My latest project.

After years using X10 and ZWave I hit the limit with these devices where they simply do not conform to my evolving home control requirements.

Having played with Arduino's and MySensors quite a bit I decided to create my own devices based on MySensors and MQTT.

I designed a custom PCB for a custom node holding a Arduino Nano, the 2.4Hz RF module, a universal PSU and all required connections for up to 6 switches, 4 relays, DHT and Motion sensor.

I had the PCB printed by PCBWay (www.pcbway.com) in China. Their price for small batch prototype boards was great. Their service and speed of delivery was excellent. The quality of the PCB's I received is very high.

After cutting the PCB's in two, as I had two designs on each board, I ended with a PCB perfectly sized for a standard USA wall switch.

I'm using wall switch blank plates, with two captive touch sensors installed and a small hole drilled for the reset switch. The populated and completed PCB is than glued on the the back side of the blank plate. I used some good old fashioned wire wrapping technique to connect the touch switch wires to the PCB.

The now ready switch unit fits perfectly, with one relay module, in a single wall switch box, pr with up to 4 relay modules in a dual wall switch box.

I have 3 of these modules installed now, and in progress of completing another 5.

The touch switches work really well. They will activate if you come within 5mm from the wall switch unit. The two switches in each unit do not interfere with each other, so no accidental switch activation.

Read my post at HomeGenie for additional detail homegenie.it

Update - 10 July 2016

I've now created the sensor plate which can be used with the MySensors Node I developed.

I started with a dual keystone insert plate, the type used for network or cable tv connections. Using some router bits in my bench drill I machined the keystone slots to fit a DHT22 and a motion sensor module.

Bu pure coincidence the DHT22 has the exact same dimensions as the keystone slot at the back of the plate, all it required was machining away some of the height of the slot so the DHT22 sits flush.

Assembling and wiring the master switch unit. next step is to add the 4 relay units, connect all wires to the node and add the safety cover/joiner to prevent accidental interaction with the 110VAC.

The unit shown will have:

• 4 x touch switch activated relay
• 2 x touch toggle switch (what ever I want them to do in HomeGenie)
• motion sensor
• temperature & humidity

I will share more as this project is moving along.

Finally, after some months of extreme travel and work related activity I had some time again to continue with my project.

Below are some pictures of the switch and sensor modules with standardised connection header so I can switch them out and organise them any way I like in my wall switch module/frame.

Updated first post.

Better pictures and the newly create sensor plate which contains DHT22 and Motion and attaches to the node.

More to come.

I have two designs of my node.
First generation, as in the pictures, where I use an fuse in the hot wire.
Second generation where thermal fuse and varistor are on the pcb.

@dbemowsk
I think that with a little effort the switch and middle PCB can become one in a custom designed PCB. You'll end up with switches and LED's on one side and the Arduino and radio etc on the other side. That's what I did. This will make your design a lot more compact.

I used https://easyeda.com/ to design and manufacture my PCB's.

@dbemowsk

Oops, attached the wrong link.

I'm using the 400ma version of this PSU. The design uses 200ma max with 4 switches/LED's/SSR's, so plenty of overhead. I actually stepped away from the HLK-PM01 due to the very poor reliability of these modules, too many that failed within a few months.

I use an LE33 in TO92 package to create and regulate the 3.3v for the radio

The ripple is a non issue as I have 7 module of the previous design installed and working around the house.

I'm enclosing the entire module with a hot vacuum formed custom enclosure, so the entire circuit is fully protected. Amazing what you can do with a sheet of plastic, some wood, vacuum cleaner and a oven.

My design is also using multiple PCB's. There is a second PCB sitting on top containing 2 SSR's and related components

This was my previous design using relays not SSR but all other components are the same.

@dbemowsk

I'm currently working on the following PCB design for US Decora Wall Plate.

