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--- content:meshextender:2ng [05/03/2017 15:56]
Paul Gardner-Stephen [Bill of Materials]
+++ content:meshextender:2ng [02/04/2018 20:37] (current)
Paul Gardner-Stephen [Quality Control and Testing]
@@ Line 4: / Line 4: @@
 As part of the Pacific Humanitarian Challenge (PHC) grant that we have received from the Australian Department of Foreign Affairs and Trade (DFAT), we are in the process of redesigning the Mesh Extender for use in tropical-maritime environment, and generally addressing the productisation of the Mesh Extender, so that we can easily produce robust and reliable Mesh Extenders that are required for the grant activities, but also so that after the grant, Mesh Extenders can be readily produced for other potential users.
+==== Software Development ====
+The primary repository for the Mesh Extender is:
+   * https://github.com/servalproject/openwrt - Modified OpenWRT repository for building firmware images with correct settings.  Contains all information required to build a working firmware image.
+If you wish to develop on the individual packages, then these are the relevant repositories:
+   * https://github.com/servalproject/openwrt-packages - MeshExtender2.0 branch, for the custom Serval Project OpenWRT packages required by the above.
+   * https://github.com/servalproject/serval-dna - MeshExtender2.0 branch
+   * https://github.com/servalproject/lbard - MeshExtender2.0 branch
+   * https://github.com/servalproject/flash-rfd900 - master branch
 ==== Specifications ====
@@ Line 9: / Line 21: @@
   * Full custom-designed injection-moulded housing.
   * Designed to meet IP65 or IP66 (although we do not have funds to subject it to certification).
-  * Integrated flexible power options: 12v/24v automotive, solar (with integrated MPPT), 5V USB and/or LiFePO4/LiIon/SLA battery (with integrated charge controller).
+  * Integrated flexible power options: 12v/24v automotive, solar (with integrated MPPT), and/or LiFePO4/LiIon/SLA battery (with integrated charge controller). It might also be possible to power with 5V USB -- stay tuned.
   * microSD slot for Rhizome bulk data storage (replacing the previous energy consuming and unreliable USB memory-stick interface).
-  * Slot for RFD900/RFD868 radio
+  * Slot for RFD900/RFD868 radio.
-  * External UHF and Wi-Fi antennae for improved radio performance
+  * External UHF and Wi-Fi antennae for improved radio performance.
   * Mesh of Things/Internet of Things (MoT/IoT) interface with 2x opto-isolated digital inputs, and 60W load rated relay switched output.  These sensor/controller interfaces will be MeshMS-controllable via future software-update.
   * 2x Internal ethernet ports (1x giga-bit and 1x 100Mbit).  These are not routed to the outside of the IP65/66-designed enclosure, due to the cost that this would entail.
@@ Line 40: / Line 52: @@
 ==== Custom-Designed Injection Moulded Housing ====
-The housing has been designed, and the injection-moulding tools are in the process of being fabricated. We expect the first shots from the injection-moulding to be received in early April.
-Industrial design for the housing was by ProEn, South Australia.  ProEn are also organising the manufacture and testing of the injection moulding tools.  Injection moulding will be performed by Garon Plastics, South Australia, after the initial test phase, which will likely involve the tool-makers in China producing a test-run of perhaps 100 parts, that we will use for the first stage of the DFAT pilot, while waiting for the tool to be shipped to Australia.
-The housing requires a BS154 o-ring to provide the seal between the two halves of the case.  We currently source these from Statewide Bearings (http://www.statewidebearings.com.au/branch-locations/south-australia/) for AU$0.53 each in lots of 100.
-The following images show 3d models of the housing, as well as how the PCB and antennae cabling will connect.
-{{:content:meshextender:board_retention.jpg?200|}}
 {{:content:meshextender:front_3-4.jpg?200|}}
-{{:content:meshextender:front_cables.jpg?200|}}
+[[content:meshextender:me2.0_injection_moulded_case|Injected Moulded Case]]
-{{:content:meshextender:rear_3-4.jpg?200|}}
-{{:content:meshextender:top_cables.jpg?200|}}
-{{:content:meshextender:underside.jpg?200|}}
-{{:content:meshextender:xsection-front_cables.jpg?200|}}
-Perhaps the greatest challenge with the housing is to ensure that it will be IP65/66 rated, so that it can endure tropical-maritime and hot/cold outback conditions, while still being able to reject enough heat to keep the internal ambient temperature below 70C for proper operation of all components.  This requires that the cases be light in colour, and ideally, have an optional shade fitted if they are to be used in full-sun situations.
 ==== Custom-Designed PCB ====
-The PCB is currently undergoing the third revision to address outstanding errata.
+The PCB is currently undergoing the third revision to address outstanding errata. We hope to have samples before the end of March.
