By speakjava on Jul 02, 2012
I'm currently working on a number of projects using embedded Java on the Raspberry Pi and Beagle Board. These are nice and small, so don't take up much room on my desk as you can see in this picture.
As you can also see I have power and network connections emerging from under my desk. One of the (admittedly very minor) drawbacks of these systems is that they have no on/off switch. Instead you insert or remove the power connector (USB for the RasPi, a barrel connector for the Beagle). For the Beagle Board this can potentially be an issue; with the micro-SD card located right next to the connector it has been known for people to eject the card when trying to power off the board, which can be quite serious for the hardware. The alternative is obviously to leave the boards plugged in and then disconnect the power from the outlet. Simple enough, but a picture of underneath my desk shows that this is not the ideal situation either.
This made me think that it would be great if I could have some way of controlling a mains voltage outlet using a remote switch or, even better, from software via a USB connector. A search revealed not much that fit my requirements, and anything that was close seemed very expensive. Obviously the only way to solve this was to build my own.
Here's my solution. I decided my system would support both control mechanisms (remote physical switch and USB computer control) and be modular in its design for optimum flexibility. I did a bit of searching and found a company in Hong Kong that were offering solid state relays for 99p plus shipping (£2.99, but still made the total price very reasonable). These would handle up to 380V AC on the output side so more than capable of coping with the UK 240V supply. The other great thing was that being solid state, the input would work with a range of 3-32V and required a very low current of 7.5mA at 12V. For the USB control an Arduino board seemed the obvious low-cost and simple choice. Given the current requirments of the relay, the Arduino would not require the additional power supply and could be powered just from the USB.
Having secured the relays I popped down to Homebase for a couple of 13A sockets, RS for a box and an Arduino and Maplin for a toggle switch. The circuit is pretty straightforward, as shown in the diagram (only one output is shown to make it as simple as possible). Originally I used a 2 pole toggle switch to select the remote switch or USB control by switching the negative connections of the low voltage side. Unfortunately, the resistance between the digital pins of the Arduino board was not high enough, so when using one of the remote switches it would turn on both of the outlets. I changed to a 4 pole switch and isolated both positive and negative connections.
IMPORTANT NOTE: If you want to follow my design, please be aware that it requires working with mains voltages. If you are at all concerned with your ability to do this please consult a qualified electrician to help you.
It was a tight fit, especially getting the Arduino in, but in the end it all worked. The completed box is shown in the photos.
The remote switch was pretty simple just requiring the squeezing of two rocker switches and a 9V battery into the small RS supplied box. I repurposed a standard stereo cable with phono plugs to connect the switch box to the mains outlets. I chopped off one set of plugs and wired it to the rocker switches. The photo shows the RasPi and the Beagle board now controllable from the switch box on the desk.
I've tested the Arduino side of things and this works fine. Next I need to write some software to provide an interface for control of the outlets. I'm thinking a JavaFX GUI would be in keeping with the total overkill style of this project.