Beacon4
From Hackstrich
Beacon4 will be the fourth incarnation of the flagpole beacon (after Beacon2 and Beacon3), for Burning Man 2012. This year the plan is to take a different approach, and light the entire scaffold tower rather than just a beacon on top of the flagpole.
Contents
Project Status
- 2012-07-15: Ordered inter-strip connectors and remaining PWR-DC5, CORE, and IO-ETH parts.
- 2012-07-14: First successful end-to-end test of the whole StrichLux system driving 5m of LED strip from the PWR-DC5.
- 2012-07-11: Ordered the switch.
- 2012-07-09: Ordered the majority of enclosure connectors.
- 2012-07-07: First functioning test of StrichLux system driving 5m of LED strip.
- 2012-06-24: LED strips all obtained. Lighting design continues, as does firmware development.
- 2012-06-17: Hardware bring-up and firmware writing continuing. Lightjams is almost certainly going to be the software of choice. Lighting design is coming along.
- 2012-06-07: Work on StrichLux continues. Evaluated lots of software, Lightjams is looking the best at this point, though would require Windows.
- 2012-05-27: Completed rev. 1 StrichLux system design of all modules required for this project and sent all boards off for manufacturing.
- 2012-04-30: Started planning the power architecture for the project.
- 2012-04-29: Work continuing on IO-DMX module.
- 2012-04-24: Permission received!
- 2012-04-23: Requested permission from NeonBunny to attach LEDs to the tower.
- 2012-04-22: Started putting together idea.
Outstanding Issues
- Software evaluation:
- Theatre-type systems
- QLC
- Max of only 4 universes, which rules it out
- MagicQ
- Very complex and more geared toward theatre setups than VJ setups
- Supports up to 16 universes over Art-Net
- x86-only
- Advanced features like sound-reactiveness or remote control require a very expensive license dongle
- QLC
- VJ-type systems
- Lightjams
- x86/Windows-only
- Supports up to 16 universes over Art-Net
- File format is XML, so a lot of setup could be programmatically generated
- Sound reactiveness, remote control, Wiimote control, and everything else is included for a low price
- May not be able to switch programs/grids by timer, could possibly implement via macros?
- Lightjams
- Patching-type systems
- Max
- x86/Windows/Mac-only
- Isadora
- x86/Windows/Mac-only
- Max
- Theatre-type systems
Ideas/Plans
- Main idea is to cover most of the scaffold tower in addressable LED strips, driven by multiple StrichLux modules
- Art-Net will be used between the controller and the StrichLux box
- Fit-PC 2i is being looked at to control the whole thing
- As nice as ARM would be power-wise, x86 will be much more flexible software-wise
- Need to make sure it will be powerful enough before we order
- Need to find a fanless very low power 4 or 5 port Ethernet switch
- Allied Telesis AT-FS705LE V5 might work, it's rugged, low power (1.5-2.5W), and cheap
- But it takes 7.5V which would be another regulator and is a potential point of failure that would bring the entire system down
- Alternative option is the GarrettCom S14H-Hi, it takes 8-15V in via screw terminals and is ruggedized, but $140 and draws 4W
- Best option may be the Sixnet SL-5ES-1, it's $100, rugged, takes 10-30VDC via screw terminals, and only draws 2W
- Ended up going with an M12 ethernet switch, the Octopus 5TX EEC
- Allied Telesis AT-FS705LE V5 might work, it's rugged, low power (1.5-2.5W), and cheap
System Components
- Fit-PC 2i (controller)
- Octopus 5TX EEC 5-port Ethernet switch
- 3 StrichLux boxes (driver), each with:
- 60m of LED strips
- Power setup
- Debugging terminal (XO-1? Toughbook?)
Power Details
- Power requirements (peak)
- Fit-PC 2i - ???
- Ethernet Switch - ???
- StrichLux box(es) - ???
