Final Presentation Senior Design November 30, 2010

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

 Problem Statement  Solution  Constraints  System Overview  Design Refinements  Materials  PCB & Packaging  Subsystem Testing  Overall System Testing  References  Questions

 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

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

Gauges Switches Yoke Throttle Rudder Pedals

 Technical Constraints  Practical Constraints

NameDescription GaugesThe device must implement five flight gauges for display (airspeed, fuel quantity, climb, compass, and altimeter). System ResponseThe device must appear to be real-time and have a delay of < 20 ms. VoltageThe device must be wall-powered. InterfaceThe device must interface with Microsoft Flight Simulator. InputThe device must implement a dual-engine throttle control with flaps.

NameCategoryDescription EconomicAffordabilityThe device must be manufactured for less than $1,500 SustainabilityMaintenanceThe device must require little maintenance

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

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

Populated PCB ItemQuantityPriceTotal PCB1$33.00 PIC 241$ uF capacitor4$0.27$ uF capacitor1$ uF capacitor2$0.44$ k ohm resistor2$0.19$ ohm resistor1$ ohm resister1$0.19 Max3051 CAN1$2.49 ULN2003A1$0.68 Voltage Regulator1$2.06 Six pin header1$1.56 Eight pin header1$1.96 Ten pin header1$1.46 Thirty pin header1$4.44 line sensors1$1.02 Total $58.93

Enclosure ItemQuantityPriceTotal Metal Enclosure1$1.50 5inch threaded rods2$0.20$0.40 Lexan polycarbonate sheet0.5$1.99$1.00 Sticker paper0.25$0.10$ screws4$0.10$ lock nuts4$0.15$ position connector housing1$ position connector housing1$ position connector housing1$1.26 stepper motor1$30.00 rubber grommet1$1.30 assorted gear set1$30.00 connector pins (set)1$10.00 Total$77.47

ItemQuantityPriceTotal Software FSUIPC1$40.00 MFS1$49.99 Total$89.99 Hardware Inputs Joystick1$ Linkages Lexan polycarbonate sheet4$1.99$7.96 potentiometers6$2.99$17.94 wires$6.99 Total$32.89

Misc. ItemQuantityPriceTotal super glue1$0.99 hot glue1$5.49 spray paint2$3.50$7.00 zip ties1$1.95 white out1$1.50 rubbing alcohol1$1.00 Epoxy2$4.99$9.98 Rubber1$8.96 bread boards2$1.99$3.98 small plastic enclosure1$2.99 large plastic enclosure1$ volt power supply1$34.99 DC Power connector1$2.85 Total$85.47

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

 Altimeter  Needed a device that could reproduce a clock movement  2 Stepper Motors  Gear set  Enclosure  Metal can

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

Left: New Gauge Right: Original Gauge

New Original

Mechanical design for attaching potentiometers to linear and revolute joints

 Internal rotational mechanism  Attach potentiometer to pivot via mechanical arm

 PCB  Wiring  CAN messages  Motor Drive & reset  Mechanical Linkages & Switches

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

 Wiring  Continuity  Gauge ▪ IR sensor ▪ Stepper Motor ▪ Power / CAN ▪ External GPIO  Enclosure ▪ Potentiometers ▪ Switches

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

 Mechanical linkages & Switches  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

Questions / Comments