Family Christmas Display

HOME WHY WE DO IT HOW IT ALL BEGAN 2016 TO PRESENT HOW IT'S DONE CREDITS

A project of this scope requires tapping numerous diverse technologies including electrical, mechanical and software design. In addition, there are opportunities to explore numerous techniques for infrastructure build.

Here is a short summary of the technologies I ended up using to integrate the display into an automated operation that I could simply turn on and let it run without further intervention.

WEB/INTERNET

Internet Domain Name
Porkbun.com provided us the Brinkman.Christmas internet domain name.
Internet Web Site
You're viewing information about the display on our internet web site, also hosted on Porkbun.com web servers.
Dynamic Domain Name
Live information for the Display is not provided by the Internet web site; it is provided by the Master unit that actually runs the Display. In order to seamlessly provide this capability a Dynamic Domain Name Service (DDNS) must be purchssed to direct users to the address Live.Brinkman.Christmas.
Local Web Site
Live information about the Display is provided by the local web site, an ESP32 microprocessor. Information provided includes the FM 89.3 MHz radio frequency, the song list (showing the song playing at the time), and weather information.
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CONTROL

Distributed Control
Outdoor displays are large - some are several blocks long. It quickly becomes impractical to run long wires to each light or string of lights. As a result, control of the display is divided into smaller, locally controlled segments.
Master Unit
The Master unit controls everything in the Display. It decides what to play, when to play it, then wirelessly commands all of the Slave units to do their part of the show. The Master unit has the Light Command script for all units, a wireless transceiver, the Music Player, the FM Radio Transmitter, a Clock, and even a Weather Station.
Slave Units
Each local Slave unit operates at the direction of the Master unit. Its instructions are received wirelessly from the Master unit. It has an assigned subset of lights to control and turns them on/off as directed. When asked, Slave units give a Health report to the Master unit.
State Machine
The computers operate as "state" machines. The computers stay in their current state until specific conditions are met before moving on to another state. The technique helps keep the logic simple because there is a single focus for each state. The Christmas display state machine is as follows:
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COMPONENTS

Software
Computer programs, or software, give the ability to take a generic computer and customize it to function exactly as required to meet the needs of the application designer. Following are the software tools that make this happen.
Arduino C++ Language Reference
Computer programs are written in a human-readable structured langage that can be interpreted by machines to do what the programmer intended them to do. Programs for the Christmas display are written in the C++ language.
Arduino Integrated Development Environment (IDE)
Before the program can actually be used by the computer it must be "compiled" into a language/format that the computer can understand. The Arduino IDE compiles and loads the program into the Christmas display computers.
Christmas Display Program
The Christmas display program that is loaded into the Master and Slave units is identical. Each unit is assigned a Unit Number, which tells that unit which role(s) it plays in the Display.
Playlist
The Master unit opens a Playlist and an Announcement List that tell the Display which songs and announcements to play. When the lists are completed they start over at the beginning.
Audio Files
The music player contains "MP3" format audio files that are played when called for on the Playlist/Announcement list.
Light Files
A microSD disk drive contains Light Command files that tell the computer what lights to turn on, and when. In addition to lights, commands that cause servos to move up/down/left/right are contained in the file. The light and servo commands are timed to match the music being played. Up to 464 lights/light strings and 12 servos can be controlled by the Display. Each time a light(s) needs to be turned on/off or a servo position changed the command for all 464 lights and 12 servos is transmitted, even if only one light changed.
Network Time Protocol (NTP)
The Display needs to turn on at 5:30 and turn off at 11:00 each day. The internet provides a service (NTP) that anybody can contact to get an accurate report of the current time. When the processor turns on one of the first things it does is contact the NTP server to get the current time. It then updates the local Real Time Clock (RTC - see below) to keep track of time from that point on. NTP is consulted for a time update once per day to update the RTC just in case the RTC has drifted slightly.
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Hardware
Software loaded into the computers tells the computers what to do; in turn, the computers are attached to other hardware to receive information or to cause an action to be taken.
Arduino Mega 2560
All the Slave units, and the Master unit through 2018 were powered by Arduino Mega 2560 microprocessor computers. The Mega is an 8 bit computer that has a 16 MHz processor and many digital and analog interfaces that make it easy to connect to other hardware. In addition, standard interfaces minimize the effort required to get the hardware devices to talk to each other.
Arduino Mega 2560 + ESP8266
In 2019 the Master unit was upgraded to pair the Mega with a ESP8266 processor that has WiFi capability. For the first time this permitted the status of the Display to be viewed and controlled via a web page.
DOIT ESP32 DEVKIT V1*
In 2020 the Master unit Arduino Mega + ESP8266 was replaced by an ESP32 microprocessor computer. The ESP32 has two 32 bit processors that run at 240 MHz; the resulting performnce is about 200 times faster than the Mega. In addition to digital and analog interfaces, the ESP32 has built-in WiFi, Bluetooth, and a Real Time Clock (RTC).
Shift Registers
The microprocessors are powerful, but they have a limited number of pins to output data. Since we need to connect up to 464 light strings, we need a way to get the data out to 464 different places. The microprocessor sends one bit at a time out to a series of 74HC5595 shift registers. Each shift register holds 8 bits but can be strung together to hold as many bits as required. Each bit is used to control a light string on or off depending on the value of the bit.
Solid State Relays (SSRs)
Microcontrollers operate at voltages between 3.3 - 5 VDC. Many light strings operate at 110 VAC. The job of the SSR is to accept a low voltage command from a shift register and activate a high voltage light string.
High Power Transistors
Microcontrollers and shift registers can provide 20-40 mA current to LED light strings. A typical LED light string requires about 340 mA. The transistors connect to a shift register pin and provide the boost needed. Transistors can drive a range of voltages from 5 to as high as 60 VDC if required.
Transceivers
Each unit has a HC-12 transmitter/receiver (transceiver) that permits communication between the Master and Slave units. The transceivers operate at a frequency of 433 MHz and have a range of a 1 Km. Each set of light commands are broadcast by the Master unit to the Slave units in about 17 ms. With plenty of room reserved for cushion, a new light command can be issued every 50 ms, or 20 times per second.

Slave units also use the transceivers to report their health back to the Master unit, permitting corrective action to be taken if there is a problem.

Real Time Clock (RTC)
The Display needs to turn on at 5:30 and turn off at 11:00 each day. The RTC keeps track of time to make this possible.

The RTC must initially be set to the correct time. Prior to the ESP8266 and ESP32 this is accomplished by manually looking at the clock and entering the corrcet time into the RTC. Once set, the RTC kept accurate time for up to two years using a small battery attached to the RTC.

When the Display was upgraded to an ESP8266 {with internet access), the manual update process was replaced by an automated NTP process (see description above).

When the Display switched to the ESP32 processor the RTC was built-in to the processor, eliminating the need for an external RTC.

Music Player
When the Playlist selects a song the DFPlayer mini is responsible to play the song. The DFPlayer mini has a built-in microSD card reader that contains the MP3 music files that are played. The output of the music player goes to the FM transmitter.
FM Transmitter
The stereo output from the music player goes to the low power (100 mW) FM transmitter. The Display broadcasts music on FM 89.3 MHz; the range is about 1 block.
Weather Station
The Display includes a temperature, humidity and barometric pressure sensor. The information from the sensors is included on the Live web page available to users.
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ASSEMBLIES

VU Meter
The Display contains a custom-built Volume Unit Meter (VUmeter) that activates up to 16 vertical LED bars based on music volume.
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DISPLAYS

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