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Interlock Automation Project

Main Device Framework Version Status

Overview

Wires Access Control is a distributed interlock door control system built on ESP8266 (NodeMCU) devices communicating over UDP.

The system ensures only one door can be open at a time, implementing a physical safety interlock. The PORTEIRO acts as the central controller — it generates its own Wi-Fi AP, manages door commands and bypass, and exposes a web dashboard for monitoring and control.

Typical use cases:

  • Security entrances and airlocks
  • Controlled access areas (labs, clean rooms, server rooms)
  • Industrial access points requiring physical interlock

System Architecture

 ┌──────────────────────────────┐
 │          PORTEIRO            │
 │  WiFi AP  ·  Web Dashboard   │
 │  BTN1 · BTN2 · Bypass Switch │
 └──────────────┬───────────────┘
│
UDP Broadcast · 192.168.4.255:4210
│
┌────────────┴────────────┐
│                         │
┌───────────────┐         ┌───────────────┐
│    PORTA_A    │         │    PORTA_B    │
│  Relay+Sensor │         │  Relay+Sensor │
│  Local Button │         │  Local Button │
└───────────────┘         └───────────────┘
Device Role
PORTEIRO Central controller — buttons, bypass, AP host, web dashboard
PORTA_A Door A controller — relay, sensor, local button
PORTA_B Door B controller — relay, sensor, local button

Network Design

The PORTEIRO always runs in WIFI_AP_STA mode:

  • AP side (PORTEIRO_AP, fixed IP 192.168.4.1) — PORTA_A and PORTA_B always connect here. All UDP interlock communication happens in this subnet. This never changes and is not affected by the router.
  • STA side (optional) — connects to the local router so you can access the web dashboard from your LAN by IP. Configured via the web portal. If the router is unavailable, the AP side continues operating normally.

This design means the interlock never depends on a router. The router connection is purely for convenience (web access from LAN).

Demo

📹 Video demonstration coming soon.

Installation

Requirements

Required libraries — all included with the ESP8266 board package, no external libraries needed:

Library Purpose
ESP8266WiFi Wi-Fi AP and STA management
WiFiUdp UDP broadcast communication
ESP8266WebServer Web dashboard (PORTEIRO only)
EEPROM Persistent router credential storage

Steps

1. Clone or download this repository.

2. Open Node_Porta_A.ino in Arduino IDE.

3. Set the role of this device by editing line 6:

#define DEVICE_NAME "PORTA_A"  // "PORTA_A", "PORTA_B" or "PORTEIRO"

4. If desired, change the AP credentials before flashing (must match on all three devices):

#define AP_SSID "PORTEIRO_AP"
#define AP_PASS "porteiro123"

5. Select your board: Tools → Board → NodeMCU 1.0 (ESP-12E Module)

6. Select the correct port under Tools → Port.

7. Upload. Repeat steps 3–7 for each device, changing only DEVICE_NAME.

First Boot

  • PORTA_A / PORTA_B — connect automatically to PORTEIRO_AP and are ready. No configuration needed.
  • PORTEIRO — AP is immediately active at 192.168.4.1. Connect to PORTEIRO_AP and open http://192.168.4.1 to access the dashboard.

Connecting the PORTEIRO to your local network (optional)

  1. Connect to PORTEIRO_AP.
  2. Open http://192.168.4.1.
  3. Scroll to the WiFi Local section and click CONFIGURAR WIFI.
  4. Enter your router's SSID and password and save.
  5. The PORTEIRO connects to the router. The AP stays active — the doors are unaffected.
  6. The router-assigned IP is shown in the dashboard topbar. Use it to access the dashboard from your LAN.

⚠️ Web access warning (HTTP vs HTTPS)

Do not use HTTPS, the website will not load!

The system uses HTTP instead of HTTPS, because the NodeMCU(ESP8266) has limited memory and processing resources.

The implementation of HTTPS requires TLS encryption, certificates and higher use of RAM, which may cause instability or failures in the microcontroller.

As the system operates in local network (LAN), the use of HTTP is sufficient, it is consumes fewer resources and guarantees better performance and reliability.

Resetting router credentials

  • Via dashboard: open http://192.168.4.1 → WiFi Local section → TROCAR REDE.
  • Credentials are stored only on the PORTEIRO's EEPROM. PORTA_A and PORTA_B never store credentials.

Web Dashboard

Accessible at http://192.168.4.1 (AP) or the router-assigned IP (LAN). PORTEIRO only.

Section Contents
Topbar AP IP, LAN IP (if connected), Wires branding
PORTEIRO card Online status, AP name, connected router, bypass toggle button
PORTAS grid Per-door card: online/offline dot, door open/closed state, IP, Open button
WiFi Local Router SSID, LAN IP, signal strength, option to change network

The page auto-refreshes every 4 seconds.

