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# Xterra Overland Power & Monitoring Dashboard Architecture
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# Xterra Overland Power & Monitoring Dashboard
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## Overview
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## Purpose
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The Xterra Overland Power & Monitoring Dashboard is a distributed monitoring and control system consisting of:
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A custom monitoring and control system for a Nissan Xterra using a Raspberry Pi Pico 2 W dashboard interface and an ESP32 cargo-area controller.
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* Raspberry Pi Pico 2 W dashboard module
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* ESP32 cargo-area controller
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* RS-485 wired communications
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* WiFi backup communications
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* Touchscreen dashboard interface
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The system provides:
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The system is designed to operate completely offline and continue functioning even when WiFi is disabled.
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---
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## System Goals
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* Monitor house battery status
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* Monitor fridge temperatures
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* Monitor rear seat temperature
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* Monitor outside ambient temperature
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* Control Starlink power
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* Control fridge power
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* Provide a dashboard display while driving
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* Expand later to vehicle telemetry and trip logging
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---
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- House battery monitoring
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- Fridge monitoring
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- Temperature monitoring
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- Power control
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- Alarm management
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- Future vehicle telemetry
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## Dashboard Module
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### Hardware
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* Raspberry Pi Pico 2 W
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* 3.5" touchscreen
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* Powered by 5V from cargo-area buck converter
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- Raspberry Pi Pico 2 W
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- 3.5" SPI Capacitive Touchscreen
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- RS-485 communications
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- WiFi backup communications
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### Responsibilities
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* Display information
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* Accept touch input
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* Send commands to controller
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* Display alarms and warnings
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* Provide user configuration interface
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- Touchscreen user interface
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- Local web dashboard
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- Alarm display
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- Configuration management
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- Relay control interface
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- Data visualization
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### Communications
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Primary:
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* RS-485 over CAT5
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Secondary:
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* WiFi HTTP API
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---
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## Controller Module
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## Cargo Module
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### Hardware
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* ESP32 relay board
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* House battery connection
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* Bosch-style automotive relays
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- ESP32 Relay Controller
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- RS-485 Interface
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- House Battery Interface
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- DS18B20 Temperature Sensor Bus
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- Bosch Relay Drivers
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### Responsibilities
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* Read sensors
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* Interface with BMS
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* Control relays
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* Serve API data
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* Handle logging
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---
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## Temperature Sensors
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### Planned Sensors
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1. Fridge Zone 1
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2. Fridge Zone 2
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3. Rear Seat Temperature
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4. Outside Ambient Temperature
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5. Battery Compartment Temperature (future)
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### Interface
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* DS18B20
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* Shared 1-Wire bus
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* Connected to ESP32
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---
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## Battery Monitoring
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### Planned BMS
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* Xiaoxiang / JBD Bluetooth BMS
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### Data Collected
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* State of Charge
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* Voltage
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* Current
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* Remaining Capacity
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* Runtime Estimate
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* Battery Temperature
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* Cell Voltages
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* Cell Imbalance
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---
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## Relay Control
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### Current Loads
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* Starlink
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* Fridge
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### Future Loads
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* Inverter
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* Camp Lights
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### Design
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ESP32 relay outputs SHALL NOT carry load current.
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ESP32 relays will only energize Bosch-style 30A/40A automotive relays.
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All loads must be fused appropriately.
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---
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- Sensor collection
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- Relay control
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- Alarm processing
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- Communications server
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- Configuration storage
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## Communications
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### Primary
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Primary:
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- RS-485
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RS-485 over CAT5
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Backup:
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- WiFi HTTP API
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Advantages:
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* Reliable
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* Noise resistant
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* Independent of WiFi
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* Works while driving
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### Backup
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WiFi HTTP API
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Used for:
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* Phone access
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* Web dashboard
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* Configuration
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* Future Home Assistant integration
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---
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## WiFi Rules
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### Starlink OFF
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* Dashboard operational
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* Sensors operational
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* Relay control operational
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* WiFi disabled
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* Web dashboard disabled
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### Starlink ON
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* WiFi enabled
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* Web dashboard enabled
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* Remote access enabled
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### Override
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User may temporarily enable WiFi for troubleshooting.
