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Extend AeroAlign with mixed CoG planning and telemetry base

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DIGIFLO - Florian Klaner
2026-03-11 23:14:33 +01:00
parent 538c3081bf
commit 56890272a0
28 changed files with 1631 additions and 1332 deletions
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hardware/schematics/bom.csv
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Component,Description,Quantity per Node,Amazon ASIN (US),AliExpress Link,Unit Price (USD),Total Price (2 nodes),Notes,Alternatives
ESP32-C3 DevKit,ESP32-C3 development board (RISC-V 160MHz WiFi/BLE),1,B09FK6F3JH,https://s.click.aliexpress.com/e/_DFKZXXX,$6.50,$13.00,"USB-C flashing ESP32-C3-DevKitM-1 or similar","ESP32-S3 (B0B6FF8K2M $12) for more power"
MPU6050 IMU,6-axis IMU (gyro + accel I2C),1,B08F7PZHVT,https://s.click.aliexpress.com/e/_DEYYYY,$4.50,$9.00,"GY-521 module with voltage regulator","BNO055 (B08M3P1KQZ $12) for better accuracy"
LiPo Battery 1S,250-400mAh 1S LiPo battery with JST connector,1,B0BKP6Y3XZ,https://s.click.aliexpress.com/e/_DFZZZZZ,$8.00,$16.00,"400mAh for Master 250mAh for Slave","500mAh (B08R3KZZZZ $9) for extended runtime"
TP4056 Charger,USB-C LiPo charging module with protection,1,B09KGGZZZZ,https://s.click.aliexpress.com/e/_DKZZZZZ,$1.50,$3.00,"Type-C USB includes overcharge/discharge protection","Micro-USB version (B07KZZZZ $1.20)"
HT7333 LDO,3.3V LDO voltage regulator (250mA),1,B07P6RZZZZ,https://s.click.aliexpress.com/e/_DLZZZZ,$0.80,$1.60,"SOT-89 package","AMS1117-3.3 (B01GZZZZ $0.50) if using through-hole"
Neodymium Magnets,N52 10mm diameter × 2mm thick magnets (optional magnetic mount),2,B08LZZZZ,https://s.click.aliexpress.com/e/_DMZZZZ,$5.00,$10.00,"For magnetic quick-mount sensor housing","Adhesive Velcro strips (B07KZZZZ $4) alternative"
3M VHB Tape,Double-sided adhesive tape for magnetic mount base,1 roll,B01MZZZZ,https://s.click.aliexpress.com/e/_DNZZZZ,$8.00,$8.00,"5m roll lasts for 50+ sensors","Gorilla tape (B06XZZZZ $6) cheaper alternative"
Rubber Pads,Silicone anti-slip pads for clips (6mm diameter),6,B07TZZZZ,https://s.click.aliexpress.com/e/_DOZZZ,$3.00,$6.00,"Self-adhesive prevent surface scratches","EVA foam pads (B08KZZZZ $2.50)"
M2 Screws,M2×6mm screws for housing assembly,4,B01MZZZZ (assortment),https://s.click.aliexpress.com/e/_DPZZZZ,$0.10,$0.40,"Stainless steel kit (500pcs)","M3 (B07ZZZZ) if using larger standoffs"
JST Connector,JST-PH 2.0mm 2-pin connector for battery,1,B07QZZZZ,https://s.click.aliexpress.com/e/_DQZZZZ,$0.30,$0.60,"Male + female pair comes with most LiPos","XH2.54 (B08ZZZZ $0.40) if battery uses different connector"
22AWG Wire,Silicone wire for battery/charging connections,0.5m,B07RZZZZ,https://s.click.aliexpress.com/e/_DRZZZZ,$0.50,$0.50,"Red + black stranded","24AWG (B06ZZZZ $0.40) also acceptable"
Heat Shrink Tubing,Heat shrink tubing assortment,5cm,B08SZZZZ (assortment),https://s.click.aliexpress.com/e/_DSZZZZ,$0.10,$0.10,"3mm diameter for wire insulation","Electrical tape (B07ZZZZ $2) if no heat gun"
10kΩ Resistor,10kΩ resistor for voltage divider (battery ADC),2,B08FZZZZ (assortment),https://s.click.aliexpress.com/e/_DTZZZZ,$0.05,$0.10,"1/4W through-hole carbon film","Resistor kit (B016ZZZZ $8) for 1000pcs"
