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
- 2012-06-17: 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
- Sound reactiveness, remote control, Wiimote control, and everything else is included for a low price
- QLC
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
- Allied Telesis AT-FS705LE V5 might work, it's rugged, low power (1.5-2.5W), and cheap
System Components
- Fit-PC 2i (controller)
- 4-port fanless Ethernet switch
- 3 StrichLux boxes (driver, each with:
- Many LED strips (need to work out dimensions)
- 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
Piece List
- Vertical Main: 450cm (Reel C)
- Vertical Main: 450cm (Reel D)
- Vertical Main: 450cm (Reel E)
- Vertical Main: 450cm (Reel F)
- Cross brace tube: 220cm (Reel G)
- Cross brace tube: 220cm (Reel G)
- Cross brace tube: 220cm (Reel H)
- Cross brace tube: 220cm (Reel H)
- Cross brace tube: 220cm (Reel I)
- Cross brace tube: 220cm (Reel I)
- Cross brace tube: 220cm (Reel J)
- Cross brace tube: 220cm (Reel J)
- Toe board: 150cm (Reel A)
- Toe board: 150cm (Reel A)
- Top middle rail: 210cm (Reel K)
- Top middle rail: 210cm (Reel K)
- Top long rail: 210cm (Reel L)
- Top long rail: 210cm (Reel L)
- Top short rail: 150cm (Reel B)
- Top short rail: 150cm (Reel B)
- Ladder box vertical: 100cm (Reel A)
- Ladder box vertical: 100cm (Reel A)
- Ladder box vertical: 100cm (Reel B)
- Ladder box vertical: 100cm (Reel B)
- Ladder box horizontal: 75cm (Reels C, D)
- Ladder box horizontal: 75cm (Reels E, D)
- Ladder box horizontal: 75cm (Reel K)
- Ladder box horizontal: 75cm (Reel L)
- Ladder box horizontal: 75cm (Reels G, H)
- Ladder box horizontal: 75cm (Reels I, H)
- Ladder box horizontal: 75cm (Reels J, H)
- Ladder box horizontal: 75cm (Reels F, H, K, L)
Reel Assignment
- Reel A (100% used)
- Toe Board: 150cm
- Toe Board: 150cm
- Ladder box vertical: 100cm
- Ladder box vertical: 100cm
- Reel B (100% used)
- Top short rail: 150cm
- Top short rail: 150cm
- Ladder box vertical: 100cm
- Ladder box vertical: 100cm
- Reel C (100% used)
- Vertical Main: 450cm
- Ladder box horizontal: 50cm (chunk 1)
- Reel D (100% used)
- Vertical Main: 450cm
- Ladder box horizontal: 25cm (chunk 2)
- Ladder box horizontal: 25cm (chunk 2)
- Reel E (100% used)
- Vertical Main: 450cm
- Ladder box horizontal: 50cm (chunk 1)
- Reel F (100% used)
- Vertical Main: 450cm
- Ladder box horizontal: 50cm (chunk 1)
- Reel G (100% used)
- Cross brace tube: 220cm
- Cross brace tube: 220cm
- Ladder box horizontal: 60cm (chunk 1)
- Reel H (100% used)
- Cross brace tube: 220cm
- Cross brace tube: 220cm
- Ladder box horizontal: 15cm (chunk 2)
- Ladder box horizontal: 15cm (chunk 2)
- Ladder box horizontal: 15cm (chunk 2)
- Ladder box horizontal: 15cm (chunk 2)
- Reel I (100% used)
- Cross brace tube: 220cm
- Cross brace tube: 220cm
- Ladder box horizontal: 60cm (chunk 1)
- Reel J (100% used)
- Cross brace tube: 220cm
- Cross brace tube: 220cm
- Ladder box horizontal: 60cm (chunk 1)
- Reel K (100% used)
- Top middle rail: 210cm
- Top middle rail: 210cm
- Ladder box horizontal: 75cm
- Ladder box horizontal: 5cm (chunk 3)
- Reel L (100% used)
- Top long rail: 210cm
- Top long rail: 210cm
- Ladder box horizontal: 75cm
- Ladder box horizontal: 5cm (chunk 4)
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
- Connec has plastic bayonet-style IP67 industrial Ethernet connectors which are somewhat reasonably priced, so far this looks like the best option even though it is a lot more expensive than regular non-weatherproof Ethernet
- 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
- Need inter-strip connectors too
- Molex MX150 or Amphenol ATP connectors look good, sealed high-current automotive connectors that aren't too expensive
Test Equipment
- 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 | Future | $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 | $880.05 |
| Total | Future | ~$2269.00 |
| Grand Total | ~$3149.05 |