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Default timeout:
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10 minutes.
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---
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## Dashboard Behavior
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### Ignition ON
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* Screen active
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* Full brightness
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### Ignition OFF
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* Screen black
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* Pico remains powered
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* Touch input remains active
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Touching screen:
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* Wake display
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* Display dashboard
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* Auto-sleep after timeout
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---
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Future:
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- MQTT
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- Home Assistant
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- Grafana
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- InfluxDB
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## Future Expansion
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### Vehicle Data
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* OBD-II
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* CAN bus
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* Fuel level
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* RPM
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* Coolant temperature
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* Vehicle speed
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### Navigation
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* GPS
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* Trip logging
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### Connectivity
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* MQTT
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* Home Assistant
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* InfluxDB
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* Grafana
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### Additional Sensors
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* Additional DS18B20 sensors
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* Voltage sensors
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* Current sensors
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* Environmental monitoring
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- JBD/Xiaoxiang BLE Battery Monitoring
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- OBD-II
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- CAN Bus
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- GPS
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- Trip Logging
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- Fuel Level
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- Coolant Temperature
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- RPM
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- Starlink Diagnostics
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@@ -0,0 +1,41 @@
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# Communications
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## Architecture
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Pico Dashboard
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↓
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RS-485
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↓
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ESP32 Controller
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Backup:
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WiFi
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## Protocol
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Message Types:
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- status_request
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- status_response
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- set_relay
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- relay_response
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- enable_wifi
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- wifi_response
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- toggle_ignition
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- ignition_response
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- toggle_sensor_fault
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- sensor_fault_response
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## Failure Handling
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If RS-485 is lost:
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- Dashboard displays warning
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- Last known values remain visible
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- Relay commands fail safely
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## Future Features
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- MQTT
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- Home Assistant
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- OTA Updates
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- Remote Diagnostics
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# Dashboard User Interface
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## Dashboard Screen
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Displays:
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- Battery %
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- Runtime Remaining
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- Fridge Zone 1 Temperature
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- Fridge Zone 2 Temperature
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- Rear Seat Temperature
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- Outside Temperature
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- Starlink Status
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- Fridge Status
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## Battery Screen
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Displays:
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- SOC
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- Voltage
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- Current
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- Remaining Ah
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- Runtime Estimate
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- Battery Temperature
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Future:
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- Cell Voltages
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- Cell Imbalance
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- Charge Cycles
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## Temperature Screen
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Displays:
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- Fridge Zone 1
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- Fridge Zone 2
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- Rear Seat
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- Outside Air
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Future:
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- Battery Bay
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- Cabin Air
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## Power Screen
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Controls:
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- Starlink
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- Fridge
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Future:
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- Inverter
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- Camp Lights
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## System Screen
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Displays:
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- RS-485 Status
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- WiFi Status
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- Message Counts
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- Latency
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- Packet Loss
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Testing:
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- RS-485 Disconnect
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- Sensor Fault Simulation
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- Ignition Simulation
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## Config Screen
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Configuration:
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- Alarm Thresholds
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- Audible Alarm Settings
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Future:
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- WiFi Settings
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- Device Naming
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- Firmware Information
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# Project Decisions
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## Communications
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Primary:
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- RS-485
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Backup:
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- WiFi
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## Dashboard
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- Touchscreen only
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- No physical buttons required
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- Screen sleeps when ignition is off
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- Touch wakes display
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## Relay Design
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- ESP32 relay board does NOT switch loads directly
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- Bosch-style automotive relays switch all major loads
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## Power Loads
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Current:
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- Starlink
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- Fridge
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Future:
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- Inverter
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- Camp Lights
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## Sensors
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Current:
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- Fridge Zone 1
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- Fridge Zone 2
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- Rear Seat Area
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- Outside Air
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Future:
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- Battery Bay
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- Cabin Air
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- Water Tank
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## Configuration
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Configuration is stored on controller side, not browser side.
