jrsteensen/openhornet

OpenHornet 1:1 F/A-18C Simulator Repository

The OpenHornet Project is a F/A-18C OFP 13C Lot 20 1:1 Replica Simulator, consisting of a physical structure and electrical/software interfaces to a PC to be driven by Digital Combat Simulator (DCS).

• If you have any questions, visit our Discord server and ask questions. The Discord server will be an invaluable resource for you as your progress through the journey of your build.

Looking for Software?

• OpenHornet GitHub Software Repository

Design Software Requirements

• Mechanical CAD Software Required: Fusion360
• Electrical CAD Software Required: KiCAD 7
• Microsoft Office (or compatible)

Contributing

Want to contribute? Let's discuss what you want to work on in Discord or in an issue!

References, Information, and How-Tos

GitHub Repository File Structure

OpenHornet
├── .github (Contains issue templates, funding info, and GitHub actions.)
├── artwork (Subdivided into end items, contains stickers, placards, etc.)
├── ECAD (All PCBs and electrical design files. See folder README file for details.)
├── images (Contains images for use in the wiki or other OH documentation.)
├── reference (Contains reference models or geometry.)
├── release (Contains all files that makeup the release package. See folder README file for details.)
├── utils (Contains fonts or other similar required resources for development)
├── .gitignore (File that instructs the git repository to ignore certain file types.)
├── CODE_OF_CONDUCT.md (Our contributor code of conduct.)
├── CONTRIBUTING.md (A file that just redirects you to the contributing wiki entry.)
├── ISSUE_TEMPLATE.md (The generic repository issue template, in case an issue doesn't fall into one 
|                      of our three predetermined categories)
├── LICENSE.md (License file for the OpenHornet repository)
├── PULL_REQUEST_TEMPLATE.md (The repository pull request template.)
└── README.md (This file)

Important Links

• OpenHornet Start Here Page - Seriously. Start here.
• OpenHornet FAQ - You guessed it! The FAQ!
• OpenHornet GitHub - OpenHornet's GitHub repository for everything other than MCAD. Where you can find the latest under-development files.
• OpenHornet Tutorials - Tutorials for OpenHornet.
• OpenHornet Issues - Go here to file a bug/enhancement/obsolescence report.
• OpenHornet Authorized Vendors - These are vendors who are licensed to sell OpenHornet parts and assemblies. By purchasing from them, you also support OpenHornet as well!

OpenHornet MCAD Model

These links will allow you to download a local copy of the OH MCAD model, for reference or so you can modify things for your personal pit. If you would like to contribute to the raw MCAD, talk to Noctum in the OH Discord. You will need to prove a basic level of proficiency and be known within the discord community before access will be granted.

Note

These links will download the latest & greatest (most likely in development and unstable) MCAD. Always verify fusion parts against release package manufacturing files prior to use, and they are used at the user's own risk.

• Top Level - This is HUGE. Consider downloading individual consoles instead.
• Upper Instrument Panel (UIP)
• Lower Instrument Panel (LIP)
• Left Console (LC)
• Right Console (RC)
• Center Tub (CT)

Branches

• Master branch is the stable release branch.
• vX.X.X is the latest working branch that will become the next release. It may or may not be functional as is.

Authors and Acknowledgment

Core Development Team

• Erik Scott (RandomTroubledMind): Project Founder, Mechanical Design
• John Steensen (Noctum): Co-Founder, Systems/Mechanical Design Lead
• Oscar Arias (Amanuense): Electrical/Software Design Lead (Retired from OH)

Contributor Team

• Exprezzo
• Sandra
• Ben-F111
• Lazarus
• Russell
• Arribe VCAW-1
• Stang
• [OCS] CrazyCanuck