- LEDs - 10W/m (~1.8A/m at 5V measured, so 10W/m after losses is reasonable)
Power Architecture
http://www.asciiflow.com/#4007824742034929919/13747898[YOB-2]
+--------------+
+--->| LED Strip 0 |
| +--------------+
|
| +--------------+
+---------------+ | +->| LED Strip 1 |
+--------------+ | +-+ | +--------------+
| | | StrichLux +---+
| Dome | +->| Controller A +---+ +--------------+
| Lighting | | | +-+ +->| LED Strip 2 |
| | | +---------------+ | +--------------+
+--------------+ | |
^ | | +--------------+
| | +--->| LED Strip 3 |
+----------+---------+ | +--------------+
| | |
| | | +--------------+
| +-+ +--->| LED Strip 4 |
| | | +--------------+
| | |
| | | +--------------+
| | +---------------+ | +->| LED Strip 5 |
+---------------+ | | | +-+ | +--------------+
| | | Distribution | | StrichLux +---+
| Battery +=======>| +--->| Controller B +---+ +--------------+
| | | Box | | +-+ +->| LED Strip 6 |
+---------------+ | | +---------------+ | +--------------+
| | |
| | | +--------------+
| | +--->| LED Strip 7 |
| | +--------------+
| +-+
| | | +--------------+
+--+-------+---------+ | +--->| LED Strip 8 |
| | | | +--------------+
+---------+ | | |
v v | | +--------------+
+--------------+ +--------------+ | +---------------+ | +->| LED Strip 9 |
| | | | | | +-+ | +--------------+
| Convienience | | System | | | StrichLux +---+
| Outlets | | Controller | +->| Controller C +---+ +--------------+
| | | | | | +->| LED Strip 10 |
+--------------+ +--------------+ +---------------+ +--------------+
Lighting Layout
Random Notes
- Decided on 60m length total (3 StrichLux boxes)
- That's 1920 RGB LEDs and ~600W peak!
- Will need to come up with a lighting layout/design that will fit within this
Dimensions
Main Module (4 of these vertically, 2 of which will be lit) ----------------------------------------------------------- +-----D-----+------E------+ |\ /| | | | | \ / | |-----D-----| | | F / | | H | | \ / | |-----D-----| | | \ / | | | | | / \ | |-----D-----+------E------| | / \ | | | | F \ | A A A / \ A |-----------B-------------+ |/ \| Top Module ---------- | | | | | | | | | | | | | | | | |-------B-----------------| |------------------C------------------| | | | | / \ | | G | |------------------C------------------| | | | | | A============B============A A A | | | |
- A - Module Height (5ft 1in)
- B - Module Width (5ft)
- C - Module Depth (7ft)
- D - Ladder Width (2.5ft)
- E - Beside-Ladder Width (B - D) (2.5ft)
- F - Cross-brace Length (7.37ft)
- G - Top Rail Support Height
- H - Ladder Section Height (3.5ft)
- n - Number of Modules (3)
- x - Number of Main Modules (2)
Idealized Layout
- Vertical Mains: A * 4 * n = 5.083 * 4 * 3 = 61ft (done piecing)
- Beside-Ladder Boxes: (E * 2 + H) * 2 * x = 34ft (done piecing)
- Cross-braces: F * 2 * 2 * x = 7 * 2 * 2 * 2 = 59ft (done piecing)