USB-C Cable,USB-C to USB-A cable for charging/flashing,1,B0BYZZZZ,https://s.click.aliexpress.com/e/_DUZZZZ,$4.00,$4.00,"1m length sufficient","USB-C to USB-C (B09ZZZZ $5) for newer laptops"
,,,,,,,
,,,,TOTAL (2 Sensors):,,$72.30,
,,,,Master Node Only:,,$36.15,
,,,,Slave Node Only:,,$36.15,
,,,,,,
,,,,4-Sensor System:,,$144.60,
,,,,6-Sensor System:,,$216.90,
,,,,8-Sensor System:,,$289.20,
,,,,,,,
Optional Upgrades,,,,,,,
BNO055 IMU,9-axis IMU with sensor fusion (I2C),1,B08M3P1KQZ,https://s.click.aliexpress.com/e/_DVZZZZ,$12.00,$24.00,"±0.1° accuracy vs MPU6050 ±0.5°","MPU9250 (B07ZZZZ $8) if 9-axis needed"
ESP32-S3 DevKit,ESP32-S3 dual-core 240MHz (8MB flash),1,B0B6FF8K2M,https://s.click.aliexpress.com/e/_DWZZZZ,$12.00,$24.00,"Faster web server response","ESP32-C3 sufficient for most users"
500mAh LiPo,Larger battery for 6+ hour runtime,1,B08R3KZZZZ,https://s.click.aliexpress.com/e/_DXZZZZ,$9.00,$18.00,"Extends Master runtime to 6h","400mAh (default) provides 4h"
,,,,,,,
3D Printing Materials,,,,,,,
PLA Filament,PLA filament for sensor housing (1kg),0.02kg,B07PZZZZ,https://s.click.aliexpress.com/e/_DYZZZZ,$20.00,$0.40,"~20g per node Black recommended","PETG (B08ZZZZ $25) for heat resistance"
PETG Filament,PETG filament for flexible clips (1kg),0.01kg,B08ZZZZZ,https://s.click.aliexpress.com/e/_DAZZZZ,$25.00,$0.25,"~10g for 6 clips","TPU (B09ZZZZ $30) for maximum flexibility"
,,,,,,,
Tools Required (One-Time Purchase),,,,,,,
Soldering Iron,Temperature-controlled soldering station,1,B08RZZZZ,https://s.click.aliexpress.com/e/_DBZZZZ,$25.00,$25.00,"Hakko FX-888D or similar","Basic iron (B06ZZZZ $15) acceptable"
Solder Wire,60/40 tin-lead solder (0.8mm),1 roll,B07SZZZZ,https://s.click.aliexpress.com/e/_DCZZZZ,$8.00,$8.00,"Lead-free (B08ZZZZ $10) for EU compliance",
Heat Gun,Heat gun for heat shrink tubing,1,B08TZZZZ,https://s.click.aliexpress.com/e/_DDZZZZ,$12.00,$12.00,"Or use lighter carefully","Mini heat gun (B07ZZZZ $8)"
Wire Strippers,Wire stripper/cutter tool,1,B08UZZZZ,https://s.click.aliexpress.com/e/_DEZZZZ,$10.00,$10.00,"Automatic recommended","Manual (B06ZZZZ $6)"
3D Printer,FDM 3D printer (200mm build volume),1,See notes,,,$200-500,"Ender 3 ($200) Prusa Mini ($400) Bambu P1P ($500)","Print service (3D Hubs) $10-20 per set"
,,,,,,,
TOTAL BOM (2-Sensor System):,,,,,$72.30,,"Competitive: GliderThrow $600 (8 sensors) SkyRC $80 (2 sensors)"
TOTAL BOM (8-Sensor System):,,,,,$289.20,,"Our 8-sensor: $289 vs GliderThrow $600 (52% savings)"
,,,,,,,
Notes:,,,,,,,
- ASIN codes are placeholders (B0XXXXXX format) - verify current Amazon listings,,,,,,,
- Prices fluctuate ±20% based on seller and shipping,,,,,,,
- AliExpress links typically 30-50% cheaper but 2-4 week shipping,,,,,,,
- Total includes all components for 2 complete sensor nodes (Master + Slave),,,,,,,
- 3D printing materials cost negligible (~$0.65 per system),,,,,,,
- Tools are one-time purchase shared across projects,,,,,,,
- Multi-sensor systems (4/6/8 nodes) use same components multiplied,,,,,,,
Category,Component,Description,Typical Qty,Used In,Notes
Core MCU,ESP32-C3 DevKit,Low-cost main board,1 per node,"Master, IMU Slave, CoG Scale","Default low-cost choice"
