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[Build Log] Christmas Light LED Matrix - Page 5

post #41 of 50
Thread Starter 
Wood frame update:

In february, I finished drilling 1152 holes, took several nights, good music, a hand drill, and a marking jig.


The choice of drill bit required research and trial and error. I ended up using a 7/16" "forstner bit" from Lee Valley, which gave me fairly accurate and clean holes, however hardboard got stuck in the bit occasionally, so it was a very slow process. I will not use hardboard again.



Spade bits are inaccurate
Standard carbide bits make sloppy holes
Brad Point bits had material build up worse then forstner, but equally clean holes.

Then in march, I made a table saw jig for cutting "exactly" and "consistently" 2" apart slots using saw blade (1/8") wide and hardboard (1/8") thick.


The lesson learned was, incorporate tolerance for error in your design. Getting it perfect is impractical and near impossible, specially on a cross cutting table saw.

First few slats cracked under pressure, so I had to hand file every.single.slot to widen slightly. Took over 10 hours to get the slats done.


Up next, is cutting up some gorgeous Roasted Oak into the outside frame, from The Wood Shed


Blind Rabbet joint for strength, as the handles on the top will pull the top upwards... this box is heavy!

Edited by kevinf - 4/29/16 at 8:46pm
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post #42 of 50
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Been a while, time for an update! Some new tools to make life a LOT easier.

Need to strip 768 x 18awg and 384 x 24awg wires.... get an automatic stripper. I remember trying one back in highschool and it was terrible, but this one by Irwin is AWESOME. Looks similar to the one by canadian tire, but feels higher quality. They all copy designs with minor tweaks these days frown.gif

https://www.amazon.ca/gp/product/B000OQ21CA/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

A "Weller 100/140 watt expert" soldering gun/iron is ideal for the 12v bus bars. I got this gem from Kijiji, newer != better. Perfect condition from 15-25 years ago, only $25, what a steal!



The big difference from newer models, is the fastener for the heating element. Old uses a nut and stays tight (full power), new models use a set-screw and loosens/strips all the time (iron doesn't get hot). Also the new has cheaper plastic / switch.

new crappy "100/140 watt universal" $55
https://www.amazon.ca/Weller-8200PKS-120-volt-Universal-Soldering/dp/B002YDMZF4
Edited by kevinf - 6/24/16 at 8:10pm
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post #43 of 50
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Its a rainbow! How many meters of Cat5 cable do you think it will take to connect all 384 channels to the 24 TLC LED controllers? 8x 100cm + 8x 90cm + 8x 85cm + 8x 80cm + 8x 60cm + 8x 55cm + 8x 40cm + 8x 30cm = 43 M / 141 Ft and 64 RJ-12 connectors (6p6c). Am I qualified for IT?



8 bars bars using copper strapping used in ducting... 384 joints...


at first you thought I was crazy, but now you can clearly see im nuts. 72 nuts and 6ft of 1/4" threaded rod to secure bus bars 2" apart. Only to realize I have to take all the nuts off and attach LED sockets one bus bar at a time.


and the prettiest sight to see, 1152 LEDs looking back at me.

Edited by kevinf - 7/4/16 at 6:27pm
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post #44 of 50
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A little late, but I am honored to present "The Pixel8r", my submission to the Toronto Maker Festival 2016!

http://makerfestival.ca/maker/kevin-folz-huge-1152-led-rgb-matrix/ Screenshot, that page may disapear (Click to show)

It was a lot of hard work to turn a pile of parts into a functioning prototype in time for the festival. There were a few technical (electrical) difficulties which delayed the finishing touches on the mechanical, and the software is never really "done".







I met a lot of supportive people, networked with industry professionals, and connected with fellow makers. Its a great event every year.
Edited by kevinf - 7/15/16 at 6:51pm
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post #45 of 50
Wow, that came together nicely, so many floating terminal blocks too haha.
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post #46 of 50
Thread Starter 
Quote:
Originally Posted by axipher View Post

Wow, that came together nicely, so many floating terminal blocks too haha.

Thanks smile.gif 4 hrs of double sided tape will fix that, but patience I have not. Procrastinate I will.

--

Something not in the original design, but useful for demos is a native speaker output. I previously purchased a $3 PAM8403 amplifier circuit on Ebay, 5V, 3+3W. Conveniently connected to a spare center speaker from a 5.1 Logitech X-540 setup. I naively shorted both "grounds" together to form a mono audio system from stereo input, but it produced garbage sound.



I then learned, to achieve such output power, this is a "Bridged / Balanced / Differential" amplifier as opposed to "Single Ended". So I can only connect 1 channel, perhaps combine in Linux instead. Glad it didn't blow the amp.

Great readings:
http://www.profusionplc.com/images/application%20notes/an12.pdf
https://en.wikipedia.org/wiki/Balanced_audio
http://www.eetimes.com/document.asp?doc_id=1274958
http://electronics.stackexchange.com/questions/95743/can-you-bridge-or-parallel-the-outputs-of-the-pam8403-amplifier/
Edited by kevinf - 7/19/16 at 6:53pm
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post #47 of 50
Thread Starter 
Updates:

- Code to decode incoming audio samples using Jack API and perform an FFT is complete, looks like I can do it within 1 video frame (16ms) latency.
- Using Unix domain sockets I transfer data from Native C "fft" process to QT/CPP "pixel8r" process
- Developed Serial API backend to talk to TLC boards, adding a 100ms timeout, so TLCs are self-correcting state machines.
- GPIO control is working well, recompiled U-boot 2013 for Beagleboard Rev C4 with the following patch: http://pastebin.com/QNEytbKU (enables pin mux)

All 4 controllers are working well in this picture, and I hooked up one (of 6) LED strips (on the left side) to Relay GPIOs. It is really hard to take pictures of this thing. Obviously I have a few (37/128) missed connections to fix.


