Beacon4

From Hackstrich
Revision as of 03:05, 2 July 2012 by SarahEmm (talk | contribs) (Adding final connector decisions for the enclosures!)

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.

Project Status

  • 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:
    • 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
    • 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

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
    • Backup plan is to have a USB hub and one OpenDMX USB interface per universe, driving the StrichLux boxes via IO-DMX input modules
  • 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

System Components

  • Fit-PC 2i (controller)
  • 4-port fanless Ethernet switch
  • 3 StrichLux boxes (driver, each with:
  • 60m of LED strips
  • Power setup (need to work out power details)
  • Debugging terminal (XO-1?)

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
  • Controller A
    • Channel 1
      • Feeder (up VM1) -> Vertical Main 1 -> Long Jumper (via TF1 Top Rail, 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 TF2 Top Short Rail, down VM4) -> MF4 LBH Top
    • Channel 4
      • Feeder (up VM4) -> Vertical Main 4 -> Long Jumper (down VM4) -> MF4 LBH Bottom
  • 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 -> CB MF1/2 B Left
    • Channel 4
      • Feeder (up ???) -> TF1 Top Short Rail -> Left Top Long Rail -> TF2 Top Short Rail
  • 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 -> CB MF 3/4 A Left
    • Channel 4
      • Feeder (up VM4) -> Toe Board 2 -> Left Top Middle Rail -> Toe Board 1

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
      • 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
  • 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
Ethernet Connector Female Panel Mount Receptacle CON-M124PF 1
Power Connector Male Flanged Receptacle RT00144PNH 1
Power Connector Male Pins SP12A1T 4
Power Connector (mating) Female Cable Plug RT06144SNH 1
Power Connector (mating) Female Sockets SS12A1T 4
LED Connector Female Flanged Receptacle RT00142SNH 4
LED Connector Female Power Sockets SS12A1T 8
LED Connector Female Signal Sockets SS20M1T 8
LED Connector (mating) Male Cable Plug RT06142PNH 4
LED Connector (mating) Male Power Pins SP12A1T 8
LED Connector (mating) Male Signal Pins SP20M1T 8

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

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 Future ~$350.00
Lightjams License Future $149.00
Ethernet Switch Future ~$100.00
2 sets of StrichLux IO-CORE + IO-ETH + PWR-DC5 Parts Future ~$350.00
Enclosures Future ???
Enclosure Connectors Future ???
Inter-Strip Connectors Future ???
Total Obtained $2200.05
Total Future ~$949.00
Grand Total ~$3149.05

Photos