Universal Garage Rotary Sensor (ESPHome + ESP32)

This project uses a KY-040 rotary encoder and an ESP32 to measure the rotation steps of a garage motor shaft.
By counting the steps, the system calculates the garage door position in percent (0–100%).

It is designed to work with ESPHome and Home Assistant.

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🧰 Hardware Used

• ✅ ESP32 Dev Board
• ✅ KY-040 Rotary Encoder
• ✅ 3D printed mounting parts (from /STLs folder)
  • Hörmann_Ritzel_Rev.D_Final.stl
  • Hörmann_Halter_RevD_Final.stl

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🖨 3D Printed Parts

Print the files from the STLs folder:

• Hörmann_Ritzel_Rev.D_Final.stl → Gear for the motor shaft
• Hörmann_Halter_RevD_Final.stl → Mounting bracket for the encoder

Mount the KY-040 encoder so it rotates together with the garage motor shaft.

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🔌 Wiring (KY-040 → ESP32)

KY-040 Pin	ESP32 Pin
CLK (A)	GPIO16
DT (B)	GPIO17
+	3.3V
GND	GND

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⚙️ ESPHome Setup

1. Copy the YAML file from the /YAMLs folder.
2. Adjust:
   • WiFi credentials
   • Static IP settings (CHANGE_ME)
   • Secrets in secrets.yaml
3. Upload to ESP32 via ESPHome.

The rotary encoder:

• Counts from 0 to 1000 steps
• Has debounce filtering
• Publishes values to Home Assistant

You can reset the counter using the Home Assistant service:

esphome.garage_rotary_reset_rotary

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🏠 Home Assistant Configuration

This is where the percentage calculation happens.

1️⃣ Create Helper

Create an Input Number Helper:

• Name: maximale_Inkrementzahl_Garage
• Min: 0
• Max: 1000
• Step: 1

This represents the maximum number of steps when the garage is fully open.

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2️⃣ Create Template Sensor

Add this template sensor:

{% set value = (float(states('sensor.garage_rotary_garagerotary')) * (1 / float(states('input_number.maximale_inkrementzahl_garage')))) * 100 %}
{% if value > 100 %}
  100
{% elif value < 0 %}
  0
{% else %}
  {{ value | round(2) }}
{% endif %}

Name it:

Position Garage in Prozent

This converts the rotary steps into a 0–100% position value.

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3️⃣ Automatic Reset via Automation (Important)

To ensure the rotary encoder always stays synchronized with the real garage door position, an automation is used.

When the garage door reports closed, the rotary counter is automatically reset to 0.

Example automation:

alias: Reset Garage Rotary when Door Closes
description: Resets the rotary encoder to 0 when the garage door closes
triggers:
  - entity_id: binary_sensor.garagentor_zustand_input
    to: "off"
    trigger: state
conditions: []
actions:
  - data: {}
    action: esphome.garage_rotary_reset_rotary
mode: single

What this does

• When the garage door state changes to closed
• Home Assistant calls:

esphome.garage_rotary_reset_rotary

• The ESP32 sets the rotary encoder value to 0

This ensures:

• No long-term drift
• Clean recalibration after every full close
• Reliable percentage calculation

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🚀 How It Works

1. Garage door moves
2. Motor shaft rotates
3. KY-040 counts steps
4. ESP32 sends step value to Home Assistant
5. If door closes → automation resets steps to 0
6. Template sensor converts steps → percentage

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🔄 Calibration

1. Ensure the door is fully closed (automation resets value to 0).
2. Fully open the garage.
3. Note the maximum step value.
4. Enter that value into:

maximale_Inkrementzahl_Garage

Now the percentage sensor will show the correct position.

Because the counter resets automatically when the door closes, recalibration is rarely needed.

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🌐 Features

• Live position in %
• ESP web interface enabled
• OTA updates
• WiFi signal monitoring
• Debug sensors
• Manual reset service

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⚠️ Notes

• Use 3.3V only for the KY-040.
• Ensure the encoder is mounted without slipping.
• Adjust max_value in YAML if your garage requires more than 1000 steps.
• Static IP is recommended.

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📁 Project Structure

/STLs → 3D print files
/YAMLs → ESPHome configuration
README.md → This file

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📜 License

Free to use and modify.