- Top Rail: B * 2 + C * 2 = 24ft (done piecing)
- Top-Middle Rail: C * 2 = 14ft (done piecing)
- Toe Board: B * 4 = 10ft (done piecing)
- Total: 202ft / 61.5m
Actual Layout
- Vertical Mains: 4.5m each * 4
- Cross brace tubes: 1.125m each * 8
- Toe board: 1.5m each * 2
- Top middle rail: 2.1m each * 2
- Top rail long side: 2.1m each * 2
- Top rail short side: 1.5m each * 2
- Ladder box vertical: 1m each * 4
- Ladder box horizontal: 0.75m * 8
- Total: 60.00m
LED Strip List
| Piece | Location | Length | # of LEDs | Reel | Controller/Channel | DMX Channels | LightJams IDs |
|---|---|---|---|---|---|---|---|
| Vertical Main 1 | Vertical Main 1 | 450cm | 144 | C | A-1 | 1-432 | AAA-AQP |
| Vertical Main 2 | Vertical Main 2 | 450cm | 144 | D | A-2 | 1-432 | BAA-BQP |
| Vertical Main 3 | Vertical Main 3 | 450cm | 144 | E | A-3 | 1-432 | CAA-CQP |
| Vertical Main 4 | Vertical Main 4 | 450cm | 144 | F | A-4 | 1-432 | DAA-DQP |
| Cross brace tube 1 | MF1/2 B Right | 218.75cm | 70 | G | B-1 | 1-210 | EAA-EIB |
| Cross brace tube 2 | MF1/2 A Right | 218.75cm | 70 | G | B-2 | 1-210 | FAA-FIB |
| Cross brace tube 3 | MF1/2 A Left | 218.75cm | 70 | H | B-3 | 1-210 | GAA-GIB |
| Cross brace tube 4 | MF1/2 B Left | 218.75cm | 70 | H | B-3 | 211-420 | GIC-GQD |
| Cross brace tube 5 | MF3/4 A Right | 218.75cm | 70 | I | C-1 | 1-210 | IAA-IIB |
| Cross brace tube 6 | MF3/4 B Right | 218.75cm | 70 | I | C-2 | 1-210 | JAA-JIB |
| Cross brace tube 7 | MF3/4 B Left | 218.75cm | 70 | J | C-3 | 1-210 | KAA-KIB |
| Cross brace tube 8 | MF3/4 A Left | 218.75cm | 70 | J | C-3 | 211-420 | KIC-KQD |
| Toe board 1 | 1 (Close) | 150cm | 48 | A | C-4 | 349-492 | KNK-KSX |
| Toe board 2 | 2 (Far) | 150cm | 48 | A | C-4 | 1-144 | LAA-LFN |
| Top middle rail 1 | Left | 212.5cm | 68 | K | C-4 | 145-348 | LFO-LNJ |
| Top middle rail 2 | Right | 212.5cm | 68 | K | C-1 | 307-510 | ILU-ITP |
| Top long rail 1 | Right | 212.5cm | 68 | L | C-2 | 307-510 | JLU-JTP |
| Top long rail 2 | Left | 212.5cm | 68 | L | B-4 | 145-348 | HFO-HNJ |
| Top short rail 1 | TF1 | 150cm | 48 | B | B-4 | 1-144 | HAA-HFN |
| Top short rail 2 | TF2 | 150cm | 48 | B | B-4 | 349-492 | HNK-HSX |
| Ladder box vertical 1 | MF1 | 100cm | 32 | A | B-1 | 283-378 | ELU-EPL |
| Ladder box vertical 2 | MF2 | 100cm | 32 | A | B-2 | 283-378 | FLU-FPL |
| Ladder box vertical 3 | MF3 | 100cm | 32 | B | C-1 | 211-306 | IIC-ILT |
| Ladder box vertical 4 | MF4 | 100cm | 32 | B | C-2 | 211-306 | JIC-JLT |
| Ladder box horizontal 1 | MF1 Top | 75cm | 24 | C, D | B-1 | 211-282 | EIC-ELT |
| Ladder box horizontal 2 | MF1 Bottom | 75cm | 24 | E, D | B-1 | 379-450 | EPM-ESF |
| Ladder box horizontal 3 | MB2 Top | 75cm | 24 | K | B-2 | 211-282 | FIC-FLT |
| Ladder box horizontal 4 | MF2 Bottom | 75cm | 24 | L | B-2 | 379-450 | FPM-FSF |
