cavs flight simulator mid-semester presentation senior design october 5, 2010

CAVS Flight Simulator

Mid-Semester PresentationSenior DesignOctober 5, 2010

Rebecca Owens Team Leader

Computer EngineeringPCB Design

Gauge & Throttle Software

Amol PatelElectrical Engineering

Mechanical DesignWiring

Candace AllgoodComputer Engineering

PCB DesignGauge & Throttle

Software

Ebi IzonfuoElectrical Engineering

Mechanical DesignWiring

Dr. J.W. BruceAcademic Advisor Sponsor

Our Team

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 fromMicrosoft FlightSimulator to drive the instruments

GaugesGauges

SwitchesSwitches

YokeYoke

ThrottleThrottle

Rudder Pedals

Rudder Pedals

The T-37 Cockpit

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:− 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

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

− Enclosure• Potentiometers• Switches

Testing

• CAN Messages− 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− 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

Face plate and needle

Line Sensor

Stepper Motor

Mounting Brackets

Printed Circuit Board

Circular Connector

Cylindrical EnclosureRemovable 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