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4 layers42 × 83.9 mmStratoSoar MK2.2, the printed circuit board in 3D

StratoSoar is an engineering project that aims to be able to fly a glider (dropped from a high-altitude balloon), down to any selected coordinates.

Size
42 × 83.9 mm
Copper layers
4
Thickness
0.8 mm
Parts
116
Nets
128
Pads
433
Tracks, vias
1,608, 212
Pours
7
Routed
Yes
KiCad
KiCad 8.0 (file 20240108)
Created
24 Oct 2023
Updated
22 Sep 2024

Overview

StratoSoar MK2.2 is an open-source printed circuit board by crnicholson, from the crnicholson/StratoSoar-MK2 repository on GitHub. It is a 4-layer board of 42 × 83.9 mm with 116 parts on 128 nets, routed with 1,608 tracks and 212 vias.

It is built around the ATSAMD21G18A-AU, ATMEGA328P-AU and BME280, with the AT24C512C-SSHD-T, MAX-M10S and MPU-9250 among its other parts. Its parts include 32 capacitors, 23 resistors, 15 connectors, 7 ICs and 6 transistors. It belongs with the AVR (ATmega, ATtiny), SAM D and SAM and NXP (LPC, Kinetis, i.MX RT) boards of this library.

Main components

8

README

README.md

StratoSoar MK2 - UAVs For the Masses

TL:DR: The StratoSoar project is a low-cost, lightweight Unmanned Aerial Vechile (UAV) designed for deployment from a weather balloon at various altitudes, aiming for autonomous and efficient flight to designated GPS coordinates. By offering a more affordable, compact, and lightweight alternative to conventional UAVs, StratoSoar aims to empower educators, researchers, and hobbyists with an accessible platform for exploration and experimentation.

Watch The Video

YouTube Video

GliderPCB
StratoSoar glider.StratoSoar MK2.0 circuit board.

What Is the StratoSoar Project?

StratoSoar is a low-power, adaptive UAV that is dropped from a weather balloon at approximately 5,000 feet, with plans to reach even higher altitudes soon. The main goal of StratoSoar is to fly to selected GPS coordinates efficiently or choose a closer, more realistic landing site without human interaction. The current aim for StratoSoar is to operate on a single 600 mAh 15 gram LiPo battery for a 10+ hour flight.

Now, What Is a UAV?

UAVs, or Unmanned Aerial Vehicles, are autonomous aircraft, usually in the form of planes or drones. They have many applications, such as delivering medicine, food, and supplies to remote areas, participating in aerial combat with the military, and conducting aerial imaging.

Common Types of UAVs Include:

  • Quadcopter (typical drones)
  • Fixed-wing aircraft (like StratoSoar)

StratoSoar vs. Conventional UAVs

Traditional UAVs Are Typically:

  • Large (5-15 meter wingspan)
  • Heavy (2-20 kg)
  • Expensive ($10,000-10,000,000 USD)
  • Closed source and propietary

StratoSoar Aims to Overcome These Limitations With:

  • Weight: less than 250 grams
  • Wingspan: 80 cm
  • Cost: less than $150 USD
  • Open source and accesible

What Are the Uses of StratoSoar?

I'm currently considering two main concepts: an educational kit for students and hobbyists or a platform designed to study the aerodynamics of the stratosphere, a field with limited existing resources. Additionally, I'm exploring other ideas such as reusable radiosondes, systems for remote delivery of medicine and parcels, and advanced atmospheric monitoring solutions.

How Does StratoSoar Work at a High Level?

StratoSoar MK2 is an advanced autonomous glider designed to operate at high altitudes, such as those reached by weather balloons. The glider is attached to a weather balloon via a cutdown mechanism. Once the balloon reaches the desired altitude, the cutdown mechanism releases the glider, initiating its descent. The glider then navigates autonomously to specified coordinates, using a combination of sensors, advanced algorithms, and low-power electronics.

