University of MinnesotaUnmanned Aerial Vehicle Research Lab

Goldy Flight Control System Manufacturing Instructions

1

Press in 1/8” 4-40 thread tee-nuts to top side of bottom board in hole locations shown. If necessary, use a clamp to apply pressure so that the three prongs settle in securely with the wood.

2

Wire the Rx Mux interconnections • Solder 'Y' interconnection for BEC. The ends are as follows:

– Male JR servo extension to connect to Rx Mux power/ground (J1)– Female JR servo extension to connect to BEC output– Power and Ground wires that will carry BEC 6V output to the 50

pin harness. These will later be soldered to the harness.

• Solder the 8 pin header connectors (P/N 609-3321-ND) to the “S” nodes along the inputs (J5, J4) and output (J3) to the Rx Mux.

• Solder two wires with a 2 position female header connector to the state/ground nodes (J2)

• Solder two wires with a female JR servo extension to the Rx Mux power/ground nodes (J1)

3

Check the daughterboard prior to installation for missing components and unsoldered grounds in the three voltage regulators

BAD BAD GOOD

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• Align the daughter board and Rx mux mounting holes with the precut holes shown on the bottom layer mounting board, placing a 0.12” inner diameter 1/8” spacer at each location. – The Rx mux is secured with four 0.375” 2-56 thread flat head machine

screws and four 3/16” 2-56 thread hex nuts. – The daughter board is secured with four 7/16” 2-56 thread flat head

machine screws and the aluminum board fasteners for the GPS board and telemetry board.

– The four aluminum board fasteners must be pre-tapped for 2-56 thread screws. Dimensions are given in the solid works drawing files.

–  Heat shrink all of the aluminum board fasteners for the GPS and telemetry modem cards. Cut holes in the heat shrink over the screw holes.

– See next slide for picture

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2x tapped aluminum telemetry modem board fasteners (must be wrapped with heat shrink)

4x H212-ND hex nuts

2x tapped aluminum GPS board fasteners(must be wrapped with heat shrink)

8x 875K-ND spacers

8x 04-00738 machine screws

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Completed Bottom Board Assembly

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Assemble the top board assembly• For the IMU sensor screws, tap two holes in the top board using the

locations given in the Solid Works Drawing file board_top_template.SLDDRW, located on the SVN

• Print out the drawing onto a sheet of paper, and cut out the top board template. Align the cutout with the board, and mark the IMU sensor screw hole locations.

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Completing Top Board Assembly• Align the three 15-pin female D-sub connectors, the 50-pin female D-sub

connector, IMU board, and IMU sensor to the top layer mounting board. • There are pre-cut holes on the mounting board for the D-sub connectors and

IMU board to line up with. • The IMU sensor mounting holes should line up with the pre-tapped holes

from the previous slide• The 0.875” 4-40 thread standoffs are secured to the mounting board by 3/8”

4-40 thread socket head cap screws. • The IMU board screws and two D-sub connector screws not threaded into

standoffs are secured by 1/4” 4-40 thread hex nuts.• See next slide for picture

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215FER-ND auxiliary D-sub connector

12x NAS1352-0406P socket head cap screws

215MER-ND auxiliary D-sub

connector

6x H216-ND hex nuts215FER-ND Output D-sub

connector

IMU sensor

IMU board

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250FER-ND 50-pin D-sub connector

6x 1896K-ND standoffs

Completed Top Board Assembly

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15 Pin D-Sub Connectors• INPUT A connector

• Solder four 1.25” wires to pins 5, 6, 7, & 8 of the D-sub connector. Then solder eight 1” wires to pins 1 through 8 of the D-sub connector. The four 1.25” wires will eventually be soldered to the PWM reader chip. Apply heat shrink to connections.

• Solder the eight 1” wires to a rectangular 8 pin female header connector (P/N S5483-ND)

• Note see next slide for picture

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• Output connector• Solder eight 1” wires to pins 1 through 8 of the D-sub connector.

