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Capstone Fall 2009 LED CUBE

Capstone Fall 2009 LED CUBE. Team 8: Nate Gimple Steven Tighe Amit Halevi Noah Husek. Project Summary. LED Cube! RGB LEDs 512 LEDs, 64 microcontrollers Massively networked (64 microcontrollers intercommunicating) Uses the Atmel ATxmega64A1 Uses the Altera Nios II softcore.

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Capstone Fall 2009 LED CUBE

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  1. Capstone Fall 2009LED CUBE Team 8: Nate Gimple Steven Tighe Amit Halevi Noah Husek

  2. Project Summary • LED Cube! • RGB LEDs • 512 LEDs, 64 microcontrollers • Massively networked (64 microcontrollers intercommunicating) • Uses the Atmel ATxmega64A1 • Uses the Altera Nios II softcore Noah

  3. Project Status • Prototype boards ordered • Almost all components acquired • Microcontroller intercommunication via UART • Currently slightly under budget! • Familiarization with Nios II IDE • Familiarization with Xmega IDE Noah

  4. Hierarchy / block diagram Nios II user input I2C module 0 super node 0 super node 1 super node 7 super node 8 super node 63 … … node 0 (LED) sensor input node 1 … node 7 Amit

  5. Addressing 011 • Fractal • 1st digit = top or bottom • 2nd digit = back or front • 3rd digit = left or right • 000 011 100 • mod sup node • This address indicates: • Top, back, left module • Top, forward, right supernode • Bottom, back, left node • 3 bits of address: • Eases writing generic code 000 001 010 100 101 110 111 Amit

  6. Communication Scheme Supernode Supernode Supernode Supernode Supernode Supernode Nios II I2C UART Amit

  7. ATxmega64A1 • 32 MHz • 64 kB Flash memory • 8 USARTs • 4 I2C • SPI • Integral timers • 2 12 bit ADCs • 128 bit crypto engine! • Donated by Atmel Amit

  8. Altera + Nios II • Master controller FPGA • Processor implemented with logic synthesis • Softcore capable of running C • I2C will be implemented in hardware, with use of extension headers on board Noah

  9. TI TLC5947 LED Driver • 24 channels • 12 bit PWM • Serial input • Programmable constant current sink • Up to 33 V on each channel • QFN 32 • Considered discrete MOSFET drivers • Not enough ports on chip • Footprint => 2 layer • Donated by TI Noah

  10. LEDs • RGB LED • 4 lead, common anode • Diffused epoxy • 5 mm diameter • 20 mA • Using leads as structural member • Surprisingly expensive to buy 500 Noah

  11. PCBs • 3 kinds of PCBs • Supernode 1.7” x 1.7” • Row 0.3” x 2.0” • Column 0.4” x 3.9” • Need 64, 64, 96 respectively • All 2 layer • Supernode was originally 4 layer • Changed to 2-layer for cost • Use of QFN package LED driver allowed this Steven

  12. Supernodes: Schematic 1 Steven

  13. Supernodes: Schematic 2 Steven

  14. Supernodes: Layout Steven

  15. Rows and Columns Steven

  16. Power Supply • Computer power supplies • Highly regulated voltage • 5 V, 3.3 V, 12 V available => 5 V used • Internal soft start • inrush current is not a problem Nate

  17. BOM and Budget Nate

  18. Schedule Nate

  19. Accomplishments by CDRA review • Super-node hardware prototype • Demo firmware • 24 channel PWM • Runs simple autonomous patterns/scripts on super-node • All parts selected (sensors, LED drivers) • Know how to program Nios II soft-core (Kind of) Nate

  20. What’s left? • Physical assembly • Kapton stencil + solder paste + pick and place = PCA • Insert through-hole LEDs by hand • Attach through-hole headers by hand • Acrylic base for structure and æsthetic • Coding • Xmega and Nios II • Basics are down, now we just need the specifics Nate

  21. Potential Problems/Concerns • Noise on the board • Fast switching LEDs – 20 mA @ 1 kHz • Lots of serial communications everywhere • Inductive kickback • Relatively large current loops to LEDs • Communication with LED driver • SPI? • Bit-banging? • I2C capacitance • Using I2C buffer/driver (LTC4300A) • Time! Nate

  22. Milestone 1 • PDR goals • “Puppet” mode (FPGA direct control) • More super-nodes (a full module = 8 super-nodes) • Establish intercommunication • Power supply (160 W @ 5V) • New goals • Build a supernode Amit

  23. Milestone 2 • Full cube construction • More complex super-node autonomous scripts • Environmental input • Simple algorithmic games (GOL) • Be ready for expo Amit

  24. Questions?

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