Hardware development guidelines - alesskerbinek/FlightSimPanel GitHub Wiki

General overview

  • Each Unit has it’s own microcontroller which handles inputs and outputs and connects to WLAN network.
  • Units communicates via WLAN with flight simulator software (FSS) on separate network station.
  • Simulator-to-unit communication is implemented using UDP broadcasts.
  • Unit-to-simulator communication is implemented by sending UDP datagrams to FSS Static IP Address.
  • Each unit has a header for programming and debugging. Unit can be optionally power supplied on that header.
  • Each unit has separate header for power supply and two additional pins that can be used as GPIO, UART or I2C bus.
  • Microcontrollers used on units are ESP32 (WROOM 32D) with build-in antenna.
  • Besides programming and I2C/UART port ESP32 has 21 GPIO pins that can be used for reading buttons, switches or driving LEDs and indicators.

PCB

TODO

Housing

  • Sides of the housing contain holes for combining units together. On one side there is an (oval?) hole and on the other hot melt insert nut.
  • For bolting we use thumbscrews.
  • There will probably need to be different raster of holes for vertical and horizontal direction. For units that can be oriented in both directions (fuel?) we can use oval holes or multiple holes.

Testing

PCB v1

POWER SUPPLY    OK
PROGRAMMING     OK
SW   1 - 5      OK
7SEG 1 - 12     OK
ROTARY ENC 1    OK (with C5 & C6 = 200nF)
ROTARY ENC 2    OK (with C3 & C4 = 200nF)
SW   6 - 8      OK (with or without C3 & C4)
POTENTIOMETER 1 NOT REQ 
POTENTIOMETER 2 OK (remove C3 & C4, replace R11-R14 to extend range*)

PCB v2

POWER SUPPLY    OK
PROGRAMMING     OK
SW   1 - 5      OK
7SEG 1 - 12     OK
ROTARY ENC 1    OK (without C5 & C6)
ROTARY ENC 2    OK (without C3 & C4)
SW   6 - 8      OK (without C3 & C4)
LED5            OK (HIGH and LOW just before programming)

Components

CABLE WRAP

HEADERS & PINS KITS

THUMBSCREWS

SMD TACTILE PUSH BUTTON

PUSHBUTTON WITH LED

BUTTON HATS

SWITCH Rocker Switch

One side spring return momentary toggle switch the other side fixed ON OFF (ON) (FLAPS)

1Pc SH T8014B-U2HBQ Long Flat Handle SPDT 3Pin Mini Toggle Switch ON-OFF-MOM One Side Momentary 3 Position (FLAPS)

SH T80-T Series Round Top Anti-mishandling Locking Lever 6.35mm Panel Mount Mini Toggle Switch (LANDING GEAR)

Push Pull Switch (CARB HEAT)

ROTARY 4 POSITION (FUEL)

LIMIT SWITCH (FUEL)

SPRING BALL PLUNGER (FUEL)

SLIDE SWITCH FOR KLIXON REPLICA

OUTSIDE THREADED INSERT FOR KLIXON REPLICA

KNOBS

DISPLAY

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