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## Logging
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No persistent logging currently planned.
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Focus:
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- Live monitoring
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- Alarms
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- Control
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# Project Roadmap
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## Phase 1 — Simulator
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Status: Complete
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Features:
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- Dashboard UI
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- Alarm System
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- Sensor Simulation
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- RS-485 Simulation
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- Protocol Layer
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## Phase 2 — Pico Dashboard
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Status: Pending
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Features:
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- 3.5" Touchscreen
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- Native Dashboard UI
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- Sleep/Wake Functionality
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## Phase 3 — ESP32 Controller
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Status: Pending
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Features:
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- Relay Control
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- RS-485 Communications
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- Configuration Storage
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## Phase 4 — DS18B20 Sensors
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Status: Pending
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Features:
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- Fridge Monitoring
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- Rear Seat Monitoring
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- Outside Temperature
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## Phase 5 — JBD BLE Integration
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Status: Pending
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Features:
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- SOC
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- Voltage
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- Current
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- Remaining Ah
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- Cell Voltages
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## Phase 6 — Vehicle Telemetry
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||||
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Status: Pending
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||||
Features:
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- OBD-II
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- CAN Bus
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- RPM
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- Coolant Temperature
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- Fuel Level
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## Phase 7 — Integrations
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Status: Future
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Features:
|
||||
- MQTT
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- Home Assistant
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||||
- Grafana
|
||||
- InfluxDB
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||||
@@ -0,0 +1,61 @@
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# Sensor Architecture
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## Current Sensors
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### Fridge Zone 1
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Purpose:
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Refrigerator or freezer monitoring.
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Alarm:
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User configurable.
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### Fridge Zone 2
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Purpose:
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Refrigerator or freezer monitoring.
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||||
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||||
Alarm:
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||||
User configurable.
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||||
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||||
### Rear Seat Area
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Purpose:
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Monitor child seating area.
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||||
Alarms:
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- Warning Threshold
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- Critical Threshold
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||||
### Outside Air
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||||
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||||
Purpose:
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Ambient outside temperature.
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||||
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||||
## Future Sensors
|
||||
|
||||
### Battery Bay
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||||
Purpose:
|
||||
Battery compartment monitoring.
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||||
|
||||
### Cabin Air
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||||
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||||
Purpose:
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||||
Cabin temperature monitoring.
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||||
|
||||
### Water Tank
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||||
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||||
Purpose:
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||||
Water freeze protection.
|
||||
|
||||
### Cooler
|
||||
|
||||
Purpose:
|
||||
Secondary food storage monitoring.
|
||||
|
||||
## Sensor Bus
|
||||
|
||||
DS18B20 OneWire
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||||
|
||||
Single bus shared across all sensors.
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||||
@@ -0,0 +1,63 @@
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||||
# Wiring Overview
|
||||
|
||||
## House Battery Power Distribution
|
||||
|
||||
House Battery Positive
|
||||
├── 5A Fuse → ESP32 Controller
|
||||
├── 3A Fuse → 12V→5V Buck Converter
|
||||
├── 30A Fuse → Fridge Relay
|
||||
└── 30A Fuse → Starlink Relay
|
||||
|
||||
House Battery Negative
|
||||
├── ESP32 Ground
|
||||
├── Buck Converter Ground
|
||||
├── Relay Grounds
|
||||
└── Sensor Grounds
|
||||
|
||||
## Dashboard Power
|
||||
|
||||
12V House Battery
|
||||
↓
|
||||
Buck Converter (5V)
|
||||
↓
|
||||
CAT5 Cable
|
||||
↓
|
||||
Pico Dashboard
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||||
|
||||
## Communications
|
||||
|
||||
Pico
|
||||
↓
|
||||
RS-485
|
||||
↓
|
||||
ESP32
|
||||
|
||||
Backup:
|
||||
WiFi
|
||||
|
||||
## Relay Control
|
||||
|
||||
ESP32 Relay Output
|
||||
↓
|
||||
Bosch Relay Coil
|
||||
|
||||
Bosch Relay Contacts
|
||||
↓
|
||||
Fridge / Starlink / Future Loads
|
||||
|
||||
No high-current loads pass through the ESP32 relay board.