Core Components and Functionality:

  • Autopilot System:

    • GPS and IMU Integration: StratoSoar uses a custom GPS module and an IMU, both designed for low-power operation. The IMU data is processed through a Kalman filter to provide accurate Attitude Heading Reference System (AHRS) data, including pitch, yaw, and roll. This information, combined with GPS coordinates, enables precise navigation.
    • Servo Control with PID: A PID control mechanism governs the rudder’s servo, ensuring precise adjustments to the glider's course based on real-time feedback.
    • Hackability: StratoSoar is designed to be highly configurable and hackable. Users can customize its descent strategy, whether by spiral descent, parachute deployment, or alternative landing locations. The codebase is modular, allowing for easy modifications or the addition of new features.
  • PCB Design:

    • StratoSoar MK3 PCB: The main PCB, optimized for power efficiency, size, and cost, integrates over 100 components, managing the various systems onboard.
    • Additional PCBs: Supporting PCBs, such as those for the GPS module, switching regulator, and IMU, are designed for specific tasks, enhancing the glider's overall functionality.

Operation and Recovery:

Upon release from the weather balloon, StratoSoar begins its guided descent following waypoints or single target coordinate. It calculates the optimal flight path using its GPS and AHRS data, making real-time adjustments to its trajectory through the PID-controlled servo system. Depending on user configurations, the glider can either glide smoothly to the target coordinates, initiate a spiral descent, or deploy a parachute for a safe landing.

If the glider's altitude drops below a certain threshold, backup landing coordinates can be used to ensure a safe recovery. Throughout the flight, the glider’s location is continuously transmitted, allowing for easy tracking and recovery.

A Quick Note on MK1, MK2, Naming, and Revisions

StratoSoar MK1 was the precursor and the spark to StratoSoar MK2. StratoSoar MK1 was officially developed from October 1st to July 30th, although StratoSoar MK2 was unofficially being worked on in the months of March through June. StratoSoar MK1 failed to fly autonomously, and it also failed to release from the balloon. Major upgrades have been made since then.

StratoSoar MK2 officially started on October 1st, and has now ended. It was a success.

My newer version, which you should check out, officially started on June 1st. It is called StratoSoar MK3 and will end in quite some time when I launch it from a weather balloon. A new major revision (eg. MK4) will come out every time when I release the glider from the balloon in the Summer. After the Summer, work on the next revision begins, with many updates and new features.

Also, I use "we" a lot in this writing. This usually refers to myself or this project, but it also refers to my small team over at New England Weather Balloon Society.

One last thing. When I refer to StratoSoar, I am referring to the project as a whole, but more specifically, the most recent version.

Is This Legal?

Yes! During flight, the ground operator has no direct control over the flight path, i.e. via a radio. Because of this, and it being unpowered, it qualifies as a free flight glider. Free flight gliders have very little regulations. You can think of them as a paper airplane.

Can I Buy a Kit or a Complete Product?

Currently, StratoSoar is not available to purchase online as a kit or complete product. We have plans in the next few years to release a kit for schools, education centers, hobbyists and a complete product for industry at an affordable price. You are welcome to make one in the mean time!

How Can I Make One? Are There Docs?

One of the goals of StratoSoar was to make an affordable and open source system for anyone to perform stratospheric research, so all the files are available for free. This means that you can construct StratoSoar from scratch. A guide to do this will be available soon.

Helpful Sources and Credits

I'm in the midst of compiling this.

Cutdown Mechanism

See my other WIP GitHub repo.

Funding and Support

We currently have very limited funding to complete this project. We would love any donations or sponsorships we could get to elevate (no pun intended) this project to the next level. If you don't want to donate, but want to help out, we would love your support with other areas of this project. Reach out to me if you have interest at:

Special Thanks

This project would not be possible without the following individuals:

  • Max Kendall (W0MXX) for working closely together with me.

  • Mike Malis for helping with the design of the glider.

  • Brett Miwa for schematic review, PCB design, electrical theory, and boost converter circuitry design.

  • Bob Phinney (K5TEC) for providing NEST and securing funding.