 First revision PCB, front and rear:
 {{:img_20161206_132612_meshextenderprototype.jpg?200|First revision PCB, front and rear}}
 ==== Power/Utility Cable ====
-We are engaging with Arkidelo to design and fabricate a low-pressure encapsulation mould for the D-SUB 25 connector, to provide appropriate environmental sealing of the cable head, from which the power input connector, battery connector and (optional) external USB charge ports will emerge.  This will also need to include provision for the thumb-tighten screw-ins for the connector.  The purchase order for Arkidelo to begin work is due to be raised on 03MAR17, and will take approximately 7 weeks before we receive the first parts.
+This cable is a IP65 D-SUB 25 female to 3-pin and 4-pin IP67 cable, designed to connect the Mesh Extender to each of:
+   * solar panel OR vehicular 12v/24v supply
+   * 2-cell LiFePO4 or 6v sealed lead acid battery
+It also contains an integrated I2C EEPROM that tells the Mesh Extender which radio frequency and transmit power it is allowed to use, along with other configuration data.
-For the power input / USB charge port connector, we are currently intending to use http://www.banggood.com/10Pairs-DC-MaleFemale-4PIN-24AWG-Waterproof-IP65-PVC-LED-Connectors-p-1073265.html?rmmds=search  (AU$1.38 each, for IP65-rated 4-pin 1A connectors)
+[[content:meshextender:me2.0_standard_power_cable_pinout|Pinout for standard power cable]]
-For the battery connector, we are currently intending to use the 3-pin version of the above (these are not mateable with the 4-pin ones) http://www.banggood.com/10Pairs-DC-MaleFemale-3PIN-22AWG-Waterproof-IP65-PVC-LED-Connectors-p-1073271.html?rmmds=search
+We are engaging with Arkidelo to design and fabricate a low-pressure encapsulation mould for the D-SUB 25 connector, to provide appropriate environmental sealing of the cable head, from which the power input connector, battery connector and (optional) external USB charge ports will emerge.  This will also need to include provision for the thumb-tighten screw-ins for the connector.  The purchase order for Arkidelo to begin work has been raised, and will take approximately 7 weeks before we receive the first parts, probably early May.
-We will also need IP65/66 rated D-SUB 25-pin female connectors, which we have yet to source.
+See the [[content:meshextender:me2.0_bill_of_materials|bill of materials]] for details on the components.
-==== Bill of Materials ====
+See [[content:meshextender:me2.0_quality_assurance|quality assurance]] for details on testing the cable, and programming the integrated I2C EEPROM.
-The current bill of materials is as follows, but note that this is subject to change, and is currently incomplete.
+==== Mesh of Things (MoT) / Utility Connector ====
-Also, for many items the purchase quantities are small, and pricing is retail rather than wholesale, and considerable cost savings are expected with bulk wholesale purchases.  Prices exclude shipping, except where specified.
+[[content:meshextender:me2.0_utility_connector_pinout]]
-^ Electronics ^^^^^ 0 ^ 0 ^
+==== Bill of Materials ====
-^ Part      ^ Source       ^ Cost          ^ Quantity ^ Unit Cost ^ Stock ^ On Order ^
-| PCB | RFDesign | TBA | 1 | TBA |
-| RFD900+/RFD868+ UHF packet radio module | RFDesign | AU$120 | 1 | AU$120 | ? | 0 |
-| 2.4GHz Wi-Fi antenna | TBA | TBA | TBA | TBA | 0 | 0 |
-| 900MHz 3dB or 9dB antenna (2 per unit) | TBA | TBA | TBA | TBA | ? | 0 |
-| 16GB microSD card | https://www.officeworks.com.au/shop/officeworks/p/sandisk-16gb-ultra-microsdhc-memory-card-br198570 | AU$9.99 | 1 | AU$9.99 | 0 | 0 |
-^    Electronics SUB-TOTAL ^^^^ AU$120.00 ^^^
-| |||||
-^ Power/Radio/USB cable ^^^^^ 0 ^ 0 ^
-^ Part      ^ Source       ^ Cost          ^ Quantity ^ Unit Cost ^ Stock ^ On Order ^
-| Female IP67 D-SUB 25 solder-cup connector (they don't make IP65/66 ones).  These are proving a problem, due to limited available stock | http://www.digikey.com/product-detail/en/norcomp-inc/772-E25-203R001/NOR1005-ND/2269287 (a little cheaper, 28 in stock immediately).  http://au.mouser.com/ProductDetail/NorComp/772-E25-203R001/?qs=hAgpCs62HLVt9xRacRKJtw%3D%3D (a little more  expensive, 9 available now, 50 more 17MAR2017).   | AU$420.56 | 28 | AU$15.02 | 0 | 28 |
-| 4-pin 12v/24v/solar/USB power input lead (20cm) | http://www.banggood.com/10Pairs-DC-MaleFemale-4PIN-24AWG-Waterproof-IP65-PVC-LED-Connectors-p-1073265.html?rmmds=search | US$10.19 | 10 | US$1.02 | 0 | 0 |
-| 3-pin battery pack input lead (20cm) | http://www.banggood.com/10Pairs-DC-MaleFemale-3PIN-22AWG-Waterproof-IP65-PVC-LED-Connectors-p-1073271.html?rmmds=search | US$9.58 | 10 | US$0.96 | 8 | 0 |
