GENG 389 • Project Journal

Thermo-Electric Infinity Table

This page documents the engineering journey behind the Thermo-Electric Infinity Table project in chronological order. It tracks how the idea started as a challenge to “run lights from fire,” evolved through several design iterations, and eventually became a working prototype ready for integration into ChippyCraft’s product line.

How This Journal Is Organized

Entries are listed from earliest to latest and grouped around key milestones: early concept, research and feasibility, design decisions, and the physical build and testing phase. Closely related events sometimes share the same date to reflect how work actually clustered in time.

May 5, 2025 (Monday)
Origin of the Thermo-Electric Lighting Concept
[Planning]
  • Completed my first Infinity Patio Table for a different course and presented it in class.
  • The professor asked whether I planned future product development and suggested adding lighting to the fire table.
  • This sparked the challenge to create a lighting system powered by the fire itself, rather than wall power.
  • Recognized that achieving this could differentiate ChippyCraft products and open future installation revenue opportunities.
September 7, 2025 (Sunday)
Exploring Mechatronic Framework and System Feasibility
[Planning]
  • Reviewed the four components of a closed-loop mechatronic system and mapped them to an off-grid fire table design.
  • Identified thermoelectric generators as the energy source and LED strips as the actuator.
  • Determined early that a microcontroller would be needed to regulate lighting behavior and patterns.
  • Began considering how this project could evolve beyond class into a real commercial concept for ChippyCraft.
September 11, 2025 (Thursday)
First System Concept and Early Requirements
[Planning / Design]
  • Defined the core project goal: operate LED lighting entirely from heat produced by a propane fire table.
  • Considered longer LED strip runs and the electrical implications of powering them from harvested heat.
  • Selected the ESP32 platform for its efficiency and flexibility compared to basic Arduino boards.
  • Established the system boundary: fully off-grid operation with minimal visible wiring and a clean installation.
September 14, 2025 (Sunday)
Component Research and Early BOM Development
[Planning]
  • Researched TEG options, LED strip types, and microcontroller platforms suitable for outdoor use.
  • Identified WS2815 LED strips as strong candidates for their 12 V architecture and signal robustness.
  • Reviewed boost and buck converter options to stabilize low, variable TEG output.
  • Noted that LED power demand increases sharply with strip length, influencing future design limits.
October 2, 2025 (Thursday)
LED Density, Load Calculations, and Power Optimization
[Design]
  • Compared LED strip densities to understand total wattage at different lengths.
  • Determined that high-density strips are not realistic for TEG-only power in this application.
  • Adopted brightness limits and animation strategies to reduce average power draw.
  • Concluded that shorter or lower-density strips would keep the system thermally feasible and stable.
October 7, 2025 (Tuesday)
Battery vs Battery-Free Architecture Evaluation
[Design]
  • Explored designs using LiFePO₄ battery buffering to smooth LED behavior.
  • Calculated that large batteries for long runtime would be expensive, heavy, and overkill for a table.
  • Evaluated micro-battery support but found wiring and charging regulation unnecessary for the prototype.
  • Shifted direction toward a battery-free architecture to simplify design and reduce long-term product cost.
October 12, 2025 (Sunday)
Thermal Analysis and TEG Capability Study
[Design]
  • Modeled TEG performance under realistic fire-table temperatures and cooling conditions.
  • Identified that TEGs near 200°F produce much better output than initially assumed.
  • Determined that multiple TEGs in series are needed to feed the boost converter effectively.
  • Concluded that a well-designed thermal sandwich could support LED loads without adding a battery.
October 19, 2025 (Sunday)
Selecting ESP32 and Final System Direction
[Design / Coding]
  • Committed to the ESP32 DevKitC as the main controller due to its built-in Wi-Fi and flexibility.
  • Confirmed that a single digital data line can drive the addressable LED strip without MOSFETs.
  • Outlined future potential for wireless control modes and lighting customization.
  • Noted that ESP32-based control aligns with long-term plans to offer smart, premium lighting products.
November 2, 2025 (Sunday)
High-Level Wiring Diagram and System Flow
[Design / Documentation]