  • Mark Jessop (VK5QI) for answering all of my questions.

  • Mike Hojnowski (KD2EAT) for PCB design and hardware/software debugging.

  • Paul Hamilton for helping me with FAA regulations.

  • My parents!

And these entities:

  • Hack Club, for providing support for projects like this.

  • New England Sci-Tech (NEST) for providing a maker space to work, funding, and hosting NEWBS.

  • New England Weather Balloon Society (NEWBS) for expertise and the opportunity.

  • Bagel Fund, for providing funding.

Affiliate Programs and Projects

  • Hack Club - Hack Club is a non-profit designed for teenagers that provides support for projects like this.
  • NEWBS - Max and Seth Kendall of NEWBS, or New England Weather Balloon Society, are helping me launch my project from a balloon. They are dedicated to helping people in New England launch weather balloons.
  • New England Sci-Tech - Bob Phinney of NEST is hosting NEWBS. NEST is a great maker space. If you are in the Greater Boston Area, go check them out!
  • StratoScience - This is the official class that I'm in helping me launch my project. This is a high altitude engineering class for teens. Check them out if your are in the Greater Boston area!

Still Have Questions?

Do you have any questions? Are the docs incomplete and you want to ask anything? Do you just want to say hi (or how cool my project is!)?

Reach out to me at charlienicholsonr@gmail.com.

License

Both the software and documentation are under the GNU GPL v3 license. The hardware and the 3D files are under the CERN Open Hardware Licence Version 2 - Strongly Reciprocal. The media is under the CC BY 4.0 DEED.