| Ladder box horizontal 5 | MF3 Top | 75cm | 24 | G, H | A-1 | 433-504 | AQQ-ATJ |
| Ladder box horizontal 6 | MF3 Bottom | 75cm | 24 | I, H | A-2 | 433-504 | BQQ-BTJ |
| Ladder box horizontal 7 | MF4 Top | 75cm | 24 | J, H | A-3 | 433-504 | CQQ-CTJ |
| Ladder box horizontal 8 | MF4 Bottom | 75cm | 24 | F, H | A-4 | 433-504 | DQQ-DTJ |
Reel Assignment
- Reel A (100% used)
- Toe Board 1: 150cm
- Toe Board 2: 150cm
- Ladder box vertical 1: 100cm
- Ladder box vertical 2: 100cm
- Reel B (100% used)
- Top short rail 1: 150cm
- Top short rail 2: 150cm
- Ladder box vertical 3: 100cm
- Ladder box vertical 4: 100cm
- Reel C (100% used)
- Vertical Main 1: 450cm
- Ladder box horizontal 1a: 50cm (chunk 1)
- Reel D (100% used)
- Vertical Main 2: 450cm
- Ladder box horizontal 1b: 25cm (chunk 2)
- Ladder box horizontal 2b: 25cm (chunk 2)
- Reel E (100% used)
- Vertical Main 3: 450cm
- Ladder box horizontal 2a: 50cm (chunk 1)
- Reel F (100% used)
- Vertical Main 4: 450cm
- Ladder box horizontal 8a: 50cm (chunk 1)
- Reel G (100% used)
- Cross brace tube 1: 218.75cm
- Cross brace tube 2: 218.75cm
- Ladder box horizontal 5a: 62.5cm (chunk 1)
- Reel H (100% used)
- Cross brace tube 3: 218.75cm
- Cross brace tube 4: 218.75cm
- Ladder box horizontal 5b: 12.5cm (chunk 2)
- Ladder box horizontal 6b: 12.5cm (chunk 2)
- Ladder box horizontal 7b: 12.5cm (chunk 2)
- Ladder box horizontal 8b: 25cm (chunk 2)
- Reel I (100% used)
- Cross brace tube 5: 218.75cm
- Cross brace tube 6: 218.75cm
- Ladder box horizontal 6a: 62.5cm (chunk 1)
- Reel J (100% used)
- Cross brace tube 7: 218.75cm
- Cross brace tube 8: 218.75cm
- Ladder box horizontal 7a: 62.5cm (chunk 1)
- Reel K (100% used)
- Top middle rail 1: 212.5cm
- Top middle rail 2: 212.5cm
- Ladder box horizontal 3: 75cm
- Reel L (100% used)
- Top long rail 1: 212.5cm
- Top long rail 2: 212.5cm
- Ladder box horizontal 4: 75cm
Cable Routing
- Overview
- When viewing the tower end-on with the ladder on the left:
- Vertical Main 1 is on the left of the close end
- Vertical Main 2 is on the right of the close end
- Vertical Main 3 is on the left of the far end
- Vertical Main 4 is on the right of the far end
- Main Frame 1 is the lower close frame of the 2 lit ones
- Main Frame 2 is the lower far frame of the 2 lit ones
- Main Frame 3 is the higher close frame of the 2 lit ones
- Main Frame 4 is the higher far frame of the 2 lit ones
- Top Frame 1 is the close top frame
- Top Frame 2 is the far top frame
- Cross Brace A are the tubes running low-to-high from MF1/3 to MF2/4
- Cross Brace B are the tubes running high-to-low from MF1/3 to MF2/4
- Toe Board 1 is the close board
- Toe Board 2 is the far board
- When viewing the tower end-on with the ladder on the left:
- Controller A
- Channel 1
