CAVS Flight Simulator

Final PresentationSenior DesignNovember 30, 2010

Our Team

Rebecca Owens Team Leader

Computer EngineeringPCB Design

Gauge & Throttle Wiring

Software

Amol PatelElectrical Engineering

Mechanical DesignWiring

Candace AllgoodComputer Engineering

PCB DesignGauge & Throttle

WiringSoftware

Ebi IzonfuoElectrical Engineering

Mechanical DesignWiring

Dr. J.W. BruceAcademic Advisor Sponsor

Outline

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

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 fromMicrosoft FlightSimulator to drive the instruments

The T-37 Cockpit

GaugesGauges

SwitchesSwitches

YokeYoke

ThrottleThrottle

Rudder Pedals

Rudder Pedals

Constraints

Technical ConstraintsPractical Constraints

Technical ConstraintsName 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: $1500Needed Items:

MFS / FSUIPC Yoke Stepping Motors PCB Manufacturing Assorted Electrical Components

Competitor’s Price: ~$37,000

Sustainability

End Users: Researchers and PilotsKnowledge of End UsersReliable HardwareReliable Software and Data

Communication

System Overview

MaterialsPopulated PCB  

Item Quantity Price Total

PCB 1 $33.00 $33.00

PIC 24 1 $6.90 $6.90

0.1uF capacitor 4 $0.27 $1.08

47 uF capacitor 1 $0.65 $0.65

10 uF capacitor 2 $0.44 $0.88

10k ohm resistor 2 $0.19 $0.38

120 ohm resistor 1 $0.18 $0.18

220 ohm resister 1 $0.19 $0.19

Max3051 CAN 1 $2.49 $2.49

ULN2003A 1 $0.68 $0.68

Voltage Regulator 1 $2.06 $2.06

Six pin header 1 $1.56 $1.56

Eight pin header 1 $1.96 $1.96

Ten pin header 1 $1.46 $1.46

Thirty pin header 1 $4.44 $4.44

line sensors 1 $1.02 $1.02

Total     $58.93

Materials continued

Enclosure

Item Quantity Price Total

Metal Enclosure 1 $1.50 $1.50

5inch threaded rods 2 $0.20 $0.40

Lexan polycarbonate sheet 0.5 $1.99 $1.00

Sticker paper 0.25 $0.10 $0.03

4 screws 4 $0.10 $0.40

4 lock nuts 4 $0.15 $0.60

8 position connector housing 1 $0.51 $0.51

10 position connector housing 1 $0.48 $0.48

30 position connector housing 1 $1.26 $1.26

stepper motor 1 $30.00 $30.00

rubber grommet 1 $1.30 $1.30

assorted gear set 1 $30.00 $30.00

connector pins (set) 1 $10.00 $10.00

Total $77.47

Materials continued

Item Quantity Price Total

Software

FSUIPC 1 $40.00 $40.00

MFS 1 $49.99 $49.99

Total $89.99

Hardware Inputs

Joystick 1 $120.00 $120.00

Linkages

Lexan polycarbonate sheet 4 $1.99 $7.96

potentiometers 6 $2.99 $17.94

wires $6.99 $6.99

Total $32.89

Materials continued

Misc.

Item Quantity Price Total

super glue 1 $0.99 $0.99

hot glue 1 $5.49 $5.49

spray paint 2 $3.50 $7.00

zip ties 1 $1.95 $1.95

white out 1 $1.50 $1.50

rubbing alcohol 1 $1.00 $1.00

Epoxy 2 $4.99 $9.98

Rubber 1 $8.96 $8.96

bread boards 2 $1.99 $3.98

small plastic enclosure 1 $2.99 $2.99

large plastic enclosure 1 $3.79 $3.79

12 volt power supply 1 $34.99 $34.99

DC Power connector 1 $2.85 $2.85

Total $85.47

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

Design Changes/ Refinements

Altimeter Needed a device that could reproduce a

clock movement 2 Stepper Motors Gear set

Enclosure Metal can

Packaging

Mounting Plate and Screws

Face plate and needle

Line Sensor

Stepper Motor

Mounting Brackets

Printed Circuit Board

Circular Connector

Cylindrical EnclosureRemovable Cap

Packaging: PCB and Stepper Motors

Packaging

Left: New Gauge Right: Original Gauge

Packaging

NewNew

OriginalOriginal

Packaging

Mechanical design for attaching potentiometers to linear and revolute joints

Packaging

Internal rotational mechanism

Attach potentiometer to pivot via mechanical arm

Subsystem Testing

PCBWiringCAN messagesMotor Drive & resetMechanical Linkages & Switches

Testing

PCB Footprints, component placement Continuity & Shorts Subsystem testing

▪ Power supply▪ Microcontroller▪ Motor Driver Chip▪ CAN transceiver

Testing

Wiring Continuity Gauge

▪ IR sensor▪ Stepper Motor▪ Power / CAN▪ External GPIO

Enclosure▪ Potentiometers▪ Switches

Testing

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

Testing

Mechanical linkages & Switches Mechanical durability Linkage Range of Motion Switches mounted and wired for correct

on/off operationFull System Test

All components are wired and powered on

Every function is evaluated, i.e. gauge, throttle movement, switch actuation

Overall System Testing

Overall System Testing

Questions / Comments