It's designed to have some components/ connections on the back, but most of the components on the front of the PCB.
It has provisions for connecting:
4 x Switch (A0, A1, A2, A3)
4 x LED (A4, A5, A6, A7)
4 x Relay/SSR (D5, D6, D7, D8 connected to NPN transistor)
2 x sensor (pin D3 and D4)

Designed for using an Arduino Pro Mini 5V with A4 to A7

I can share the gerbers once completed

PSU: https://www.aliexpress.com/item/220V-to-5V-2W-ac-dc-power-supply-width-voltage-input-85-264V-Smart-Home-AC/2036637836.html?spm=2114.13010608.0.0.TDfk9B

I'm also working on a Dual Decora style wall plate switch containing 4 x 8Amp SSR

@csa02221862
Progress is a bit slow, since creating the last batch of various modules work kept me busy travelling again. Just clocked another 26000 miles sitting in planes in the last 3 weeks.

I now have the controller modules, sensor and switch modules and all the programming done in mysensors and homegenie.

the last things on my list are sturdy wire-looms to connect it all and protective cover for the controller modules.

Getting close to the point that I will have all main areas of the house connected using these modules.

Finally, after some months of extreme travel and work related activity I had some time again to continue with my project.

Below are some pictures of the switch and sensor modules with standardised connection header so I can switch them out and organise them any way I like in my wall switch module/frame.

These modules work very well if you take some rules in account.

Don't exceed a continuous load of 500mA, they can handle 600mA but will fail sooner.

They don't like shorts, if you have a short on the 5VDC side they will fail very quickly. Either protect by fuse or ensure good workmanship and connect everything correctly.

There are various captive touch sensors available on the market, so more and some less sensitive. Sensitivity is related to the capacitor value the touch contact is attached to.

The commercial available touch sensors can all be configured to either work as toggle or as on/off switch. The more expensive ones also have time delay feature.

You can get little touch sensor boards like this 4 way Touch Sensor. These sensors are very small, less than half the size as shown on the pictue. With these you must create toutch plates on the outside of the decora wall plate and solder these to the touch pads on the sensor. I've done this as one of my experimental designs and it works well. I ended up going for a completely slick look Dual Touch Sensor + Custom Node.

I have two designs of my node.
First generation, as in the pictures, where I use an fuse in the hot wire.
Second generation where thermal fuse and varistor are on the pcb.

Updated first post.

Better pictures and the newly create sensor plate which contains DHT22 and Motion and attaches to the node.

More to come.

My latest project.

After years using X10 and ZWave I hit the limit with these devices where they simply do not conform to my evolving home control requirements.

Having played with Arduino's and MySensors quite a bit I decided to create my own devices based on MySensors and MQTT.

I designed a custom PCB for a custom node holding a Arduino Nano, the 2.4Hz RF module, a universal PSU and all required connections for up to 6 switches, 4 relays, DHT and Motion sensor.

I had the PCB printed by PCBWay (www.pcbway.com) in China. Their price for small batch prototype boards was great. Their service and speed of delivery was excellent. The quality of the PCB's I received is very high.

After cutting the PCB's in two, as I had two designs on each board, I ended with a PCB perfectly sized for a standard USA wall switch.

I'm using wall switch blank plates, with two captive touch sensors installed and a small hole drilled for the reset switch. The populated and completed PCB is than glued on the the back side of the blank plate. I used some good old fashioned wire wrapping technique to connect the touch switch wires to the PCB.

The now ready switch unit fits perfectly, with one relay module, in a single wall switch box, pr with up to 4 relay modules in a dual wall switch box.

I have 3 of these modules installed now, and in progress of completing another 5.

The touch switches work really well. They will activate if you come within 5mm from the wall switch unit. The two switches in each unit do not interfere with each other, so no accidental switch activation.

Read my post at HomeGenie for additional detail homegenie.it

Update - 10 July 2016

I've now created the sensor plate which can be used with the MySensors Node I developed.

I started with a dual keystone insert plate, the type used for network or cable tv connections. Using some router bits in my bench drill I machined the keystone slots to fit a DHT22 and a motion sensor module.

Bu pure coincidence the DHT22 has the exact same dimensions as the keystone slot at the back of the plate, all it required was machining away some of the height of the slot so the DHT22 sits flush.

Assembling and wiring the master switch unit. next step is to add the 4 relay units, connect all wires to the node and add the safety cover/joiner to prevent accidental interaction with the 110VAC.

The unit shown will have:

• 4 x touch switch activated relay
• 2 x touch toggle switch (what ever I want them to do in HomeGenie)
• motion sensor
• temperature & humidity

I will share more as this project is moving along.