Core MCU,ESP32-S3 DevKit,Higher headroom alternative,1 per node,"Master, IMU Slave, CoG Scale","Useful for USB and future UI/diagnostics"
IMU,MPU6050,GY-521 style 6-axis IMU,1 per IMU node,"Master, IMU Slave","Current robust driver implemented"
Power,LiPo 1S,Portable battery pack,1 per portable node,"Master, IMU Slave, CoG Scale","Capacity depends on runtime target"
Power,TP4056 USB-C,LiPo charger/protection board,1 per portable node,"Master, IMU Slave, CoG Scale","Optional for bench-powered scale jig"
Power,3.3V regulator,Clean 3.3V supply,1 per portable node,"Master, IMU Slave, CoG Scale","Avoid noisy supply rails"
Battery ADC,10k resistor,Voltage divider top resistor,1 per monitored node,"Master, IMU Slave","Use only where ADC monitoring is actually wired"
Battery ADC,10k resistor,Voltage divider bottom resistor,1 per monitored node,"Master, IMU Slave","Master S3 currently optional"
CoG Sensor,HX711,24-bit load cell ADC,2 per CoG scale,"CoG Scale","One per support recommended"
CoG Sensor,Load cell,Single-point or suitable existing load cell,2 per CoG scale,"CoG Scale","Choose range for aircraft mass"
Assembly,JST-PH 2.0,Battery connector,1 per battery node,"Master, IMU Slave, CoG Scale","Often already fitted to LiPo"
Assembly,Wire,Signal and power wiring,as needed,"All","Keep I2C runs short"
Assembly,Heat shrink,Insulation and strain relief,as needed,"All","Recommended for portable nodes"
Mechanical,Sensor housing,3D printed IMU enclosure,1 per IMU node,"Master, IMU Slave","Existing AeroAlign style"
Mechanical,Control surface clip,3D printed clip,1 per IMU node,"Master, IMU Slave","3 mm / 5 mm / 8 mm variants"
Mechanical,Scale support cradle,3D printed support fixture,2 per CoG scale,"CoG Scale","To be designed"
Mechanical,Scale base,3D printed baseplate,1 per CoG scale,"CoG Scale","To be designed"
Reference,Known calibration mass,Weight for HX711 calibration,1 set,"CoG Scale","Needed for repeatable scale factors"
1 Category Component Quantity per Node Description Amazon ASIN (US) Typical Qty AliExpress Link Used In Unit Price (USD) Notes Total Price (2 nodes) Alternatives
2 Core MCU ESP32-C3 DevKit 1 ESP32-C3 development board (RISC-V 160MHz WiFi/BLE) Low-cost main board B09FK6F3JH 1 per node https://s.click.aliexpress.com/e/_DFKZXXX Master, IMU Slave, CoG Scale $6.50 USB-C flashing ESP32-C3-DevKitM-1 or similar Default low-cost choice $13.00 ESP32-S3 (B0B6FF8K2M $12) for more power
3 Core MCU MPU6050 IMU ESP32-S3 DevKit 1 6-axis IMU (gyro + accel I2C) Higher headroom alternative B08F7PZHVT 1 per node https://s.click.aliexpress.com/e/_DEYYYY Master, IMU Slave, CoG Scale $4.50 GY-521 module with voltage regulator Useful for USB and future UI/diagnostics $9.00 BNO055 (B08M3P1KQZ $12) for better accuracy
4 IMU LiPo Battery 1S MPU6050 1 250-400mAh 1S LiPo battery with JST connector GY-521 style 6-axis IMU B0BKP6Y3XZ 1 per IMU node https://s.click.aliexpress.com/e/_DFZZZZZ Master, IMU Slave $8.00 400mAh for Master 250mAh for Slave Current robust driver implemented $16.00 500mAh (B08R3KZZZZ $9) for extended runtime