Apply heat shrink to connections.• Solder the eight 1” wires to a rectangular 8 pin female header

connector (P/N S5483-ND)

Input D-Sub Connectors Output D-Sub

Connectors

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• Remove any wires from the Daughter board harness that are not used (Wires 9, 13, 26, 27, 32, 41, 43, 45, 46, 47, 48, 53, 55, 57, 76, 79, 82, 84, 93 of the harness)– This is done by taking a small flat head screw diver, gently applying

pressure to exposed nodes of the harness, and pulling out the wire

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Use the wiring diagram to solder the following to the harnesses:– the INPUT B RX mux 8 pin connector– RX mux ground & state 2 pin connector – IMU connector

RX mux ground & state 2 pin connector

the INPUT B RX mux 8 pin connector

IMU connector

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Use the wiring diagram to solder the following to the harness:– Main GPS connector (COM2)

• There is an adapter between the daughter board harness and the GPS board• See the GPS Board sheet inside the wiring diagram for Crescent vs. Novatel

– Telemetry board connector (COM3)

Main GPS connector

Telemetry board connector

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Use the wiring diagram to solder pins 16, 17 of the 50 Pin harness:– The four power wires that lead to the daughter board harness must share a 3-way

connection with an approximately 4.5" power wire that will connect to the auxiliary D-sub connector (let it hang freely for now), and the input power wire to the BEC, cut to approximately 2.75".

• NOTE: It may be helpful to remove the aluminum standoff next to pin 17 of the 50 pin harness (See image below)

– The four ground wires that lead to the daughter board harness must share a 'Y' connection with the input ground wire to the BEC, cut to approximately 2.75".

– Clip the output BEC wires to approximately 1", and solder a male JR servo connector which plugs in to the 'Y' interconnection from Step 1, to the ends.

Pin 17 Pin 16 &17

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Use the wiring diagram to solder pins 30, 31, 32, 34 of the 50 pin connector (I2C connections).– Create a 3-way connection (pin 32 only needs to be a 2-way -- see

diagram) at the 50 pin connector solder cup nodes. – One set of wires is from the daughter board harness to the 50 pin

connector (approx. 1.5”) – One set is from the 50 pin connector nodes to the auxiliary D-sub

connector (wires approximately 4.5")– One set is from the 50 pin connector nodes to the I2C nodes of the PWM

reader chip (approximately 2.25“)– Stay consistent by using the same color of wires that correspond to each

I2C pin– Leave the wires that are to be connected to the auxiliary D-sub

connector and PWM reader chip hanging until the entire 50 pin harness is soldered

– See next slide for images from this step

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I2C Nodes

Use the wiring diagram to solder pins 49 & 50 of the 50 Pin harness – Solder a 'Y' connection to pin 50, where one wire, approximately 4.5",

leads to the auxiliary D-sub connector, and the other is the power wire from the 'Y' BEC interconnection of Slide 2. Pin 49 solders to the ground wire of the same interconnection.

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• Use the wiring diagram to solder the rest of the wiring harness to the 50 pin connector and RX mux. – Pins 6, 7, 35, and 36 of the 50 pin connector must share 'Y' connections

that go to the auxiliary D-sub connector. These wires should be approximately 4.5"

– It seems to work best to go down row by row from the connections that are already soldered.

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• Use the wiring diagram to solder: – the auxiliary D-sub connections – the PWM reader connections

– Secure the PWM reader to the bottom of the Top Board using a Velcro stripPWM reader

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AUX D-Sub

Secure the BEC to the bottom of the Top Board using strips of Velcro.

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Solder together the desired GPS connector

OEMStar connector Crescent connector

• Plug the MPC5200 into the daughter board• Thread the IMU connector through the Top Board hole, and connect it to the

J1 connection. • Connect the BEC interconnections and RX mux ground/state connector• Plug the daughter board harness into the daughterboard.• Connect the GPS board connector

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• Gently squeeze the top board assembly down onto the bottom board assembly until the wires are bent enough that the board screws (P/N 04-00741) can be secured into the standoffs.

USE CAUTION TO NOT BREAK THE TOP AND BOTTOM BOARDS

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Secure GPS receiver and telemetry modem boards to the assembly • The OEMStar GPS receiver is secured by two 2-56 thread 5/16” pan head screws

– A small washer (or two) must be placed between the aluminum fasteners and the receiver to ensure clearance between the fasteners and components on the receiver

• The Crescent GPS receiver and telemetry modem board are secured by two 2-56 thread 3/16” pan head screws each

• Connect the GPS and telemetry board wired connectors onto their respective boards. Finally, connect the three 8 pin RX mux connectors

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