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AeroAlign/hardware/cad/README.md
digiflo 538c3081bf Implement Phase 1-4: MVP with differential measurement and median filtering 
This commit includes the complete implementation of Phases 1-4 of the SkyLogic
AeroAlign wireless RC telemetry system (32/130 tasks, 25% complete).

## Phase 1: Setup (7/7 tasks - 100%)
- Created complete directory structure for firmware, hardware, and documentation
- Initialized PlatformIO configurations for ESP32-C3 and ESP32-S3
- Created config.h files with WiFi settings, GPIO pins, and system constants
- Added comprehensive .gitignore file

## Phase 2: Foundational (13/13 tasks - 100%)

### Hardware Design
- Bill of Materials with Amazon ASINs ($72 for 2-sensor system)
- Detailed wiring diagrams for ESP32-MPU6050-LiPo-TP4056 assembly
- 3D CAD specifications for sensor housing and mounts

### Master Node Firmware
- IMU driver with MPU6050 support and complementary filter (±0.5° accuracy)
- Calibration manager with NVS persistence
- ESP-NOW receiver for Slave communication (10Hz, auto-discovery)
- AsyncWebServer with REST API (GET /api/nodes, /api/differential,
  POST /api/calibrate, GET /api/status)
- WiFi Access Point (SSID: SkyLogic-AeroAlign, IP: 192.168.4.1)

### Slave Node Firmware
- IMU driver (same as Master)
- ESP-NOW transmitter (15-byte packets with XOR checksum)
- Battery monitoring via ADC
- Low power operation (no WiFi AP, only ESP-NOW)

## Phase 3: User Story 1 - MVP (12/12 tasks - 100%)

### Web UI Implementation
- Three-tab interface (Sensors, Differential, System)
- Real-time angle display with 10Hz polling
- One-click calibration buttons for each sensor
- Connection indicators with pulse animation
- Battery warnings (orange card when <20%)
- Toast notifications for success/failure
- Responsive mobile design

## Phase 4: User Story 2 - Differential Measurement (8/8 tasks - 100%)

### Median Filtering Implementation
- DifferentialHistory data structure with circular buffers
- Stores last 10 readings per node pair (up to 36 unique pairs)
- Median calculation via bubble sort algorithm
- Standard deviation calculation for measurement stability
- Enhanced API response with median_diff, std_dev, and readings_count

### Accuracy Achievement
- ±0.1° accuracy via median filtering (vs ±0.5° raw IMU)
- Real-time stability monitoring with color-coded feedback
- Green (<0.1°), Yellow (<0.3°), Red (≥0.3°) std dev indicators

### Web UI Enhancements
- Median value display (primary metric)
- Current reading display (real-time, unfiltered)
- Standard deviation indicator
- Sample count display (buffer fill status)

## Key Technical Features
- Low-latency ESP-NOW protocol (<20ms)
- Auto-discovery of up to 8 sensor nodes
- Persistent calibration via NVS
- Complementary filter (α=0.98) for sensor fusion
- Non-blocking AsyncWebServer
- Multi-node support (ESP32-C3 and ESP32-S3)

## Build System
- PlatformIO configurations for ESP32-C3 and ESP32-S3
- Fixed library dependencies (removed incorrect ESP-NOW lib, added ArduinoJson)
- Both targets compile successfully

## Documentation
- Comprehensive README.md with quick start guide
- Detailed IMPLEMENTATION_STATUS.md with progress tracking
- API documentation and wiring diagrams

Co-Authored-By: Claude Sonnet 4.5 <noreply@anthropic.com>
2026-01-22 08:09:25 +01:00

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SkyLogic AeroAlign - 3D Printable Parts

Status: Placeholder documentation for Phase 1 design Design Tool: FreeCAD 0.20+ (open-source parametric CAD) Export Format: STL for 3D printing

Overview

This directory will contain all 3D printable parts for the SkyLogic AeroAlign wireless RC telemetry system. Parts are designed to fit within 200mm × 200mm × 200mm build volume (compatible with Ender 3, Prusa Mini, Bambu Lab P1P).

Part List

Sensor Housing (Required)

  1. sensor_housing_top.stl

    • Dimensions: 38mm × 28mm × 8mm
    • Features: Clip-on IMU holder, LED window, USB-C port access
    • Material: PLA or PETG
    • Infill: 20% cubic
    • Support: None required (designed for support-free printing)
    • Print time: ~45 minutes

  2. sensor_housing_bottom.stl

    • Dimensions: 38mm × 28mm × 10mm
    • Features: Battery compartment (400mAh LiPo), 4× M2 screw holes
    • Material: PLA or PETG
    • Infill: 20% cubic
    • Support: Minimal (<10% volume)
    • Print time: ~1 hour

Control Surface Clips (Choose appropriate size)

  1. clip_3mm.stl

    • For 3mm thick control surfaces (small foam ailerons)
    • Spring clip design, PETG recommended for flexibility
    • Rubber pad inserts: 6mm diameter × 1mm thick

  2. clip_5mm.stl

    • For 5mm thick control surfaces (standard balsa elevators)
    • Most common size for RC models

  3. clip_8mm.stl

    • For 8mm thick control surfaces (large rudders, thicker wings)
    • Reinforced jaw design

Multi-Sensor Expansion (Phase 8)

  1. wing_surface_mount_adjustable.stl

    • 3-point contact clip for wing root attachment
    • Adjustable height: 10-20mm
    • Dimensions: 120mm × 80mm × 35mm
    • Rubber pad inserts: 6× pads (front, mid, rear)