-| 2KB I2C 8-pin DIP EEPROM for power/radio ID cable | http://au.element14.com/microchip/24lc16bh-i-p/serial-eeprom-16kbit-400khz-dip/dp/1847846 | AU$0.348 | 1 | AU$0.348 | 8 | 0 |
-| Thumb-screws. Not sure if metric or imperial. | http://au.element14.com/multicomp/spc14961/d-sub-thumb-screw-4-40-unc-1-9in/dp/1221355 | $0.881 | 1 | $0.89 | 0 | 0 |
-| Low-pressure over-moulding of power/radio cable, including assembly of cable components. | To be provided by Akidelo. | TBA | 1 | AU$15.00 | 0 | 0 |
-^    Power/radio cable SUB-TOTAL ^^^^ AU$31.26 + US$1.98 ^^^
-| |||||
-^ Housing ^^^^^ 0 ^ 0 ^
-^ Part      ^ Source       ^ Cost          ^ Quantity ^ Unit Cost ^ Stock ^ On Order ^
-| Injection-moulded housings, produced from our custom injection-moulding tools.  ~AU$400 to mount tool in machine, then fixed unit cost thereafter. | Self-supply via Garon Plastics | TBA | TBA | ~AU$10 ? | 0 | 0 |
-| BS154 o-ring seal for housing | Statewide bearings (http://www.statewidebearings.com.au/branch-locations/south-australia/) | AU$65.45 | 100 | AU$0.66 | 98 | 0 |
-| reverse-sma fly-lead with bulk-head connector | RFDesign? | TBA | TBA | TBA | 0 | 0 |
-| fly-lead from Domino Core to reverse-sma bulk-head connector | GL-INET or RFDesign? | TBA | TBA | TBA | 0 | 0 |
-| Internal and external serial number and product identification labels.   | TBA - likely a Trotec laminate + adhesive, plus local manufacture. It is also possible we might be able to get the cases laser-marked. | TBA | TBA | TBA | 0 | 0 |
-| Goretex breather hole adhesive membrane spots. Shelf life of unused adhesive may be short (<1 year), also they need to confirm the most appropriate part and carry out a fitness for purpose appraisal.  500 is the normal minimum order, but they may be willing to entertain a smaller job-lot for us  | http://gore.com, Sydney office, +61 2 94736800 | AU$1600 + GST + delivery | 500 | AU$3.20 | 0 | 0 |
-^    Housing SUB-TOTAL ^^^^ AU$13.86 ^^^
-| |||||
-^    GRAND TOTAL ^^^^ AU$165.12 + US$1.98 ^^^
-==== Quality Control and Testing ====
-We need to establish quality control, programming, test and qualification procedures for the Mesh Extender units.  To be confirmed.
-===== Mesh Extender PCB Test & Programming Rig =====
-To be designed and implemented with Theo.  Test rig that will allow flash programming and testing of all functions of the PCB.
-  * Super-cap safe shutdown
-  * Ethernet port 1
-  * Ethernet port 2
-  * Wi-Fi (access point)
-  * Wi-Fi (ad-hoc)
-  * Servald and LBARD operate
-  * Internal UHF packet radio operation (sniff serial port?)
-  * Internal UHF packet radio reads, honours and reports Power/Radio cable I2C EEPROM status
-  * External radio operation
-  * Relay-switched output
-  * Opto-isolated inputs
-  * microSD card bulk storage
-  * Control of ssh login via microSD card special file
-  * Control of ssh login via Power/Radio cable I2C EEPROM
-  * Web-server operates
-  * Web-server reports radio regulatory settings
-  * Over-the-air update operates
-  * Over-the-air update BID can be configured via microSD card special file
-  * Over-the-air update BID can be configured in Power/Radio cable I2C EEPROM, and is honoured
-  * ...
-===== Power/Radio Cable Test & Programming Rig =====
-To be designed and implemented with Ryan.  Largely based on our flash-rfd900 utility to probe and program cable, combined with functional indication through a set of LEDs.
-===== Informal IP/Environmental Testing of Enclosures =====
+[[content:meshextender:me2.0_bill_of_materials|Bill of Materials]]
-Details to be confirmed.
+==== Provisioning, Quality Control and Testing ====
-Suggested tests:
+We need to establish quality control, programming, test, qualification and certification procedures for the Mesh Extender units.  To be confirmed.
-  * Hot weather test (operation in full sun and high humidity to 45C).
-  * Temperature and humidity cycling test.
-  * Water spray test with Power/Radio cable connected.
-  * Repeated sudden power-loss
-  * ... ?
-Success criteria:
+[[content:meshextender:me2.0_quality_assurance|Quality Control & Testing]]
-  * Uninterrupted operation through tests (confirm via pingability via Wi-Fi?).
-  * System reboots cleanly.
-  * No condensation or dust ingress at conclusion of testing.
-  * ... ?
-==== Certifications ====
-The ME2.0 has not yet been subjected to any certifications.  We intend to pursue Australian/New Zealand, EU and US certifications of the electronics, and IP65 or IP66 certification of the hardware.

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