My A-10C preparation

[rocketeer]

This is my idea of the NMSP panel. I want a push button of the exact size (around 14mm) with LED. Rather than trying to find switches like NKK ones (which are very expensive), I decided to have some fun.

 

1. cut a square from a thick acrylic sheet. Drill a recess (not too deep that it breaks through to the other side).

 

2. Get a LED that is relatively flat. This one is dome shaped and is super bright. I bent the legs sideways to reduce its height further.

 

 

3. take an Omron tactile switch and stick it into an acrylic cube.

 

 

4. Put the LED under the thick acrylic sheet with its dome head into the recess of the acrylic, then put both on top of the tactile switch and cube. This way I'd get to have LED light plus the push button.

 

5. Secure them with hot glue.

 

6. Cut a panel for the NMSP, cut some square holes. Put a few of the above combinations together plus a toggle. This will be the top row of the panel.

 

 

Testing the size of the square holes to fit the toggles without too much gap or being too tight.

 

7. Test the LED to make sure it still works.

 

The label is just some random paper I picked up from my leftovers. When to switch on the LED will be driven by helios and OC connection to mirror the state in the sim. I hope this works!

[talisman]

A tip would be to use some finishing paper on the top of the acrilic - 1 it spreads the light more evenly and it will also make it easier to adhere labels to it.

 

Use thick photopaper and when you print do it twice. Cut both and stick them on top of eachother. makes it hard wearing and also reduces the light output throught the black. the white makes little difference and shows through clearly.

[Alex_rcpilot]

Guys, which type of buttons do you think is used on the real CDU?

 

Tactile is the most frequently discussed type of switch, but it looks from the game that those buttons on the CDU travel much farther than tactiles would do. Probably 2~3mm downwards. So I'm thinking maybe I should use something similar with the reset button on PC cases.

[Alex_rcpilot]

By the way, how high are the buttons pertruding above the CDU's top surface? Something like 3mm?

 

Now I can't upload images. No matter what I do, the forum keeps telling me 'This is not a valid image file.' :music_whistling:

[Deadman]

for photos you should use Photo bucket the site has quanity and size restrictions

[Alex_rcpilot]

Looks like a site issue to me. Coz I tried uploaded images I've posted before, no joy.

 

Alright, photobucket is alive again. I was having problem with it a couple of months later. Imageshack is totally banned from here.

 

This is what I was talking about:

 

[CAT_101st]

By the way, how high are the buttons pertruding above the CDU's top surface? Something like 3mm?

 

Now I can't upload images. No matter what I do, the forum keeps telling me 'This is not a valid image file.' :music_whistling:

 

You can change the file type to one that works. JPEG.

[Alex_rcpilot]

You can change the file type to one that works. JPEG.

 

Nah... Still says not a vaild image file. Since photobucket is back, I'm giving up on the forum album.

 

I'm finishing up the CDU sketch now.

[Alex_rcpilot]

Guys, hope you don't mind about metric dimensions:

 

 

Please try to spot anything wrong with this drawing. Some dimensions are not provided because there're simpliy too many of them, if you need to know something, just ask.

 

I'm sure there are many mistakes in this diagram, coz a couple of screenshots and low resolution pictures are all that I could refer to.

 

Currently the primary issues are:

- If the DZUS fasteners on a real CDU is mounted on a receptical strip, is the hole spacing something like 9.53mm (0.375")?

- Which type of switchs should I choose for the buttons?

- How high do the LCD cover, the buttons and the transimissive frame protrude above the panel surface?

- How long does a button or rocker travel when it's pressed?

 

I may have to embed my PCB inside the aluminum back plate so it doesn't get stuck between the plate and the receptical strips along both edges. Sounds like a tough job, any suggestions?

 

* Receptical strip reference image:

[Alex_rcpilot]

A couple of render shots just for a better understanding of the structure:

 

If the PCB has to be embeded within the back plate, aluminum under the entire keypad area will be removed.

 

Currently, the small slots along where the frame edge sits above are meant to hold back light LED's.

 

I didn't give the DZUS studs any detail, because I'm planning on two versions. The cheaper solution involves replacing the DZUS studs with ordinary screws.

[Dropship Pilot]

Hi Alex,

 

I love your stuff! :)

If you have a look at this picture, ...

 

 

 

... you'll notice that the light panel of the CDU is much thicker than standard panels. Judging from the DZUS height, I'd say it's about 12,7mm (1/2"). So the buttons are probably integrated into the light panel and don't protude through the back plate. (Ups, I just notived that this is a replica - I hope it's a good one ;) )

 

 

Cheers,

Stefan

 

PS: Have been lurking quite a while and this is my first post. :)

Edited December 20, 2010 by Dropship Pilot

[Kuky]

Damnit guys, what you're making is just mind blowing

[Dropship Pilot]

Alex,

 

you are right - the DZUS mounting interval is 0.375" (=9,525mm). The center of the DZUS holes of the CDU would be at 1.5/6.5/8.5/17.5 increments from the top of the panel (e.g. at 14.3/61.9/81.0/166.7 mm).

 

Look here for more on DZUS spacing (be careful about the radius of the DZUS cutouts given there - it uses the maximum tolerance! MS25212 states a radius of 0.219" +0.030" -0.000". So stick with the 11mm width you have or go to 11.5mm if you want to be "in spec" and look good.)

