

This code create sample gamma table. I took the code and converted it to openhab rule

	import org.openhab.core.library.types.*
	import java.lang.Math
	var Number maxPwmValue = 4095
	rule "Set RGB value TreeLight"
	when
	Item TreeLight changed
	then
	val hsbValue = TreeLight.state as HSBType
	val redValue = ((((hsbValue.red.intValue * maxPwmValue))) / 100)
	val greenValue = ((((hsbValue.green.intValue * maxPwmValue))) / 100)
	val blueValue = ((((hsbValue.blue.intValue * maxPwmValue))) / 100)
	redValue = (maxPwmValue - (Math::pow(redValue.floatValue/maxPwmValue.floatValue,2.8) * maxPwmValue + 0.5)).toString
	greenValue = (maxPwmValue - (Math::pow(greenValue.floatValue/maxPwmValue.floatValue,2.8) * maxPwmValue + 0.5)).toString
	blueValue = (maxPwmValue - (Math::pow(blueValue.floatValue/maxPwmValue.floatValue,2.8) * maxPwmValue + 0.5)).toString
	val color = redValue + "," + greenValue + "," + blueValue
	sendCommand( TreeLightColor, color )
	end

view raw gamma.java hosted with ❤ by GitHub

Testing

The white is really great at 100W max
Usually in the night I am at 25%-33% power, in the day about 50% power. Fully power the LEDs my room becomes white torture room, really bright.
For now the firmware is really basic. I don't mind because of the OTA feature, I don't have to disassemble the LEDs from the sealing.
Future plans may include
- Sending thermal only when active
- Thermal protection in the firmware
- What to do with the 220V GPIO
- Fast protocol for changing colors faster
- Connecting the LEDs to VLC and changing the colors according to the movie.
- (Not mine!!)

Thats it for now!