5 Power TP4056 Charger LiPo 1S 1 USB-C LiPo charging module with protection Portable battery pack B09KGGZZZZ 1 per portable node https://s.click.aliexpress.com/e/_DKZZZZZ Master, IMU Slave, CoG Scale $1.50 Type-C USB includes overcharge/discharge protection Capacity depends on runtime target $3.00 Micro-USB version (B07KZZZZ $1.20)
6 Power HT7333 LDO TP4056 USB-C 1 3.3V LDO voltage regulator (250mA) LiPo charger/protection board B07P6RZZZZ 1 per portable node https://s.click.aliexpress.com/e/_DLZZZZ Master, IMU Slave, CoG Scale $0.80 SOT-89 package Optional for bench-powered scale jig $1.60 AMS1117-3.3 (B01GZZZZ $0.50) if using through-hole
7 Power Neodymium Magnets 3.3V regulator 2 N52 10mm diameter × 2mm thick magnets (optional magnetic mount) Clean 3.3V supply B08LZZZZ 1 per portable node https://s.click.aliexpress.com/e/_DMZZZZ Master, IMU Slave, CoG Scale $5.00 For magnetic quick-mount sensor housing Avoid noisy supply rails $10.00 Adhesive Velcro strips (B07KZZZZ $4) alternative
8 Battery ADC 3M VHB Tape 10k resistor 1 roll Double-sided adhesive tape for magnetic mount base Voltage divider top resistor B01MZZZZ 1 per monitored node https://s.click.aliexpress.com/e/_DNZZZZ Master, IMU Slave $8.00 5m roll lasts for 50+ sensors Use only where ADC monitoring is actually wired $8.00 Gorilla tape (B06XZZZZ $6) cheaper alternative
9 Battery ADC Rubber Pads 10k resistor 6 Silicone anti-slip pads for clips (6mm diameter) Voltage divider bottom resistor B07TZZZZ 1 per monitored node https://s.click.aliexpress.com/e/_DOZZZ Master, IMU Slave $3.00 Self-adhesive prevent surface scratches Master S3 currently optional $6.00 EVA foam pads (B08KZZZZ $2.50)
10 CoG Sensor M2 Screws HX711 4 M2×6mm screws for housing assembly 24-bit load cell ADC B01MZZZZ (assortment) 2 per CoG scale https://s.click.aliexpress.com/e/_DPZZZZ CoG Scale $0.10 Stainless steel kit (500pcs) One per support recommended $0.40 M3 (B07ZZZZ) if using larger standoffs
11 CoG Sensor JST Connector Load cell 1 JST-PH 2.0mm 2-pin connector for battery Single-point or suitable existing load cell B07QZZZZ 2 per CoG scale https://s.click.aliexpress.com/e/_DQZZZZ CoG Scale $0.30 Male + female pair comes with most LiPos Choose range for aircraft mass $0.60 XH2.54 (B08ZZZZ $0.40) if battery uses different connector
12 Assembly 22AWG Wire JST-PH 2.0 0.5m Silicone wire for battery/charging connections Battery connector B07RZZZZ 1 per battery node https://s.click.aliexpress.com/e/_DRZZZZ Master, IMU Slave, CoG Scale $0.50 Red + black stranded Often already fitted to LiPo $0.50 24AWG (B06ZZZZ $0.40) also acceptable
13 Assembly Heat Shrink Tubing Wire 5cm Heat shrink tubing assortment Signal and power wiring B08SZZZZ (assortment) as needed https://s.click.aliexpress.com/e/_DSZZZZ All $0.10 3mm diameter for wire insulation Keep I2C runs short $0.10 Electrical tape (B07ZZZZ $2) if no heat gun
14 Assembly 10kΩ Resistor Heat shrink 2 10kΩ resistor for voltage divider (battery ADC) Insulation and strain relief B08FZZZZ (assortment) as needed https://s.click.aliexpress.com/e/_DTZZZZ All $0.05 1/4W through-hole carbon film Recommended for portable nodes $0.10 Resistor kit (B016ZZZZ $8) for 1000pcs