 

Cheers,

Stefan

Edited December 20, 2010 by Dropship Pilot

[Alex_rcpilot]

Thanks, and it's nice to have your reply Stefan, the document is very informative.

 

The CDU-900 image is one of the references I had. And I just wasn't sure about how thick the acrylic is. Anyway, I adjusted the acrylic to 12.7mm now, and the Dzus measures 7.6mm in height.

 

Put them side by side, what'd ya say? 12.7 still looks a little too think for me:

 

Personally I'd like it to be thicker. That way I can have a wider selection on switches and integrate them within that space.

 

I gotta adjust the dimensions and locations for the Dzus fastners to meet the standards. Will have the blueprint updated soon as it's done.

 

A couple of questions still remain:

- How high do the white frame and the buttons protrude above the surface?

- What's the key travel distance of those buttons?

- If I build a screw variation for Dzus fastners, what lentgh and thread type is prefered?

 

Here's an exploded view of the 12.7mm version:

 

*edit: I've also reduced the backplate to 1.5mm thick.

Edited December 20, 2010 by Alex_rcpilot

[Dropship Pilot]

Sadly, I don't know of any picture of the A-10C showing the new CDU.

 

Here is a picture of a similar unit:

 

It might help in a "guesstimate".

As for dimensions and travel range of the knobs I wouldn't trust in the ED cockpit model too much. It sure is nicely done, but there are some errors:

For example: the height of the AN/ARC-186 radio is too big (the original is 6 DZUS high) and there should be a one DZUS (0.375") wide spacer between the CMSP and the caution light panel.

 

Hope this helps,

Stefan

[Deadman]

but there are some errors:

For example: the height of the AN/ARC-186 radio is too big (the original is 6 DZUS high) and there should be a one DZUS (0.375") wide spacer between the CMSP and the caution light panel.

 

Hope this helps,

Stefan

Both of these statements are incorrect the AN/ARC 186 Radio control box is not 6 DZUS high

 

 

There is all so no small one Duze wide spacer between the EWMU/ CMSP Panel and the Caution Annunciation Panel. Reference the cockpit lay out posted here http://forums.eagle.ru/showthread.php?t=63481 and The Modern Warthog guide pages 78,89

http://www.planespotters.nl/joomla/images/stories/events/ehvk/190609/Cockpit%20A10.jpg

[Dropship Pilot]

Have a look at the photo on page 54 of the DCS A-10C Beta Flight Manual (figure 39). It clearly shows the spacer between the CMSP and the caution light panel. There may be differend configurations, but at least there has to be enough space on the DZUS rails for the spacer to fit in.

 

As for the radio - I'll have to ckeck that.

 

Stefan

[Dropship Pilot]

Deadman,

 

according to the Collins data sheet for the AN/ARC-186(V) the Remote Control C-10604 (shown on the left in the picture) is 2.25" high. With 2.25/0.375=6 you get 6 DZUS units.

Also check the photo on page 53 of the DCS A-10C Beta Flight Manual (figure 38 ). It shows an relatively undistorted view of the radio and that looks pretty much like 6 DZUS too.

 

Cheers,

Stefan

Edited December 20, 2010 by Dropship Pilot

[Deadman]

Are you trying to use the Dzus holes in the rail as a measurement?witch would be unusual. I understood you say there were 6 Drus on the AnARC 186 radio head, with clearly hads 4 as you can see in the picture off one of the heads i have.That has a measurement of 2,25 inch by 5,75inch

[Dropship Pilot]

Yep, I was using the DZUS holes/heads as reference for the size of the panel:

the height of the AN/ARC-186 radio is too big (the original is 6 DZUS high)

As the height of all panels are multiples of the DZUS spacing of 0.375" it is very easy to handle. In most cases you can tell the size of the panel just by looking at the DZUS distances (at least for panels with < 7 or 8 DZUS units).

 

Stefan

[Dropship Pilot]

Yep, I was using the DZUS holes/heads as reference for the size of the panel:

the height of the AN/ARC-186 radio is too big (the original is 6 DZUS high)

As the height of all panels are multiples of the DZUS spacing of 0.375" it is very easy to handle. In most cases you can tell the size of the panel just by looking at the DZUS distances (at least for panels with < 7 or 8 DZUS units).

 

Stefan

[Deadman]

Or you could just ask and i could tell you the measurement of most panels. But your right if it appears that way to you

[Dropship Pilot]

That'd be too easy! :D

 

But thanks for the offer - I'll sure get back on that!

Actually - do you know the size/part number of the caution lights?

 

Cheers,

Stefan

[Alex_rcpilot]

As the height of all panels are multiples of the DZUS spacing of 0.375"

 

It also sounds very reasonable to me to base my guesstimations on that, but if the fact proves otherwise, I'd be curious to know why.

 

Deadman, should there be any discrepancy from Stefan's quotation, could it be because adjacent panels don't always have their bundary line sitting exactly at multiples of 3/8"? I figured that could be possible because those panels aren't supposed to be swapped around.

 

And do you happen to have some data regarding the CDU dimensions? I'd really appreciate your info as I've been trying to perfect this unit. Thank you.

[rocketeer]

Alex, what you are doing is beyond my budget and skills. I can only do quick and dirty stuff and make it functional. But your design is so awesome!

 

A bit OT here. Somebody rang the bell yesterday and ran away and left a gift basket. Didn't get the chance to see who it was.

 

 

I took the most important item inside and told wife she can have the nuts and chocolate and everything else.