Planning a New Weather Station Revision#

Today was a different kind of day.

It was far too hot to work in the workshop, so I spent the afternoon planning, designing, and sitting under the air conditioner. For reference, the UK has been recording some record-breaking June temperatures this week, and it has been absolutely sweltering.

With workshop work off the table, I turned my attention back to the weather station project I completed a few weeks ago and started thinking about a possible new revision.

The original project has been running away in my workshop for a few weeks now, also recording some rather uncomfortable temperatures. Since then, I have created a few more building block boards, and I think there is now an opportunity to expand the weather station into something more versatile and more generic.

It could become a building block board in its own right, or perhaps a more general-purpose data logger board.

A Small Online Dashboard Demo#

My current idea is to create a simple online dashboard demo for the Protoworks website.

The dashboard would allow visitors to check the current conditions in my workshop, but I would like it to be more than just a static temperature readout. I want to add a few extra features to make it more interesting and interactive.

It will probably sit on the low-priority queue for now, but I think it could become a useful little showcase for what can be done with the building block boards.

A live workshop dashboard would be a nice practical demo: real hardware, real sensor readings, real logging, and a simple web interface.

Possible Hardware Changes#

Some of the enhancements I am considering include:

  • ESP32-C3 Integration: Replacing the original SuperMini dev board with a raw ESP32-C3-WROOM-02-N4 module soldered directly to the PCB for a cleaner, production-ready footprint.
  • Onboard USB-to-Serial: Integrating a CH340C or similar USB-to-UART converter to allow direct programming and serial debugging via a USB-C port without needing external programmers.
  • RS485 Transceiver: Adding native RS485 support. I am still weighing whether a simple, low-cost transceiver is enough, or if this board warrants fully isolated transceivers for harsher environments.
  • Local Data Logging: Adding a micro SD card slot to act as a local storage buffer in case the Wi-Fi drops out.
  • Expanded Bus Exposure: Breaking out the remaining SPI and I2C lines to terminal blocks or headers so the board can easily accept external industrial sensors.

The biggest design challenge here will be managing the ESP32-C3’s tight pin budget. Balancing an SPI-based micro SD card, two independent UARTs (USB and RS485), and an I2C bus on a chip with only 15 accessible GPIOs means careful layout planning around the hardware’s critical strapping pins.

At that point, the board starts to look less like a fixed-purpose weather station and more like a small ESP32-based sensor, logging, and communications platform.

Weather Station or General-Purpose Data Logger?#

That is probably the most interesting design question.

The original version was built to solve a specific problem: measure workshop conditions and report them wirelessly. A revised version could still do that, but if I expose enough useful interfaces, it could also be used for other small data-logging projects.

For example:

  • environmental monitoring
  • simple machine monitoring
  • remote sensor nodes
  • RS485-connected measurement points
  • local logging with later upload
  • dashboard and demo projects

That would make the board a better fit for the building block board idea: small, practical, reusable, and flexible enough to be used in several different projects.

Isolated RS485 Planning#

I also started turning my attention back to the isolated RS485 building block board.

One possible route is to use a TI ISO1430 transceiver with a small isolated DC-to-DC converter to provide the isolated power supply. The goal is to keep the design robust while still keeping the bill of materials under control.

I would like to avoid expensive parts where a lower-cost option will do the job properly, but the isolated RS485 board is one area where it is worth being careful. The whole point of the board is to provide better protection and better behaviour when connecting equipment across longer cable runs, different supplies, or noisier environments.

So the current design direction is:

  • keep the non-isolated RS485 board simple and low cost
  • make the isolated RS485 board more robust
  • use the right parts where isolation genuinely matters
  • avoid adding unnecessary complexity where it does not help

Next Steps#

For now, both ideas are still in the planning stage.

The weather station revision could become a fun public demo for the website, while the isolated RS485 board feels like a more serious addition to the building block board range.

Both are useful in different ways.

The weather station/data logger would show what the boards can do in a visible and interactive way. The isolated RS485 board would strengthen the more practical communications side of the range.

Not a bad result for a day spent avoiding the workshop heat.

If you are working on custom carrier boards, sensor integration, or ESP32 prototypes and need an experienced engineering partner, let’s discuss your project at Protoworks (NI).