- Feeder (up VM1) -> Vertical Main 1 -> Long Jumper (via Toe Board 1, down VM2) -> MF3 LBH Top
- Channel 2
- Feeder (up VM2) -> Vertical Main 2 -> Long Jumper (down VM2) -> MF3 LBH Bottom
- Channel 3
- Feeder (up VM3) -> Vertical Main 3 -> Long Jumper (via Toe Board 2, down VM4) -> MF4 LBH Top
- Channel 4
- Feeder (up VM4) -> Vertical Main 4 -> Long Jumper (down VM4) -> MF4 LBH Bottom
- Channel 1
- Controller B
- Channel 1
- Feeder (up VM4) -> CB MF1/2 B Right -> MF1 LBH Top -> MF1 LBV -> MF1 LBH Bottom
- Channel 2
- Feeder (up VM2) -> CB MF1/2 A Right -> MF2 LBH Top -> MF2 LBV -> MF2 LBH Bottom
- Channel 3
- Feeder (up VM1) -> CB MF1/2 A Left -> Short Jumper -> CB MF1/2 B Left
- Channel 4
- Feeder (up VM3) -> Short Jumper (via TF2 Top Short Rail) -> TF2 Top Short Rail -> Left Top Long Rail -> TF1 Top Short Rail
- Channel 1
- Controller C
- Channel 1
- Feeder (up VM4) -> CB MF3/4 A Right -> Short Jumper -> MF3 LBV -> Long Jumper (via MF3 LBH Top, VM2) -> Right Top Middle Rail
- Channel 2
- Feeder (up VM2) -> CB MF 3/4 B Right -> Short Jumper -> MF4 LBV -> Long Jumper (via MF4 LBH Top, VM4) -> Right Top Long Rail
- Channel 3
- Feeder (up VM3) -> CB MF3/4 B Left -> Short Jumper -> CB MF 3/4 A Left
- Channel 4
- Feeder (up VM4) -> Toe Board 2 -> Left Top Middle Rail -> Toe Board 1
- Channel 1
Feeders and Jumpers
- Feeders
- Feeder A-1 - 310cm
- Feeder A-2 - 310cm
- Feeder A-3 - 310cm
- Feeder A-4 - 310cm
- Feeder B-1 - 360cm
- Feeder B-2 - 360cm
- Feeder B-3 - 360cm
- Feeder B-4 - 711cm
- Feeder C-1 - 576cm
- Feeder C-2 - 576cm
- Feeder C-3 - 516cm
- Feeder C-4 - 687cm
- Jumpers
- Jumper A-1 - 308cm
- Jumper A-2 - 262cm
- Jumper A-3 - 308cm
- Jumper A-4 - 262cm
- Jumper B-3 - 92cm
- Jumper B-4 - 152cm
- Jumper C-1.1 - 73cm
- Jumper C-1.2 - 142cm
- Jumper C-2.1 - 73cm
- Jumper C-2.2 - 142cm
- Jumper C-3 - 92cm
StrichLux Enclosures
- Each StrichLux controller with its 4 output modules, 1 input module, and 1 power module will need an enclosure of some kind.
- Pelican case? Could do one larger one with all 3 controllers in it, or 3 smaller ones
- Assuming each StrichLux box has its own enclosure, would need a bunch of connections made through it:
- Power - 2x12V @ 20A each - 4 20A power pins
- Ethernet input - RJ45 - 1 RJ45
- Will use M12 ethernet connectors (either from L-com or wherever else we're getting connectors) rather than RJ45s as they're cheap and IP67
- Not RJ45-compatible, but an M12->RJ45 cable will be brought for troubleshooting, and they're not expensive
- Will use M12 ethernet connectors (either from L-com or wherever else we're getting connectors) rather than RJ45s as they're cheap and IP67
- Strip outputs - SPI+5V - 2 signal pins, 2 10A power pins each x 4
- JAE SRCN2A16-7S / SRCN6A16-7P would be good and extremely rugged, but the cost may be too high
- Not weatherproof, doh!
