Mid-Semester Presentation Senior Design October 5, 2010 CAVS Flight Simulator Mid-Semester Presentation Senior Design October 5, 2010

Our Team Rebecca Owens Team Leader Computer Engineering PCB Design Gauge & Throttle Software Candace Allgood Computer Engineering PCB Design Gauge & Throttle Software Amol Patel Electrical Engineering Mechanical Design Wiring Ebi Izonfuo Electrical Engineering Mechanical Design Wiring Dr. J.W. Bruce Academic Advisor Sponsor

Outline Problem Statement Solution Technical Design Constraints Practical Design Constraints System Overview Design Refinements Testing Plan PCB & Packaging

Problem Our sponsor, CAVS, primarily researches problems with vehicles and human factors relating to vehicular systems CAVS does not currently have a device to perform aviation research CAVS wants to convert a cockpit familiarization trainer into a working, realistic simulator

Solution Design gauges and throttle to integrate with the current hardware of the cockpit. Use data from Microsoft Flight Simulator to drive the instruments

The T-37 Cockpit Gauges Throttle Switches Yoke Rudder Pedals

Constraints Technical Constraints Practical Constraints

Technical Constraints Name Description Gauges The device must implement five flight gauges for display (airspeed, fuel quantity, climb, compass, and altimeter). System Response The device must appear to be real-time and have a delay of < 20 ms. Voltage The device must be wall-powered. Interface The device must interface with Microsoft Flight Simulator. Input The device must implement a dual-engine throttle control with flaps.

Practical Constraints Name Category Description Economic Affordability The device must be manufactured for less than $1,500 Sustainability Maintenance The device must require little maintenance

Economic Budget: $1500 Needed Items: Competitor’s Price: ~$37,000 MFS / FSUIPC Yoke Stepping Motors PCB Manufacturing Assorted Electrical Components Competitor’s Price: ~$37,000

Sustainability End Users: Researchers and Pilots Knowledge of End Users Reliable Hardware Reliable Software and Data Communication

System Overview

Design Changes / Refinements Altimeter Needed a device that could reproduce a clock movement using metric steps Metric Clock Internal hand driving mechanism can be bypassed

Test Plan PCB Wiring CAN messages Motor Drive & reset Mechanical Linkages & Switches Full System Test

Testing PCB Footprints, component placement Continuity & Shorts Subsystem testing Power supply Microcontroller Motor Driver Chip CAN transceiver

Testing Wiring Gauge Enclosure IR sensor Stepper Motor Power / CAN External GPIO Enclosure Potentiometers Switches

Testing CAN Messages Motor Drive & Reset Simple echo test to confirm communication between device and PC. Motor Drive & Reset Test drive command Check accuracy Fine-tune IR positioning for home position

Testing Mechanical linkages & Switches Full System Test Mechanical durability Linkage Range of Motion Switches mounted and wired for correct on/off operation Full System Test All components are wired and powered on Every function is evaluated, i.e. gauge, throttle movement, switch actuation

Printed Circuit Board

Printed Circuit Board Ground Plane for heat dissipation 2.5” X 2.5” Octagonal shape designed to fit in circular enclosure Mostly surface mount

Printed Circuit Board

Packaging Mounting Plate and Screws Printed Circuit Board Line Sensor Face plate and needle Line Sensor Stepper Motor Mounting Brackets Printed Circuit Board Circular Connector Cylindrical Enclosure Removable Cap

Packaging Left: PCB mounted with stepper motor Right: PVC enclosure for gauge PVC enclosure with threaded cap removed.

Packaging Internal rotational mechanism Attach potentiometer to pivot via mechanical arm

Packaging Linear Motion Toe brakes – Revolute Motion

Packaging Mechanical design for attaching potentiometers to linear and revolute joints

Questions / Comments