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AeroAlign/hardware/schematics/bom.csv
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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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,,,,,,,
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