Custom Sensor Boards: Beyond the Rev Hub

Why pay $40 for a sensor you can build for $2? Designing custom PCBs for break-beams and limit switches.

Custom Sensor Boards

The Rev Control Hub has plenty of digital ports (0-3.3V logic). Everything is just closing a circuit.

The “Break Beam” Project

Commercial break beams are huge.

  • The Idea: Detect when a pixel is inside the claw.
  • The Hardware: An IR LED (Emitter) and a Phototransistor (Receiver).
  • The PCB: A tiny 10mm x 10mm board that fits inside your claw wall.

How to make it (JLCPCB)

  1. KiCad: Draw the schematic. Connect VCC, GND, and SIGNAL.
  2. Order: Get 5 boards for $2.
  3. Assembly: Solder the tiny components (or pay $10 for assembly).

Why do this?

  • Space: Fits where commercial sensors can’t.
  • Cost: $2 vs $40.
  • Flex: Judges love “Custom Electronics”.

Conclusion

Don’t be afraid of the green board. It sets your robot apart from the “Plug and Play” teams.