Kurt Andros
IDEENzumNULLTARIF.de

Assembly & Tests

All components are listed here: Standard Parts, Special- & Small Parts

Prepare box

Wooden box
Wooden box
Bottom side
Bottom side
Cut-out and drill holes
Cut-out and drill holes

Unscrew cover with hinges.

Remove the two skirting boards by carefully bending them back and forth with pliers. Make sure that the side walls are not damaged in the process.

Insert drill holes

Rework the hole for the volume potentiometer with a flat countersink, taking into account the thread length of the potentiometer.

Insert impact nuts.

Cut out the wooden floor; leave 10 mm on the left edge (front view); 20 mm on the other edges; also here take care not to damage the side walls

Prepare lower front panel and connect to housing

Front panel (here already with a display)
Front panel (here already with a display)

Drill eight holes for M4 countersunk screws in front panel and bottom of housing.

Make sure that they lie approximately in the middle of the 20 mm edge of the bottom.

Screw front panel.

The rotary switches and potentiometers have a "nose" to prevent their housing from turning. Finish the lower front panel accordingly.

Prepare and install display elements

Displays and backpack PCBs
Displays and backpack PCBs
Boards, backpacks and connectors soldered
Boards, backpacks and connectors soldered
Solder bridge for addressing
Solder bridge for addressing

Carefully drill the mounting holes of the backpack to Ø 2.5 mm.

Solder the displays into the backpack.

Solder in the 5-pin connecting cables.

Solder the yellow display with a "A0" solder bridge so that it gets the I2C address 0x71.

Drill mounting holes in the lower front panel for the M2 countersunk screws.

Connect displays to the front panel, making sure that the surface of the displays is flush with the surface of the lower front panel.

Prepare RTC module

Button cell and RTC module
Button cell and RTC module

Solder on pin header and insert button cell.

Prepare DFPlayer module and SD card

DFPlayer and SD card
DFPlayer and SD card

Rename any MP3 file (song or sound to wake you up with) so that it starts with "0001-" and ends with ".mp3" (e.g. "0001-my-song.mp3") and copy it to the root directory of a FAT32 formatted SD card.

Plug the card into the slot of the DFPlayer.

Prepare the FRAM module

FRAM module
FRAM module

Solder on the pin header.

Prepare control elements

Push buttons
Push buttons
Potentiometers
Potentiometers
Switches
Switches
Switches and connections
Switches and connections

Solder 2-pole connecting cables to the 8 push-buttons.

Solder 3-pole connecting cables to the 3 rotary potentiometers. Assignment see photo.

Shorten the actuating shafts of the potentiometers until the knobs fit on them at a suitable distance from the front panel or the wooden wall of the speaker.

Solder a 2-pole connecting cable to one of the two rotary switches. Solder one 3-pole connecting cable to the other rotary switch. Assignment see photo.

Tip 1

The connecting cables can be soldered directly, but with switches and potentiometers it is easier to connect crimp sockets to the cables first, plug them onto the pins and then solder them.

Tip 2

In order to protect the connection electrically and to make it mechanically more robust you can use shrink tubing (here in the pictures: transparent).

Install speaker and volume control

Speaker and Potentiometer
Speaker and Potentiometer

Insert loudspeaker, attach volume potentiometer and attach rotary knob.

Prepare insert sheet

Insert sheet on cutting mat
Insert sheet on cutting mat

Print the insert sheet on the thickest possible paper and cut off the edges.

Cut out the rectangles for the displays and the holes for the switches, potentiometers and buttons with a sharp knife. Best on a cutting mat.

Mount upper front panel and install operating elements

Finished control panel
Finished control panel

Insert tinted foil to cover the displays together with the insert sheet.

Insert front panel.

Cut the holes for switches, potentiometers and buttons in the tinted foil.

Limit the clock switch to two switching positions using the setting ring.

Insert and screw in switches, potentiometers and buttons.

Prepare, assemble and wire PCB

Equipped board on Arduino(-Klon)
Equipped board on Arduino(-Klon)

Solder components in this order

Screw the PCB with spacer sleeves to the front wall of the box (push-button side) so that there is still enough space on the right for the small relay PCB.

Insert DFPlayer, FRAM and RTC DS3231.

Connect according to the PCB labeling or connection diagram (see Wiring).

Install relay PCB and connect

Arduino(-clone), PCB and Relay PCB
Arduino(-clone), PCB and Relay PCB

Screw the relay PCB to the right of the motherboard to the front panel.

Connect one wire of the speaker to the relay PCB, the other to the terminal block of the motherboard.

Create the remaining connections between the relay PCB and the motherboard (see Wiring).

Plug in the USB cable and secure it


Pass the USB cable through the rear panel of the housing and connect it to the Arduino.

Attach strain relief to the side wall.

Download and install libraries

Adafruit FRAM I2C Lib

Adafruit LED Backpack Lib

Adafruit GFX Lib

Adafruit RTC Lib

DFPlayer Lib

Close the IDE. Extract the libraries if necessary, rename them if necessary and copy them to the folder "[Arduinosketchbook]/libraries".

Download and install sketch and parameter set

Download the latest version of the sketch and parameter set and save it in the Arduino Sketchbook folder.

Connect the USB cable to the PC on which the Arduino IDE is installed.

Open the sketch, select the board type and COM port if necessary and upload the sketch.

Test functions

Check whether

After IDE termination, disconnect the USB cable from the PC, connect it to the Powerbank and check if

Change constants

The sketch contains the line:

"#include "parameterset4clock3.h"

That's because I built three alarm clocks back then. Please change to:

"#include "parameterset4clock1.h"

In "parameterset4clock1.h" you can set some constants with which you can adjust the behaviour of the displays, the DFPlayer and the minute buttons of the alarm time.

Wall mounting

Ideal mounting height: the user should stretch his arms slightly angled upwards in the supine position and lying on his usual cushion. This height is optimal for the underside, the control panel of the alarm clock. Attach the mounting plate to the wall using dowels and screws.

Cable duct, power supply and power bank

Power supply with mains failure protection
Power supply with mains failure protection

To route the USB cable downwards or sideways, you can optionally use a cable duct (DIY store).

Place power supply unit and Power Bank according to the room conditions and make sure that both remain free of dust and objects (duvets, soft toys, magazines, etc.) that could impede heat dissipation. Otherwise there is fire hazard!


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