15 Mechanical USB-C Cable Sensor housing 1 USB-C to USB-A cable for charging/flashing 3D printed IMU enclosure B0BYZZZZ 1 per IMU node https://s.click.aliexpress.com/e/_DUZZZZ Master, IMU Slave $4.00 1m length sufficient Existing AeroAlign style $4.00 USB-C to USB-C (B09ZZZZ $5) for newer laptops
16 Mechanical Control surface clip 3D printed clip 1 per IMU node Master, IMU Slave 3 mm / 5 mm / 8 mm variants
17 Mechanical Scale support cradle 3D printed support fixture 2 per CoG scale TOTAL (2 Sensors): CoG Scale To be designed $72.30
18 Mechanical Scale base 3D printed baseplate 1 per CoG scale Master Node Only: CoG Scale To be designed $36.15
19 Reference Known calibration mass Weight for HX711 calibration 1 set Slave Node Only: CoG Scale Needed for repeatable scale factors $36.15
4-Sensor System: $144.60
6-Sensor System: $216.90
8-Sensor System: $289.20
Optional Upgrades
BNO055 IMU 1 9-axis IMU with sensor fusion (I2C) B08M3P1KQZ https://s.click.aliexpress.com/e/_DVZZZZ $12.00 ±0.1° accuracy vs MPU6050 ±0.5° $24.00 MPU9250 (B07ZZZZ $8) if 9-axis needed
ESP32-S3 DevKit 1 ESP32-S3 dual-core 240MHz (8MB flash) B0B6FF8K2M https://s.click.aliexpress.com/e/_DWZZZZ $12.00 Faster web server response $24.00 ESP32-C3 sufficient for most users
500mAh LiPo 1 Larger battery for 6+ hour runtime B08R3KZZZZ https://s.click.aliexpress.com/e/_DXZZZZ $9.00 Extends Master runtime to 6h $18.00 400mAh (default) provides 4h
3D Printing Materials
PLA Filament 0.02kg PLA filament for sensor housing (1kg) B07PZZZZ https://s.click.aliexpress.com/e/_DYZZZZ $20.00 ~20g per node Black recommended $0.40 PETG (B08ZZZZ $25) for heat resistance
PETG Filament 0.01kg PETG filament for flexible clips (1kg) B08ZZZZZ https://s.click.aliexpress.com/e/_DAZZZZ $25.00 ~10g for 6 clips $0.25 TPU (B09ZZZZ $30) for maximum flexibility
Tools Required (One-Time Purchase)
Soldering Iron 1 Temperature-controlled soldering station B08RZZZZ https://s.click.aliexpress.com/e/_DBZZZZ $25.00 Hakko FX-888D or similar $25.00 Basic iron (B06ZZZZ $15) acceptable
Solder Wire 1 roll 60/40 tin-lead solder (0.8mm) B07SZZZZ https://s.click.aliexpress.com/e/_DCZZZZ $8.00 Lead-free (B08ZZZZ $10) for EU compliance $8.00
Heat Gun 1 Heat gun for heat shrink tubing B08TZZZZ https://s.click.aliexpress.com/e/_DDZZZZ $12.00 Or use lighter carefully $12.00 Mini heat gun (B07ZZZZ $8)
Wire Strippers 1 Wire stripper/cutter tool B08UZZZZ https://s.click.aliexpress.com/e/_DEZZZZ $10.00 Automatic recommended $10.00 Manual (B06ZZZZ $6)
3D Printer 1 FDM 3D printer (200mm build volume) See notes Ender 3 ($200) Prusa Mini ($400) Bambu P1P ($500) $200-500 Print service (3D Hubs) $10-20 per set
TOTAL BOM (2-Sensor System): $72.30 Competitive: GliderThrow $600 (8 sensors) SkyRC $80 (2 sensors)
TOTAL BOM (8-Sensor System): $289.20 Our 8-sensor: $289 vs GliderThrow $600 (52% savings)
Notes:
- ASIN codes are placeholders (B0XXXXXX format) - verify current Amazon listings
- Prices fluctuate ±20% based on seller and shipping
- AliExpress links typically 30-50% cheaper but 2-4 week shipping
- Total includes all components for 2 complete sensor nodes (Master + Slave)
- 3D printing materials cost negligible (~$0.65 per system)
- Tools are one-time purchase shared across projects
- Multi-sensor systems (4/6/8 nodes) use same components multiplied