Project Overview
Step-by-Step Development Process
STEP 1: Sourcing the core brewing components.
I needed a system that was high quality, reasonably priced, and flexible allowing me to tap into the system with custom sensors and control PCBs.
This electric brew kettle and mashtun (2 in 1 system) with conical fermenter was the perfect fit. It allows for precise control with an electric heat element, pump ports, and temperature sensor built in. Made of high quality stainless steel at a decent price.
STEP 2: Designing the PCBs
Before going further with building the system, I wanted to architect my data collection and control system. This is the brains behind the entire operation.
Luckily, there are low cost tools to use that can organize and prepare your electrical systems for a professional outcome.
STEP 3: PCB Assembly
Soldering components onto PCBs can be extremely tricky. The right tools and the right setup ensure you get the best results without mistakes.
I took some time to research and invest in a soldering station and it made the process much easier. See how I did it in the video below.
STEP 4: PCB Enclosure Boxes
PCBs need protection from physical damage as well as water and dust and it's also important to protect the electrical connections while still allowing airflow over the components so they don't overheat.
The answer? A well made enclosure box. See how I set mine up for these PCBs and witness the boards come to life for the first time in the following video.
It also covers basic voltage readings to check for functionality, a critical step before moving forward with the rest of the build. If you have a problem with the PCB, find out first before you finish the build to save on time and resources.
STEP 5: PCB Enclosure Boxes, Finished!
Always consider bulkhead connectors on enclosure boxes instead of pass through wiring. It makes for much easier installation and removal for maintenance purposes. And, if you choose water-proof connections it can lead to better protection against water and dust ingress.
Also, put some kind of filter on the box inlet if using a fan to minimize dust and dirt being sucked in. Here, I chose standard PC fans and filters as they are readily available and inexpensive.
I also used standard 2.1mm barrel jack connectors for my two wire circuits as they are readily available, inexpensive, and very easy to install. In the end, I was able to find bulkhead connectors for all circuits which will make my life much easier when installing and routing cables in my brewery.
I also included a WiFi antenna on the box to boost the signal of my ESP32 WiFI board to ensure stable connection.
STEP 6: Dashboard is Live!
Now that we have PCBs that work and fully assembled enclosure boxes, we need to start building out the collection and control software.
I'm building out a slick dashboard web application that will control circuits remotely, log data, and display real-time statistics of the brewing process as it happens. This will enable automation, edge computing, and AI analytics and optimization.
I also include some valuable lessons learned and one powerful framework that leverages AI and transforms it into an extremely fast, flexible, and powerful tool to help your teams win.