Honorable Mentions

• Logo Design: NegativeONE
• Development Builders/Testers: Ajmilner, Arribe VCAW-1, Ben-F111, BlaBlaCZ, bnepethomas, Dave the boss 918, DG, DotDotDotBH, Exprezzo, Higgins, Krikeee, Lazarus, Otso, Rampage2010, Russell, Sandra, Splash, Thib-O, tonyg, TripRodriguez, Yannick
• Ultimate Supporters: Sandra, Higgins, Chaps, [OCS] CrazyCanuck, Arribe VCAW-1, FL370Pilot, CorgiStyle, Swaney409, DenzilLee, ssgcline, Tyler | "Soapbox" - F-15E
• Elite Supporters: thib_o54, ChrisTiger#001, Nodar, Matt
• Donators: AJMilner, bnepethomas, Carbine, Crosshairs, Exprezzo, Goutch, Higgins, hrnet940, hunstone, icemarkom, jcstreek, jkkicks, kika, Nik S, Rampage2010, Russell, Sandra, SrSosio, Swaney409, Tekadept + many more…
• Inactive Dev Contributors: Balz Reber (Balse), Magic_Man, Bullant, Gaberun24, Damien022, Baago, Caviar4, NegativeONE, Ravell
• Subject Matter Expert: FlyNavy75, Sixtigers, USMARINE108, Luft101, Lex

openhornet's Issues

Rudder Pedal Gantry

Design, model and integrate into NHA

Hydraulic Press Gauge Stepper Mount

Design, model, and integrate HYD PRESS Stepper Mount for VID28-05 into NHA.

Upper Instrument Panel Electronics MCAD Integration

Electrical system MCAD integration.

• L DDI Display HDMI Controller
• R DDI Display HDMI Controller

• Raspberry Pi 4 Model B (Pi 1 - L DDI, R DDI)
• Raspberry Pi 4 Model B (Pi 2 - AMPCD, Standby Instruments/SARI/RWR)
• Raspberry Pi 4 Model B (Pi 3 - IFEI)
• Netgear GS105 Unmanaged Ethernet Switch, 5 Port
• USB Hub

• Arduino Mega ( -> UFC -> HUD, AP, HUD BIT Panels)
• Arduino Mega (Master 1)
• ABSIS Nano Lite (Slave 1-1 -> Master Arm Panel, AoA Indcator)
• DDI Shield (Slave 1-2 -> L DDI Bezel PCB)
• L WARN INDICATORS Module (Slave 1-3)
• R WARN Indicator Module (Slave 1-4)
• DDI Shield (Slave 1-5 -> R DDI Bezel PCB)
• ABSIS Nano Lite (Slave 1-6 -> SPIN RCVY Panel)

• Backpanel connectors

IFEI PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

Master Mode Button PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

EWI Right PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

Right Console Skins

Design, model, and integrate right console skins.

• Exterior skin
• Interior skin

FCS Panel corners need to be rounded

The panel for the FCS does not have rounded corners like the other panels. attached images compare FCS with SNSR panels.

UFC Mega Shield

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

Requirements

Shield for Mega, breaks out to two UFC IDC connectors and standard power bus 4-pin connector.

Caution Lights PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

BATT (Voltage) Gauge Stepper Mount

Design, model, and integrate BATT Stepper Mount for VID28-05 into NHA.

UFC PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

DDI/AMPCD Shield Bezel Changes

TODO for this PCB:

• Remove 1x POT connector
• Add 4 pin connector for DDI rotary (3 DI + GND)
• Add 2x 3 pin connector (2 DI + GND) for AMPCD HDG/CRS toggles
• Fix i2c addressing.

Fix errors in DISP Button

Fix errors in DISP Button Assembly.sldasm. Will likely require remodeling.

HUD/HUD Box

Design, Model and Integrate into NHA the HUD frame and HUD Box details.

• HUD Box
• HUD Camera

Center Tub Structure

Design, model, integrate into NHA:

• Center Tub Structure
• Install HW
  • Utilize console mounted pins and 2x electromagnets per side of the "hump" to lock center tub into place.
• Seat Mounting Interface
  • Interface will consist of aluminum U-channel with rubber liner inside to act as a vibration isolator to support Buttkicker or similar. Should be medium to hard durometer isolation substrate. Will also require isolation against the "hump" of the center tub.
• Flight Control Stick Interface
  • Interface should be accessible from the top.
• Casters
  • Add 4X 2406T33 fixed casters, then replace wheels with Acetal Multidirectional Skate Wheel
• Cable Routing
  • Add flexible cable tray/carrier/drag chain on outboard side of left seat mount for routing cables to left console.

Gear Replacement

Evaluate all gears in components and replace metal gears with printed gears where possible within design constraints.

• Left Console
• Lower Instrument Panel
• Upper Instrument Panel
• Right Console

Map Holder

Design for map holder on right rear console.