- Amphenol SINE MotionGrade M23/M40-series connectors look really nice, aren't too badly priced (compared with 5015 connectors anyway) and are weatherproof
- They're really tall though, sticking out would negatively affect durability, so RT360 connectors might be better (but a bit more expensive)
- Pricing is Receptacle, Sockets, Plus, Pins, Grip/Shell (* 4 per box * 3 boxes)
- SINE M23: (6.46 + 0.728*4 + 8.430 + 0.640*4 + 3.61) * 4 = $95.88 * 3 = $287.64
- SINE M40: (8.09 + 1.660*4 + 11.05 + 1.780*4 + 7.83) * 4 = $162.92 * 3 = $488.76
- SINE RT360: (4.85 + 0.351*4 + 12.28 + 0.351*4 + 6.62) * 4 = $106.23 * 3 = $318.69
- JAE SRCN2A16-7S / SRCN6A16-7P would be good and extremely rugged, but the cost may be too high
- Molex MX150L will be used for inter-strip connections
- Reasonably priced
- Tooling is reasonably priced
- Matte sealed
Enclosure Connectors
| Function | Description | Part # | Qty Req'd per Enclosure | Status |
|---|---|---|---|---|
| Ethernet Connector | Female Panel Mount Receptacle | CON-M124PF | 1 | Ordered |
| Power Connector | Male Flanged Receptacle | RT00144PNH | 1 | Ordered |
| Power Connector | Male Pins | SP12A1T | 4 | Ordered |
| Power Connector (mating) | Female Cable Plug | RT06144SNH | 1 | Ordered |
| Power Connector (mating) | Female Sockets | SS12A1T | 4 | |
| LED Connector | Female Flanged Receptacle | RT00142SNH | 4 | Ordered |
| LED Connector | Female Power Sockets | SS12A1T | 8 | |
| LED Connector | Female Signal Sockets | SS20M1T | 8 | Obtained |
| LED Connector (mating) | Male Cable Plug | RT06142PNH | 4 | Ordered |
| LED Connector (mating) | Male Power Pins | SP12A1T | 8 | Ordered |
| LED Connector (mating) | Male Signal Pins | SP20M1T | 8 | Obtained |
Inter-Strip Connectors
| Description | Part # | Qty Req'd | Status |
|---|---|---|---|
| Female Receptacle | 19418-0019 | 51 | Ordered |
| Female Crimp Socket | 19420-0001 | 204 | |
| Male Plug | 19419-0004 | 51 | Ordered |
| Male Crimp Pin | 19417-0047 | 204 | Ordered |
Test Setup
- Want to be able to power the whole setup from AC power for configuration/testing/programming
- ATX power supplies provide plenty of +12V which could feed the PWR-DC5 modules
- A modular supply like the OCX ZT-series would be cleanest, could modify the cables with Sabre connectors on the ends
- Need 100W per channel, 200W per board, 600W total @ 12V
- 100W per channel @ 12V means 8.33A
- PCI-E and 8-pin CPU power connectors on ATX PSUs provide 6 amps per pin
- PCI-E connectors have 3 pin pairs each
- 8-pin CPU power connectors have 4 pin pairs each
- Need four pins per board
- Two boards get 8-pin CPU power -> Sabre connectors
- The last board gets a 2xPCI-E power -> Sabre connector
- OCZ ZT-series 750W power supply has all the required connectors
- ATX power supplies provide plenty of +12V which could feed the PWR-DC5 modules
Cost
| Item | Status | Cost |
|---|---|---|
| IO-DMX + IO-BO Rev. 1 PCBs | Obtained | $40.69 |
| IO-DMX + IO-BO Parts | Obtained | $18.31 |
| IO-SPI Rev. 1 PCBs | Obtained | $49.65 |
| CORE + IO-ETH + PWR-DC5 PCBs | Obtained | $454.66 |
| CORE + IO-SPI + IO-ETH + PWR-DC5 Parts | Obtained | $184.40 |
| Test LED Strip | Obtained | $25.00 |
| OCZ ZT 750W Test PSU | Obtained | $107.34 |
| 60m LPD8806 LED Strip | Obtained | $1320.00 |
| Fit-PC 2i | Ordered | $455.00 |
| Lightjams License (design PC) | Obtained | $78.59 |
| Lightjams License (installation PC) | Future | $78.59 |
| Ethernet Switch | Ordered | $363.85 |
| 2 sets of StrichLux IO-CORE + IO-ETH + PWR-DC5 Parts | Ordered | $512.83 |
| 12 sets of StrichLux IO-SPI Parts | Future | ~$165.00 |
| Enclosure A | Future | $62.15 |
| Enclosures B-D | Future | $186.45 |
| Enclosure Connectors (order 1) | Ordered | $563.09 |
| Enclosure Connectors (order 2) | Ordered | ~$50 |
| Inter-Strip Connectors | Future (ordered, awaiting confirmation) | ??? |
| Total | Obtained | $4235.66 |
| Total | Future | ~$480.04 |
| Grand Total | ~$4715.70 |
Photos
Beacon4 Scaffold 3D Model