Goal: 16 bars


For the bright day-time use Maker Faire (and because my wood grid warped), I settled for 1/16" acrylic diffuser. I have to remake the slats, then purchase the thicker 1/8" acrylic to remove the hotspots shown.
Edited by kevinf - 8/31/16 at 3:23pm
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post #48 of 50
Thread Starter 
During the Maker festival it became apparent I was having power drop-outs during full matrix fade animations (~50W). Although the 12V PSU had 4x the capacity I needed, the regulation and ripple were terrible as it was an old salvaged PSU.

Before:


Meet the evil OctoCap monster! A quick test-setup with high quality 8x1000uF (35V) capacitors (one per 12V power distribution rail) to verify caps would help


After:


then around the second week of September, I replaced the PSU to a newer 130W model which helped even more and cleaned up the wiring with binding posts for easy measurement.

Edited by kevinf - 1/16/17 at 10:11pm
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post #49 of 50
Thread Starter 
RIP Beagleboard. The TI PowerManagementIC gets instantly to 100C on power-on, and no longer boots. Thats a 20 Hr set back. I had just finished the cable assemblies too frown.gif



I connected a oscilloscope to the expansion connector on the Beagleborad as I've done many times before. In a dark cramped area, I unfortunately shorted the 1.8V and 5V pins with the scope probe while the power was live. I learned my lesson the hard way, always use wire leads and/or power off the DUT while switching probe positions!

I had voltage translation issues (1.8V beagleboard to 5V GPIOs) which triggered relays / TLC controllers inappropriately. I hope the PI has no issues with its 3.3V I/O voltage, I know my level translator can handle it.

Thats not a great square wave.




Bye bye Beagleboard and say hello to Raspberry Pi 2 Model B, which was a gift smile.gif Time to redo GPIO mappings, physical wires, reconfigure audio stack, and compile a bunch of programs. I will really miss the HW dsp, audio, and RS-232. Built-in ethernet is nice, but I will continue using USB as I have a big hole in wood for it already.


Edited by kevinf - 1/16/17 at 10:15pm
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post #50 of 50
Thread Starter 
A long while back, I drafted up some rough diagrams on how the system would come together on paper, then created a full 3D model.

I realized proper system diagrams would be useful, so I turned to ol' faithful Microsoft Visio (from Office suite).

< Electrical Schematic of Data Signals >


I was reminded how frustrating it was to work with Visio... so I looked for alternatives and remembered Diagram.ly .. except its gone. jgraph renamed the service to https://www.draw.io (which is now also a plugin for Atlassian suite)

< System Power Diagram >


< Top Level Software Component Overview >


< Pixel8r Main Application UML Class Diagram >


I've fallen in love with Draw.io, it is a pleasure to use, and feels far more expressive. The GitHub integration is also very nice!
OC'in beast
(21 items)
 
  
CPUMotherboardGraphicsGraphics
AMD FX-8350 (Vishera) Gigabyte GA-990XA AMD 285X (unreleased) AMD 285X (unreleased) 
RAMHard DriveHard DriveHard Drive
Mushkin Enhanced Blackline 8GB (996679) Western Digital WD10EALS 1TB Blue Corsair Force Series GT CSSD-F180GBGT-BK 180GB Intel 530 Series SSDSC2BW240A401 240GB 
Optical DriveCoolingCoolingCooling
Sony 20X Sata DVD-RW Scythe Mugen 2 rev B (3) Scythe Slip Stream SY1225SL12H-P Antec Tri-Cool 140mm 
CoolingCoolingOSMonitor
Antec Tri-Cool 120mm Scythe Ultra Kaze DFS123812-3000 Windows 7 Pro 64bit ASUS PA248Q 24.1" IPS 
KeyboardPowerCaseMouse
Coolermaster Storm QuickFire Stealth Cherry MX ... Antec Earthwatts EA-750 Antec 300 Logitech G5 
Mouse Pad
Steel Series Starcraft 2 Marine 
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Reply
OC'in beast
(21 items)
 
  
CPUMotherboardGraphicsGraphics
AMD FX-8350 (Vishera) Gigabyte GA-990XA AMD 285X (unreleased) AMD 285X (unreleased) 
RAMHard DriveHard DriveHard Drive
Mushkin Enhanced Blackline 8GB (996679) Western Digital WD10EALS 1TB Blue Corsair Force Series GT CSSD-F180GBGT-BK 180GB Intel 530 Series SSDSC2BW240A401 240GB 
Optical DriveCoolingCoolingCooling
Sony 20X Sata DVD-RW Scythe Mugen 2 rev B (3) Scythe Slip Stream SY1225SL12H-P Antec Tri-Cool 140mm 
CoolingCoolingOSMonitor
Antec Tri-Cool 120mm Scythe Ultra Kaze DFS123812-3000 Windows 7 Pro 64bit ASUS PA248Q 24.1" IPS 
KeyboardPowerCaseMouse
Coolermaster Storm QuickFire Stealth Cherry MX ... Antec Earthwatts EA-750 Antec 300 Logitech G5 
Mouse Pad
Steel Series Starcraft 2 Marine 
  hide details  
Reply
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