  • Established the conceptual wiring architecture from heat source to LEDs and controller.
  • Defined the power flow: TEGs into a boost converter for 12 V, then into a buck converter for 5 V.
  • Confirmed the system does not require sensors to operate reliably; light output follows available heat.
  • Separated thermal, power, and logic zones for better layout inside the enclosure.
November 6, 2025 (Thursday)
LED Strip Vendor Comparison and Outdoor Requirements
[Design]
  • Reviewed multiple outdoor-rated LED strip options from different vendors.
  • Compared IP ratings, mechanical durability, silicone coatings, and mounting options.
  • Identified that many inexpensive strips rely on weak adhesive backing not ideal for long-term outdoor use.
  • Focused on options that can be mechanically clamped or channeled instead of relying only on adhesive.
November 9, 2025 (Sunday)
Refining LED Compatibility and System Constraints
[Troubleshooting / Design]
  • Analyzed compatibility between more rugged neon-flex LED strips and the ESP32 + converter system.
  • Reviewed power injection needs, signal integrity, and voltage drop for longer runs.
  • Recognized that 25 ft continuous runs introduce significant complexity for a first prototype.
  • Decided to keep LED length within a realistic, manageable range for the initial build.
November 13, 2025 (Thursday)
Two Build Proposals and System Simplification
[Design]
  • Developed two full system proposals: a simple 5 V WS2812B build and a 24 V neon-flex build.
  • Outlined wiring, fuses, and converter requirements for both approaches.
  • Found that the 24 V neon-flex design added cost and sourcing difficulty without strong benefits for the class prototype.
  • Chose to simplify and return to a focused WS2815-based design with light weatherproofing upgrades.
November 23, 2025 (Sunday)
BOM Refinement and Removal of Unnecessary Components
[Design]
  • Removed unneeded level shifters, capacitors, and duplicate converters from the design.
  • Simplified LED data wiring so the ESP32 connects directly to the LED DI input.
  • Confirmed that the relay should only switch 12 V power to the LEDs, not data.
  • Aligned the BOM with both class requirements and realistic cost targets for future products.
November 25, 2025 (Tuesday)
Power Architecture and Housing Strategy Finalized
[Design]
  • Completed the power-flow design: TEGs into a boost converter for 12 V, then a buck converter down to 5 V for the ESP32.
  • Confirmed the need for shared ground across the converters, ESP32, relay, and LED strip.
  • Selected a weather-resistant polycarbonate enclosure and a layout based on thermal zones.
  • Planned to mount components using standoffs and Velcro to simplify service and revision work.
December 5, 2025 (Friday)
Wiring Strategy and Material Setup
[Design]
  • Finalized wiring paths from TEGs to converters and from converters to the LED strip and ESP32.
  • Chose 18 AWG wire for power paths and 22 AWG for data and control signals.
  • Reviewed the behavior of the boost and buck converters before permanent wiring.
  • Organized the physical layout inside the enclosure to support clean routing and troubleshooting.
December 6, 2025 (Saturday)
Soldering Practice and ESP32 Power Validation
[Build]
  • Practiced soldering pin headers and small-gauge wires to gain confidence for the main assembly.
  • Soldered the buck converter output to the ESP32 and verified a stable 5 V supply using a multimeter.
  • Confirmed all power connections were correctly oriented before powering the board.
  • Transitioned from design work into hands-on build work with validated power wiring.
December 7, 2025 (Sunday)
Relay Wiring and Control Verification
[Build / Testing]
  • Wired the relay coil to the ESP32 and the buck converter output.
  • Uploaded a simple test sketch to toggle the relay and confirm logic control.
  • Heard and observed the relay clicking in response to the program, confirming functional control.
  • Verified that the relay subsystem worked correctly before adding the LED load.
December 7, 2025 (Sunday)
ESP32 Environment Setup and Code Deployment
[Coding / Troubleshooting]
  • Installed ESP32 board definitions in the Arduino IDE and fixed COM port recognition by adding CP2102 drivers.
  • Learned the correct BOOT and EN button timing for forcing the ESP32 into programming mode when needed.
  • Uploaded a FastLED-based red-white-blue demo pattern to the board without compilation errors.
  • Confirmed that relay control still functioned correctly under the new program.
December 8, 2025 (Monday)
TEG Harness and Waterproof Connector Integration
[Design]
  • Designed a three-TEG series harness to maximize the voltage supplied to the boost converter.