Circuit Diagram

PORTA_A / PORTA_B

NodeMCU (ESP8266)
        │
        ├── D1 (GPIO 5)  ── Facial recognition trigger / local button
        │                   (other pin → GND, INPUT_PULLUP)
        │
        ├── D5 (GPIO 14) ── Magnetic door sensor  (HIGH = open)
        │                   (other pin → GND, INPUT_PULLUP)
        │
        ├── D6 (GPIO 12) ── Relay IN1 → Magnetic lock   (active LOW)
        │
        └── D7 (GPIO 13) ── Relay IN2 → Push/pull LED   (active LOW)

PORTEIRO

NodeMCU (ESP8266)
        │
        ├── D1 (GPIO 5)  ── Button 1 → opens PORTA_A
        │                   (other pin → GND, INPUT_PULLUP)
        │
        ├── D2 (GPIO 4)  ── Button 2 → opens PORTA_B
        │                   (other pin → GND, INPUT_PULLUP)
        │
        ├── D4 (GPIO 2)  ── Bypass toggle switch  ⚠️ see note below
        │                   (other pin → GND, INPUT_PULLUP)
        │
        ├── D5 (GPIO 14) ── Door sensor (if PORTEIRO has a door)
        │
        ├── D6 (GPIO 12) ── Relay IN1 (if applicable)
        │
        └── D7 (GPIO 13) ── Relay IN2 (if applicable)

⚠️ GPIO2 (D4) — Bypass Pin Boot Warning

GPIO2 must be HIGH at boot or the ESP8266 may not start correctly. Do not connect the bypass switch to GND while the device is powering on.

Recommended: use a normally-open switch. The firmware reads INPUT_PULLUP, so the pin is HIGH by default (bypass off) and goes LOW when the switch is pressed (bypass on).

Note: All inputs use INPUT_PULLUP. Connect switches and sensors between the pin and GND.

Power Supply Recommendations

For reliable 24/7 operation:

  • Use a 5 V / 2 A minimum power supply per NodeMCU.
  • Place a 100 µF electrolytic capacitor between VIN and GND close to the NodeMCU. Relay switching generates current spikes that can cause spurious resets without it.

Interlock Logic

A door open request is approved only when all of the following are true:

  1. The other door's sensor reports closed (recent STATUS message, within 10 s).
  2. The other door's relay is not active — tracked from the moment the relay energises, before the physical sensor moves. This closes the race window on rapid double-presses.
  3. The system is not in the 2 s post-open cooldown.

If bypass mode is active, conditions 1 and 2 are skipped and the door opens immediately.

If communication with the other door is lost (no STATUS in 10 s), opening is blocked by default for safety.

Bypass Mode

When bypass is active:

  • The interlock check is fully skipped — doors can be opened regardless of the other door's state.
  • Controlled by the physical switch on PORTEIRO (D4/GPIO2) and by the toggle button on the web dashboard.
  • State is broadcast to all devices on every change so all nodes stay in sync.

UDP Message Reference

All messages are plain-text, pipe-delimited, broadcast to 192.168.4.255:4210.

Message Direction Description
DISCOVERY|name|ip All → All Announces presence on boot and every 5 s
CONFIRM|name|ip All → All Acknowledgement of a new device discovery
PING|name|ip All → All Keepalive every 10 s
PONG|name|ip Response Reply to PING
STATUS|name|OPEN|CLOSED All → All Door state, sent every 3 s and on change
OPEN|name PORTEIRO → Door Command to open a specific door
REQ_OPEN|door|requester Door → PORTEIRO Door requests permission to open
BYPASS|ON|OFF PORTEIRO → All Broadcast bypass state change
LOCK|name Door → All Relay just activated (before sensor moves)
UNLOCK|name Door → All Door closed, relay off

Hardware Reference

Inputs

Constant NodeMCU Pin GPIO Function
BTN1_PIN D1 5 Facial recognition / Button 1
BTN2_PIN D2 4 Button 2 — opens PORTA_B (PORTEIRO only)
BYPASS_PIN D4 2 Bypass toggle switch ⚠️ HIGH at boot required
SENSOR_PIN D5 14 Magnetic door sensor (HIGH = open)

Outputs

Constant NodeMCU Pin GPIO Function
RELAY_PIN D6 12 Relay IN1 — magnetic lock (active LOW)
PUPE_PIN D7 13 Relay IN2 — push/pull indicator (active LOW)

Configuration Reference

Constant Default Description
DEVICE_NAME "PORTA_A" Role of this node — change per device
AP_SSID "PORTEIRO_AP" SSID of the PORTEIRO's AP
AP_PASS "porteiro123" Password of the PORTEIRO's AP
UDP_PORT 4210 UDP port for all communication
RELAY_TIME 5000 ms Duration relay stays active
PORTA_TIMEOUT 300000 ms Alert threshold for door left open (5 min)

Router credentials (SSID + password) are stored in EEPROM at runtime via the web portal — no hardcoded credentials in the firmware.

EEPROM Layout

Address Content
0 – 63 Router SSID (null-terminated)
64 – 127 Router password (null-terminated)
128 Validity flag (0xAA = credentials present)

Used by the PORTEIRO only. PORTA_A and PORTA_B never write to EEPROM.

Future Improvements

  • OTA (over-the-air) firmware updates
  • Persistent event log (SPIFFS / LittleFS)
  • HTTPS dashboard with login
  • MQTT / cloud integration for remote monitoring
  • Mobile app
  • Multi-door expansion beyond two interlocked doors
  • ESP-NOW as a secondary communication channel

Author

Developed by Davi Han Ko — Wires Solução e Serviços

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