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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