  • Integrated a waterproof connector pair so the TEG assembly could be detached from the electronics enclosure.
  • Verified correct polarity and series wiring from TEG1 positive to TEG3 negative.
  • Positioned the boost converter input lines through the harness to prepare for full system testing.
December 8, 2025 (Monday)
LED Wiring and Early Power Troubleshooting
[Build / Troubleshooting]
  • Connected LED ground directly to the boost converter ground and routed the +12 V line through the relay and fuse.
  • Ran the LED data line from ESP32 GPIO18 to the LED strip DI input.
  • Observed that boost output sagged when the LED strip was connected, revealing an underpowered USB source.
  • Confirmed that wiring from the boost converter through the relay, fuse, and LED connector was correct.
December 8, 2025 (Monday)
Confirming Circuit Integrity Before TEG Testing
[Testing]
  • Verified that the relay logic, LED wiring, and connector continuity were all functioning correctly.
  • Determined that the main issue was an inadequate test power source, not a wiring error.
  • Prepared to switch from USB-based testing to real TEG-based power input.
  • Ensured the system was ready for outdoor trials with the actual fire table setup.
December 8, 2025 (Monday)
Outdoor TEG Trial Run in Harsh Conditions
[Testing / Troubleshooting]
  • Conducted the first outdoor TEG test during cold, windy conditions around the fire table.
  • Recorded very low TEG voltage due to a poor temperature differential between hot and cold sides.
  • Verified that the TEG wiring and harness remained correct despite weak output.
  • Concluded that environmental limitations, not design flaws, were causing the low electrical performance.
December 9, 2025 (Tuesday)
Preparing Interim Demonstration and Next Steps
[Planning / Documentation]
  • Recognized the need to clearly explain thermal and environmental limitations in the project presentation.
  • Planned messaging that emphasizes working control electronics and wiring, with thermal design as the next optimization stage.
  • Prepared fallback options for showing LED behavior using an alternate 12 V source if TEG output is too low during demo.
  • Established that the current prototype is ready for inclusion in the Mechatronics E-Portfolio and on the ChippyCraft website.
December 10, 2025 (Wednesday)
First LED flashes and diagnosing power limitations
[Testing / Troubleshooting]
  • Powered the ESP32 and LED strip using a USB power bank and achieved the first visible LED flashes (blue pixels), confirming data wiring and strip integrity.
  • Observed the power bank shutting off immediately after the flashes, indicating an inrush current spike beyond the bank’s current limit.
  • Verified that the boost converter and LED strips were functioning correctly and traced the issue to insufficient power supply capability.
  • Learned that even short LED strips draw significant surge current during initialization, requiring a stronger 5 V source for stable operation.
December 10, 2025 (Wednesday)
Replacing faulty LED connectors and confirming clean 12 V at pad
[Build / Troubleshooting / Testing]
  • Noticed the factory pins on the LED plug we loose wo replaced with waterproof, 3-pin plugs for 12 V, Data in, and GND.
  • Confirmed a solid 12 V reading directly on the LED strip’s +12 V and GND pads, proving the connector fix and wiring were successful.
  • Retested with the 5 ft LED strip and saw identical “flash then shutdown” behavior, confirming the issue was not wiring-related but due to the power bank being unable to handle LED startup current.
  • Verified that a single LED could light when the ESP32 was powered directly, demonstrating that data, grounding, and strip logic were correct and that the remaining limitation is the available power source.
December 16, 2025 (Tuesday)
Successful final system test under live fire conditions
[Testing] [Validation]
  • Performed a full system test with the electronics powered through the intended architecture and the fire table operating normally.
  • Observed stable ESP32 operation, reliable relay control, and consistent LED behavior without unexpected shutdowns.
  • Confirmed that prior power and connector issues had been resolved and that the system could sustain operation during the test window.
  • Verified that the lighting effect achieved the intended “floating glow” aesthetic when paired with the fire table.
  • Recorded video documentation of the successful test for inclusion in the Mechatronics E-Portfolio and ChippyCraft website.
  • Concluded that the prototype met the functional goals of the project and was ready for presentation and further refinement.
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