Because the first version performed well, it would be interested to scale up the sensor cocktail with more sensors and refine the already existing functionality. We first look at an errata that mentions the problems that were spotted, as some sort of list of QA detected faults that will now be addressed in the next version, whilst leveraging the overall idea of the first version.
The overall design follows the initial design but uses PCB/ circuit standoffs with screws to separate the levels of the tower which allows for the tower to be infinitely expandable. Note that the structure only needs to hold, but it will not be subjected to any sort of torque and will be suspended in mid air so there is no need for any vertical stability.
Naturally, expanding the tower requires larger outer shell that, this time will not be pained over. Ironically, the same producer that provided the box for the first version, has a larger variant of the same box, exactly double in size as the original one.
With all that laid out, it's time to build the solution and see what can be obtained.
Wood is a great material to work with when the realization does not need to be waterpoof. First, wood is a perfect isolator and then wood is also a very malleable material that is easy to work with and easy to correct mistakes if necessary. In this case, the tower will be protected by an outer transparent plastic shell such that the only requirement here is to make the tower stand and no water proofing is necessary.
For starters, three levels are cut as small shims of wood, and then a hole is drilled through all of them. The hole will be used to pass wires such that the different levels will be able to communicate and will also keep the wires contained within the tower itself without reaching around and making the wires prone to disconnections. Keep in mind that Dupont cables will be used and Dupont cables are really meant for prototyping; definitely not the type of connection that is renowned to be resistant to shocks.
The painting process is all the same as usual:
Some excess purple paint was available, so it was used for this project in order to spare up on the most used paints (white and black). Later on, another fourth stage was added and the process was all the same.
It was decided to use nylon standoffs, the biggest benefit being less metal and hence less weight, along with the fact that nylon is not conductive so it provides a better protection in case wires end up detached and dangling. After the tower is finalized and then placed next to the old box, just to compare the dimensions, although a later stage will make the older box unusable due to the size of the tower.
The initial design had the power cable reaching through the wood but for this revised build, a bottom seal made out of rubber will be used instead. The rubber seal will be glued onto the last layer, cut as a star and then the power cable will reach through the bottom seal in order to prevent any water from splashing inside the cocktail tower. The same design is preserved, with the bottom part being cut off and then replaced with a metal grate in order to allow air to circulate through the box freely in order to be able to impress the sensors.
The rest of the job will not be detailed because it involves nothing too eventful. A Brother label printer came very much in handy because it became very easy to mess up all the Dupont cables so many of them had to be labeled along with keeping a map of which cable goes to which corresponding GPIO analog pin on the WEMOS ESP32 D1 Mini.
Maybe as a deviation from the plan was that the levels were built with variable height, which is a great solution to preserve space in case the sensors being used do not need all that extra space. For example, one of the tower stages hosted a temperature and a noise / decibelmeter sensor, both of which where fairly large in size, such that they occupied the entire level, but at the same time the sensor were fairly short in height so smaller circuit board standoffs could be used. The same was true for another stage hosting a dust sensors, that could be made shorter in height.
All the same, the very first level (the one on the bottom), that hosted the WEMOS ESP32 D1 Mini and the buck convertors ended up double in height compared to the rest because it was deemed very handy to be able to just move the Dupont connectors with fingers without having to dismantle the tower. Even so, given the multi-stage build, it is fairly cool to be able to just unscrew the level that needs to be worked on, instead of having to take everything apart (this can be done simply by rotating the standoffs for a given level, that remove themselves and open the build in two).
Some sensors were configured but did not fit the plan:
Interestingly, all the sensors and the WEMOS could have been powered directly from the rail with the
rail not being used at all but it was decided to keep both rails for now, just in case something else gets added that needs the
rail.
Either way, at least three more levels could be added, just judging by the look of the external box, which promises good extensibility in the future.
In order to get an overview of how the sensor cocktail will be used in practice, the box will be suspended from a tree or a metal rod, just like a lamp, with the bottom cable being used for power that will be pulled to the power source.
One further development might be to add a solar panel and make the cocktail self-powered, which is now even more feasible given the low consumption of the WEMOS ESP32 D1 Mini that has been swapped in. Similarly, the sensor cocktail only collects data on a timer, such that in-between collections, the ESP could deep sleep and greatly reduce the power. For the time being, it was decided that the build requires Wifi anyway, such that it might just be powered by a longer cable that can reach to a power source.