Hard Mounted Rudder Configuration

Add an optional configuration for hard mounting rudders.

Instrument Panel Glareshield

Require MCAD and integration into next higher assembly.

Knob Review

Check to see if all knobs in pit have setscrews installed in the model.

• Left Console
• Lower Instrument Panel
• Upper Instrument Panel
• Right Console

Defog Lever

Needs MCAD for lever, no good source reference exists. Close enough may be required on this part. Potentiometer already exists in mating bracket in console.

Double actuated toggle switch

The engine crank switch on the APU panel is actuated from both sides. Not yet implemented in the design.

Trackball/Mount

A hinged trackball mount either near the throttle or off the seat. This item is a very low priority.

ABSIS Nano Lite

Create a ABSIS Nano Lite to minimize board footprint, remove 12V lines, and replace DIP switch with two pin header (Short header to enable PGM).

Indicator configurations scrambled

Go through all legends on indicators and correct to proper configurations. Somehow button legends and indicator legends all got scrambled pretty badly in the model.

JETT Select PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

Parts List

Create a parts list for the major end items and top level assembly.

• Left Console
• Lower Instrument Panel
• Upper Instrument Panel
• Right Console
• Center Tub
• SJU-17 Ejection Seat
• Top Level Assembly

RWR Control Panel PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

DDI/AMPCD Arduino Shield

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

Upper Instrument Panel Interconnect Diagram

Add Upper Instrument Panel Interconnect Diagram to Interconnect Diagram

• UIP RS485 Bus with components
• Internal Cockpit Displays, RPis, Controllers, Ethernet Switch
• UFC
• USB Hub

Replace RALT OFF Flag

Consider replacing the servo driven OFF flag in RALT with OLED (or simple blacked out indicator light) to simplify gauge.

Power Distribution Unit (PDU)

• Requirements definition
• Schematic completed
• PCB(s?) routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

Hook Indicator

Design, Model, and Integrate into NHA.

AP Button PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

EWI Left PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

Display Driver RPi software/configurations

Software stack for internal cockpit display RPis.

• Left DDI RPi
• Right DDI RPi
• AMPCD RPi
• IFEI RPi
• SARI/RWR RPi

Duplicate Hardware Check

Review MCAD model for duplicate hardware. When found, remove duplicates and replace with primary.

ER-TFTV101A1-1 Controller and Keyboard

Require model of the ER-TFTV101A1-1 display controller and keyboard PCBs for the model.

Given that these two PCBs are COTS components, a STEP file of each PCB is perfectly okay.

Redesign Standby Instrument Cluster

Redesign left LIP to remove existing screen and utilize 10.4 or similar LCD for standby instrument cluster, SARI, and RWR. Additionally, update system architecture and bezels.

LIP Skins

Design, model, and integrate LIP Skins on either side of the exterior of the instrument panel structure.

• left skin
• right skin

AMPCD Bezel PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

.55 SQ Indicator PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

DDI Bezel PCB

• Requirements definition
• Schematic completed
• PCB routed
• Schematic/PCB reviewed
• BOM generated
• Gerbers generated
• MCAD generated

UFC MS21382-0XNX missing shaft hole and set screw hole

UFC MS21382-0XNX.sldprt missing shaft hole and set screw hole

Left Console Skins

Design, model, and integrate left console skins.

• Exterior skin
• Interior skin

F/A-18C Hornet™ HOTAS Add-On Grip

Require a model for further flight control stick development of the Thrustmaster F/A-18C Hornet™ HOTAS Add-On Grip. This model can either be created in SW2019 (or earlier) or STEP. High fidelity model with an accurate weight and approximate center of mass is required.

Add internal radii to CNC'd parts

Add .125/.25 internal radii on CNC'd parts as applicable.

Flight Control Stick

This is the mechanism for the flight control stick. It must meet the specifications as denoted below, utilizing the TM F/A-18C Stick Grip (#2) .

• Grip Mounting Box
• Roll Axis Mechanism
• Pitch Axis Mechanism
• Center Tub Intergration

Rudder Pedal Adjust Handle

Design and integrate a Rudder Pedal Adjust Handle that clamps/glues over the switch bat for releasing the rudder pedal locking solenoid.