|
||||
|
||||
## Temperature Sensors
|
||||
|
||||
Single DS18B20 Bus
|
||||
|
||||
Sensors:
|
||||
- Fridge Zone 1
|
||||
- Fridge Zone 2
|
||||
- Rear Seat Area
|
||||
- Outside Air
|
||||
|
||||
Future:
|
||||
- Battery Compartment
|
||||
- Cabin Air
|
||||
- Water Tank
|
||||
|
||||
@@ -0,0 +1,26 @@
|
||||
# Hardware BOM
|
||||
|
||||
## Ordered
|
||||
|
||||
- Raspberry Pi Pico 2 W
|
||||
- ESP32 2-Channel Relay Board
|
||||
- 3.5" SPI Capacitive Touchscreen
|
||||
|
||||
## Required
|
||||
|
||||
- 2x MAX3485 RS-485 Modules
|
||||
- 4x DS18B20 Waterproof Sensors
|
||||
- 12V→5V Buck Converter
|
||||
- CAT5 Cable
|
||||
- Bosch Relay Sockets
|
||||
- 30A/40A Bosch Relays
|
||||
- Automotive Fuse Block
|
||||
- Assorted ATC Fuses
|
||||
|
||||
## Future
|
||||
|
||||
- Pi Zero 2 W
|
||||
- GPS Module
|
||||
- ELM327 OBD-II Interface
|
||||
- CAN Interface
|
||||
- Additional DS18B20 Sensors
|
||||
|
||||
@@ -0,0 +1,23 @@
|
||||
# CAT5 Pinout
|
||||
|
||||
Pair 1
|
||||
Blue +5V
|
||||
Blue/White +5V
|
||||
|
||||
Pair 2
|
||||
Orange Ground
|
||||
Orange/White Ground
|
||||
|
||||
Pair 3
|
||||
Green RS-485 A
|
||||
Green/White RS-485 B
|
||||
|
||||
Pair 4
|
||||
Brown Ignition Sense
|
||||
Brown/White Spare
|
||||
|
||||
Notes:
|
||||
|
||||
- Use twisted pair for RS-485
|
||||
- Double conductors for power
|
||||
- Spare conductor reserved for future use
|
||||
@@ -0,0 +1,18 @@
|
||||
# ESP32 Pinout (Planned)
|
||||
|
||||
GPIO 16 Relay 1 (Starlink)
|
||||
GPIO 17 Relay 2 (Fridge)
|
||||
|
||||
GPIO 4 DS18B20 Bus
|
||||
|
||||
GPIO 21 RS-485 TX
|
||||
GPIO 22 RS-485 RX
|
||||
GPIO 23 RS-485 DE/RE
|
||||
|
||||
GPIO 34 Ignition Sense
|
||||
|
||||
Future:
|
||||
- Additional Relays
|
||||
- Additional Sensor Inputs
|
||||
|
||||
Final assignments pending exact relay board verification.
|
||||
@@ -0,0 +1,17 @@
|
||||
# Pico Pinout (Planned)
|
||||
|
||||
Display:
|
||||
- SPI Touchscreen
|
||||
|
||||
Communications:
|
||||
- RS-485 Interface
|
||||
|
||||
Inputs:
|
||||
- Touchscreen
|
||||
|
||||
Future:
|
||||
- Physical Wake Button
|
||||
- Rotary Encoder
|
||||
- Status LED
|
||||
|
||||
Final pin assignments pending touchscreen testing.
|
||||
Reference in New Issue
Block a user