Revision as of 03:05, 2 July 2012

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:
- 1x IO-ETH
- 4x IO-SPI
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

Beacon4 Scaffold 3D Model

@@ Line 584: / Line 584: @@
 **** JAE SRCN2A16-7S / SRCN6A16-7P would be good and extremely rugged, but the cost may be too high
 ***** Not weatherproof, doh!
-**** Amphenol SINE MotionGrade connectors look really nice, aren't too badly priced (compared with 5015 connectors anyway) and are weatherproof
+**** 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
+***** 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
@@ Line 595: / Line 595: @@
 ** Matte sealed
+== Enclosure Connectors ==
+{| class="wikitable sortable" border="1"
+|-
+! 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 [[StrichLux/PWR-DC5|PWR-DC5]] modules

Difference between revisions of "Beacon4"