CDE HAM-2 Antenna Rotor WiFi Controller

WiFi remote control system for a CDE HAM-2 antenna rotor with safety-first design principles for mechanical control systems.

Features

• Web Interface: Real-time compass display, manual CW/CCW controls, automatic go-to-heading
• Safety State Machine: Enforced brake release timing (1s before rotation, 1.5s after)
• Position Feedback: ADC-based position reading with averaging and calibration
• WiFiManager: No hardcoded credentials - configure via captive portal on first boot
• OTA Updates: Update firmware over WiFi
• mDNS: Access at http://rotor-control.local

Hardware

• Microcontroller: ESP32 Dev Module with integrated 4-channel relay module
• Relay Logic: Active LOW (LOW = ON, HIGH = OFF)
• GPIO Mapping:
  • GPIO 32: Brake Release (Relay 1)
  • GPIO 33: Clockwise Rotation (Relay 2)
  • GPIO 25: Counter-Clockwise Rotation (Relay 3)
  • GPIO 26: Spare (Relay 4)
  • GPIO 34: ADC Position Input
• Position Feedback: 470kΩ/100kΩ voltage divider from rotor meter (0-12.6V → 0-2.2V)

Safety Features

• 1 second brake release delay before rotation starts
• 1.5 second delay after rotation stops before brake re-engages
• 60 second maximum continuous rotation timeout
• Emergency stop with immediate halt
• All relays initialize to OFF on startup

Installation

Required Libraries

Install via Arduino Library Manager:

• WiFiManager (by tzapu)

Built-in libraries (no installation needed):

• WiFi, WebServer, ESPmDNS, ArduinoOTA, EEPROM

Arduino IDE Settings

• Board: ESP32 Dev Module
• Upload Speed: 115200
• Partition Scheme: Default (with OTA)

First-Time Setup

1. Upload firmware via USB
2. Connect to "Rotor-Controller-Setup" WiFi AP
3. Configure your home WiFi in the captive portal
4. Access web interface at http://rotor-control.local

Calibration

The CDE HAM-2 indicator starts at South (180°) at 0V and sweeps CW through 360° back to South at ~12.5V.

1. Manually rotate rotor to 0° (North) - this is mid-scale on the meter
2. Note: Calibration is set via web interface "Set 0°" and "Set 360°" buttons
3. Position at minimum voltage (South/180°) and click "Set 0°" (represents start of sweep)
4. Position at maximum voltage (South/180° after full rotation) and click "Set 360°"

API Endpoints

Endpoint	Method	Description
/	GET	Web interface
/status	GET	JSON status data
/cw	GET	Start clockwise rotation
/ccw	GET	Start counter-clockwise rotation
/stop	GET	Stop rotation
/emergency	GET	Emergency stop
/clear	GET	Clear emergency stop
/goto?heading=N	GET	Auto-rotate to heading (0-359)
/cal/min	GET	Set current ADC as 0°
/cal/max	GET	Set current ADC as 360°
/cal/reset	GET	Reset calibration to defaults

License

MIT License