Radio panel design files

Copyright Theo Deckers 2019

This documentation describes Open Hardware and is licensed under the CERN Open Hardware License OHL version 1.2  You may redistribute and modify this documentation under the terms of the CERN OHL v.1.2. This documentation is distributed WITHOUT ANY EXPRESS OR IMPLIED WARRANTY, INCLUDING OF MERCHANTABILITY, SATISFACTORY QUALITY AND FITNESS FOR A PARTICULAR PURPOSE. Please see the CERN OHL v.1.2 for applicable conditions.

 

ZIP file with all design files on this page for easy all-in-one download.

Custom libraries common to all schematics and PCB layouts

KiCAD 5.0 mcp_panel symbol library with all the custom schematic symbols used in the schematics on this page. You need this only if you want to open the source schematics below in KiCAD. There is also a PDF variant of all the KiCAD schematics and layouts.

KiCAD mcp_panel layout footprint library with all custom layout footprints used in the PCB layouts on this page.  You need this only if you want to open the source PCB layouts below in KiCAD.

Universal B737 COM/NAV/ADF radio panel with 5×2 mm rectangle LEDS (tested)

KiCAD 5.0 schematic  (PDF)

KiCAD 5.0 PCB layout (PDF)

Gerber files (can be uploaded to a PCB manufacturer, see the instruction at the bottom of this page)

Interactive Bill of Materials COM variant (page takes some time to load)

Interactive Bill of Materials NAV variant (page takes some time to load)

Interactive Bill of Materials ADF variant (page takes some time to load). Conn_SWADFON and Conn_SWANT are no components, but show in the PCB layout where to connect the ADFON and ANT switches.

SimVim configuration file (save as data.cfg file in X-Plane SimVim plugin directory). Note that SimVim is still under development, so occasionally things may change in newer releases. When this happens I’ll update the config files at this page.

SimVim pin mapping picture

‘Assemble and simultaneous test’ instruction for the radio panel. It’s strongly recommended to use this approach so that you’re sure that the 7-segment displays are working before soldering them:

 

Sketchup 3D model of the 3 mm acrylic clear or opal and 2.4 mm White/Smoke Grey Troply front panel designs.

DXF files

STL files

NOTE: you may need to experiment a bit with the value of the backlight LED series resistors depending on the manufacturer of your LEDs and the material that you use for the front panels. I used 10K for the panel backlight LEDs and 4.7K for the microswitch LEDs.

 

Files for testing a standalone radio PCB (displays, rotaries and transfer button only)

As long as the radio backplane is not yet available you can make the following radio PCB to Arduino Mega connections and use the SimVim configuration file below to test the 7-segment displays, rotary encoders and transfer switch for the radio panel:

Radio PCB to Arduino connections

SimVim config file for standalone radio PCB testing – captain COM (save as resources/plugins/SimVim/data.cfg in the X-Plane installation directory)

SimVim config file for standalone radio PCB testing – captain NAV (save as resources/plugins/SimVim/data.cfg in the X-Plane installation directory)

SimVim config file for standalone radio PCB testing – captain ADF (save as resources/plugins/SimVim/data.cfg in the X-Plane installation directory)

 

Universal B737 COM/NAV/ADF radio panel with yellow 7.05 x 1.8 rectangle LEDs

Uses the same schematic as above, only the LEDs above the frequency band switches have been rotated 90 degrees so that OSY5JA7234B LEDs can be used.

KiCAD 5.0 PCB layout (PDF)

Gerber files (can be uploaded to a PCB manufacturer)

Interactive Bill of Materials COM variant (page takes some time to load)

Interactive Bill of Materials NAV variant (page takes some time to load)

Interactive Bill of Materials ADF variant (page takes some time to load). Conn_SWADFON and Conn_SWANT are no components, but show in the PCB layout where to connect the ADFON and ANT switches.

Same SimVim configuration file and SimVim pin mapping picture as above

Revision 1.0 radio backplane design (tested)

NOTE that the revision 1.0 backplane uses almost all pins of the connected Arduino Mega, while SimVim doesn’t support multiple Arduino’s, so other systems of the cockpit must be interfaced in a different way when using this prototype rev1.0 backplane.

A new rev2.0 backplane and matching Arduino shield under development can be used with the same radio panels, but use more multiplexers so that also the First Officer ADF panel can be connected and other cockpit systems (MCP, 2 x EFIS, 2 x FMC, MIP) can be interfaced to X-Plane with the same Arduino.

KiCAD 5.0 schematic (PDF)

KiCAD 5.0 PCB layout (PDF)

Gerber files (can be uploaded to a PCB manufacturer)

Interactive Bill of Materials (page takes some time to load)

The first prototype of this backplane design completely works, but some connectors could have a better orientation / location.
If you build it, please check the following pictures for correct cabling and jumpers:

Using 3 radio panels and the revision 1.0 backplane for B737 MCP functions (tested)

The combination of the COM1, NAV1 and ADF1 radio panels can be used to control most of the B737 Mode Control Panel functions by copying the SimVim configuration file below to the data.cfg file in the X-Plane resources/plugins/SimVim directory.

SimVim ‘MCP on radios’ configuration file (save as data.cfg file in X-Plane SimVim plugin directory)

SimVim ‘MCP on radios’ pin mapping picture

Future

New designs are under development for a complete system with Arduino Master PCB, MCP PCB, EFIS PCB, revision 2.0 radio backplane PCB (using the existing radio panel PCB design at this page for 6 radio panels), MIP PCB and FMC PCB. Development and testing of these will take time, but once successfully tested these will also be made available for free download in this blog.