Prototype demonstrated · expanded product design in progress
Enclosed controller prototype · connection sides
01ESP32Microcontroller
0216 + 16Inputs / outputs
03Ethernet / PoELocal networking
04ESPHomeHome Assistant
AT A GLANCE
The engineering challenge
One project, two stages: a working 16-input/16-output ESP32 automation prototype and a more ambitious SmartHub 16 product architecture. The PoE relay controller is the SmartHub 16—not a separate product.
Create a locally operated controller that connects physical wall switches and outputs to a modern automation platform without making cloud connectivity a prerequisite for basic control. The prototype combines an ESP32 with Ethernet/PoE, I/O expansion and ESPHome/Home Assistant.
The longer-term product direction adds higher-power switching, dimming, per-channel power monitoring and additional integrations. Those features are design goals, not demonstrated capabilities of the current prototype.
01 / PROTOTYPE
Working prototype
The earlier hardware and firmware work established a 16-input / 16-output controller with local switch-to-output behaviour, Ethernet connectivity and Home Assistant exposure.
16 IN
16 digital inputs
Wall-switch and other low-voltage control signals read through an MCP23017 I/O expander.
16 OUT
16 controlled outputs
Output states driven through a second MCP23017 and interface circuitry for relay/SSR control.
ETH / PoE
ESP32 + Ethernet / PoE
Local network connection and firmware integration through ESPHome.
HA
Home Assistant integration
Exposed switch entities and local automation behaviour for control and monitoring.
02 / HARDWARE & INTERFACES
From PCB to prototype
Actual PCB layout and enclosure photographs, followed by local-control and dashboard interface visuals.
Main Board v1.0 · PCB front layoutMain Board v1.0 · PCB back layoutTerminal connections · enclosure detailEthernet / PoE connector side · enclosure detailLocal control interface · screenshotHome automation dashboard · visual concept (not a verified feature list)
PCB images are layout renders; enclosure photographs show the physical prototype. The dashboard is a concept visual.
02 / SYSTEM ARCHITECTURE
Prototype architecture
The functional block diagram below describes the prototype at a system level. It is illustrative—not a PCB layout or verified electrical schematic.
PHYSICAL CONTROL16 inputsMCP23017 · 0x20
→
CONTROLLERESP32Local firmware · ESPHome
→
OUTPUT CONTROL16 outputsMCP23017 · 0x21
↕
LOCAL NETWORKEthernet / PoEHome Assistant integration
Conceptual architecture; not an electrical wiring diagram
03 / EMBEDDED SOFTWARE
Firmware & integration
The prototype firmware was developed with ESPHome, using ESP32 networking, MCP23017 input/output expanders, switch entities and status indication. Development included troubleshooting optocoupler drive, SSR leakage and input mapping.
01Input sampling / events
02Local switch logic
03Output state update
04Home Assistant synchronization
04 / VALIDATION & ITERATION
Engineering lessons
Relay and SSR selection must consider drive current, leakage, load compatibility and thermal limits.
Physical controls should remain useful when a home automation dashboard or internet connection is unavailable.
A manufacturable mains-voltage product requires a separate safety, isolation, thermal and certification design process.
05 / PRODUCT ROADMAP
SmartHub 16 product direction
The following capabilities belong to the proposed production-oriented revision. They are not represented here as completed or certified.
01
12 high-current switching channels plus 4 dimmable channels
Design target
02
Up to 16 channels of power monitoring
Design target
03
Ethernet/PoE, Zigbee and KNXnet/IP integration targets
Design target
04
Custom main PCB, enclosure, thermal and electrical protection design
Design target
05
Electrical safety testing and applicable certification before mains installation or commercial deployment
Design target
Safety note: this case study is an engineering overview, not instructions for wiring mains-voltage equipment.
ENGINEERING EVIDENCE
Prototype implementation & validation
This section separates implemented prototype functions from verification still to be documented. It does not imply production qualification or certification.
Implemented
16 digital inputs
MCP23017 input expansion and physical switch handling are implemented in prototype firmware.
Implemented
16 controlled outputs
Firmware-driven outputs and prototype relay/SSR control interface are implemented.
Implemented
Local control
Local input-to-output control and a local interface have been developed.
Implemented
ESPHome / Home Assistant
Controller entities and local automation integration have been developed.
Verification to document
Ethernet / PoE endurance
Formal power, uptime and reconnection test reports have not been published.
Verification to document
Electrical safety and loads
Thermal, insulation, representative-load and certification evidence remains to be documented. No certification is claimed.
Next validation milestones
Document 16-channel I/O tests, network recovery, thermal and electrical measurements, and safety verification before making any qualification claims.
Engineering scope
Building a connected hardware product?
Embedded architecture, GPIO expansion, local control logic, connectivity, Home Assistant integration, hardware troubleshooting and product planning.
Konceptux works across electronics, embedded firmware, networking and prototype integration.
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