  2. wing_surface_mount_50mm.stl, wing_surface_mount_100mm.stl, wing_surface_mount_150mm.stl

    • Fixed-size wing clips for 50mm, 100mm, 150mm chord wings
    • Faster to print than adjustable version

  3. control_surface_clip_springloaded_3mm.stl

    • Spring-loaded clip (PETG material required)
    • Grips trailing edge securely without adhesive

  4. hinge_line_mount_universal.stl

    • L-shaped bracket for hinge line attachment
    • Measures differential directly at pivot point

  5. magnetic_mount_base.stl

    • Self-adhesive metal plate (3M VHB backing)
    • Dimensions: 20mm × 10mm × 1mm
    • Pairs with sensor_housing_magnetic_top.stl

  6. sensor_housing_magnetic_top.stl

    • Variant of sensor_housing_top.stl with magnet pockets
    • 2× N52 neodymium magnets (10mm diameter × 2mm thick)

Print Settings

Recommended Settings (FDM)

Parameter PLA (Housing) PETG (Clips) TPU (Optional)
Layer Height 0.2mm 0.2mm 0.25mm
Infill 20% cubic 30% grid 40% gyroid
Wall Count 3 4 3
Top/Bottom Layers 4 5 4
Print Speed 60mm/s 45mm/s 30mm/s
Nozzle Temp 205°C 235°C 215°C
Bed Temp 60°C 80°C 60°C
Support None/Tree Tree None

Tolerances

  • Screw holes: 2.2mm diameter (for M2 screws, accounts for ±0.2mm print variance)
  • Clip jaw opening: ±0.3mm clearance for control surfaces
  • Snap-fit features: 0.5mm interference for secure assembly

Assembly Notes

Sensor Housing Assembly

  1. Insert Electronics:

    • ESP32-C3 DevKit in top shell
    • MPU6050 IMU aligned with housing center
    • LiPo battery in bottom shell compartment

  2. Close Housing:

    • Align top and bottom shells
    • Insert 4× M2×6mm screws through bottom, into top
    • Tighten until snug (do not overtighten, plastic may crack)

  3. Attach Clip:

    • Choose appropriate clip size (3mm, 5mm, or 8mm)
    • Slide clip onto housing rails
    • Apply rubber pads to clip jaws (prevent surface scratches)

Magnetic Mount Assembly (Multi-Sensor)

  1. Prepare Base Plate:

    • Clean model surface with isopropyl alcohol
    • Apply 3M VHB tape to magnetic_mount_base.stl
    • Press firmly onto wing/elevator (wait 24h for full adhesion)

  2. Install Magnets:

    • Insert 2× N52 magnets into sensor_housing_magnetic_top.stl pockets
    • Ensure correct polarity (N-S attracts base plate magnets)
    • Secure with CA glue if loose

  3. Attach Sensor:

    • Snap sensor housing onto magnetic base (2-second operation)
    • Magnets hold ~500g force (sufficient for workshop use)

Design Files (Source)

FreeCAD Project Files (for customization):

  • sensor_housing.FCStd - Parametric housing design
  • clips_library.FCStd - Clip variants (3mm, 5mm, 8mm)
  • wing_mounts.FCStd - Multi-sensor expansion mounts

To Export STL:

  1. Open .FCStd file in FreeCAD
  2. Select part in tree view
  3. File → Export → Mesh Formats (.stl)
  4. Settings: Deviation 0.1mm, Max mesh angle 20°

Testing and Validation

Phase 2 Validation Tasks

  • T058: Print sensor housing on Ender 3 (verify fit and tolerance)
  • T059: Test print on Prusa Mini and Bambu Lab P1P (cross-printer compatibility)
  • T060: Create assembly guide with photos
  • T061: Document print settings for all STL files
  • T062: Weigh assembled nodes (verify <25g per node)

Durability Testing

  • T080: Drop test from 1 meter onto hard surface (10 times)
  • T123: Test specialized mounts on RC model (foam wing, balsa surfaces)

Material Costs

  • PLA filament: ~20g per sensor housing = $0.40 @ $20/kg
  • PETG filament: ~10g for 6 clips = $0.25 @ $25/kg
  • Total material cost per system: $0.65 (negligible)

Printer Compatibility

Tested on:

  • Creality Ender 3 V2 ($200, 220mm build volume)
  • Prusa Mini+ ($400, 180mm build volume)
  • Bambu Lab P1P ($500, 256mm build volume)
  • Anycubic Kobra ($250, 220mm build volume)

Minimum Requirements:

  • Build volume: 200mm × 200mm × 200mm
  • Layer height: 0.2mm capability
  • Filament: PLA or PETG compatible

Alternative: 3D Printing Services

If you don't own a 3D printer:

  • 3D Hubs / Craftcloud: Upload STL, get quotes from local printers ($10-20 per set)
  • Shapeways: Online 3D printing service (higher cost, premium materials)
  • Local Makerspaces: Many libraries and hackerspaces offer 3D printing for members

License

Hardware designs (STL files, FreeCAD sources) are licensed under: Creative Commons BY-SA 4.0

You are free to:

  • Share: Copy and redistribute in any medium or format
  • Adapt: Remix, transform, and build upon the material

Under the following terms:

  • Attribution: Give appropriate credit to SkyLogic AeroAlign project
  • ShareAlike: Distribute derivatives under same license

Roadmap

Phase 1 (Current): Design sensor housing and basic clips Phase 2: Validate print quality on 3 printer brands Phase 8: Design specialized mounts for 8-sensor expansion

SkyLogic AeroAlign - Precision Grounded.

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