Parts

116
QtyValueFootprintReferences
14100nFCapacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolderC1, C3, C6, C8, C11, C15, C16, C17, C19, C21, C22, C23, C25, C29
610KResistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolderR15, R16, R17, R18, R19, R20
41.8KResistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolderR6, R7, R9, R10
410uFCapacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolderC4, C10, C18, C26
41KResistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolderR1, R5, R11, R13
41uFCapacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolderC12, C20, C27, C28
422pFCapacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolderC7, C9, C13, C14
4MountingHoleMountingHole:MountingHole_2.2mm_M2H1, H2, H3, H4
310Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolderR21, R22, R23
32N3906Package_TO_SOT_SMD:SOT-23-3Q1, Q2, Q3
347uFCapacitor_Tantalum_SMD:CP_EIA-3528-21_Kemet-BC30, C31, C32
3DMN1019USN-13Package_TO_SOT_SMD:SC-59_HandsolderingQ4, Q5, Q6
21MResistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolderR2, R3
2220Resistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolderR4, R14
25.1KResistor_SMD:R_0805_2012Metric_Pad1.20x1.40mm_HandSolderR8, R12
2AAABattery:BatteryHolder_BK-82BT1, BT2
2LEDLED_SMD:LED_0805_2012Metric_Pad1.15x1.40mm_HandSolderD1, D4
2LOGOLOGOG***, G***
2XO_ENJumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mmJP9, JP10
1100pFCapacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolderC24
110nFCapacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolderC2
110uHInductor_SMD:L_0805_2012Metric_Pad1.15x1.40mm_HandSolderL2
11575AT43A0040001E1575AT43A0040E:ANT_1575AT_JOT-LAE1
11nFCapacitor_SMD:C_0805_2012Metric_Pad1.18x1.45mm_HandSolderC5
132.768kHzCrystal:Crystal_C26-LF_D2.1mm_L6.5mm_HorizontalY2
133nHInductor_SMD:L_0805_2012Metric_Pad1.15x1.40mm_HandSolderL1
18MHzCrystal:Crystal_HC18-U_VerticalY1
1AAAButton_Switch_SMD:SW_SPDT_PCM12SW3
1AT24C512C-SSHD-TPackage_SO:SOIC-8_3.9x4.9mm_P1.27mmU4
1ATSAMD21G18A-APackage_QFP:TQFP-48_7x7mm_P0.5mmU6
1ATXK-H11-E-32.768Crystal:Crystal_SMD_Abracon_ABM8AIG-4Pin_3.2x2.5mmU5
1AT_ISPConnector_PinHeader_2.54mm:PinHeader_2x03_P2.54mm_VerticalJ3
1AT_LEDLED_SMD:LED_0805_2012Metric_Pad1.15x1.40mm_HandSolderD2
1AT_LED_ENJumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mmJP4
1AT_RESETButton_Switch_SMD:SW_SPST_CK_RS282G05A3SW1
1ATmega328P-APackage_QFP:TQFP-32_7x7mm_P0.8mmU3
1BLM18AG121SN1DResistor_SMD:R_0603_1608Metric_Pad0.98x0.95mm_HandSolderFB1
1BME280Connector_PinHeader_2.54mm:PinHeader_1x04_P2.54mm_VerticalJ1
1ButtonConnector_PinHeader_2.54mm:PinHeader_1x02_P2.54mm_VerticalJ8
1EEPROMButton_Switch_SMD:SW_SPDT_PCM12SW2
1ERR_LEDLED_SMD:LED_0805_2012Metric_Pad1.15x1.40mm_HandSolderD3
1ERR_LED_ENJumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mmJP5
1ElevatorConnector_PinHeader_2.54mm:PinHeader_1x03_P2.54mm_VerticalJ11
1FTDIConnector_PinHeader_2.54mm:PinHeader_1x06_P2.54mm_VerticalJ2
1GND ConfigJumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mmJP7
1GY-91Connector_PinHeader_2.54mm:1x08_SMD_PadsJ13
1LED_ENJumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mmJP6
1MAX-M10SRF_GPS:ublox_MAXU1
1MCP1700x-330xxTTPackage_TO_SOT_SMD:SOT-89-3U7
1MPU-9250Sensor_Motion:InvenSense_QFN-24_3x3mm_P0.4mmU2
1ONE_CELLJumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mmJP3
1PPS_ENJumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mmJP1
1PWR_SWButton_Switch_SMD:SW_SPDT_PCM12SW4
1ParachuteConnector_PinHeader_2.54mm:PinHeader_1x03_P2.54mm_VerticalJ12
1PowerConnector_PinHeader_2.54mm:PinHeader_1x05_P2.54mm_VerticalJ7
1RESETButton_Switch_SMD:SW_SPST_CK_RS282G05A3SW5
1RudderConnector_PinHeader_2.54mm:PinHeader_1x03_P2.54mm_VerticalJ10
1SWDConnector_PinHeader_2.54mm:PinHeader_1x05_P2.54mm_VerticalJ6
1SignalConnector_PinHeader_2.54mm:PinHeader_1x11_P2.54mm_VerticalJ4
1USB-CConnector_USB:USB_C_Receptacle_GCT_USB4105-xx-A_16P_TopMnt_HorizontalJ5
1VINConnector_PinHeader_2.54mm:PinHeader_1x02_P2.54mm_VerticalJ9
1VINConnector_PinHeader_2.54mm:1x02_SMD_PadsJ15
1VIN ConfigJumper:SolderJumper-2_P1.3mm_Open_RoundedPad1.0x1.5mmJP8
1VOUTConnector_PinHeader_2.54mm:1x02_SMD_PadsJ14
1VoltmeterJumper:SolderJumper-3_P1.3mm_Open_RoundedPad1.0x1.5mm_NumberLabelsJP2

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Questions

How big is the StratoSoar MK2.2 PCB?

It measures 42 × 83.9 mm and has 4 copper layers, 0.8 mm thick.

What parts does the StratoSoar MK2.2 use?

116 parts, built around the ATSAMD21G18A-AU, ATMEGA328P-AU, BME280 and AT24C512C-SSHD-T. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.

Where can I download the StratoSoar MK2.2 KiCad files?

From the crnicholson/StratoSoar-MK2 repository on GitHub, at the commit this page was made from: the board is PCB + Schematic/StratoSoar-MK2.2/StratoSoar-MK2.2.kicad_pcb and its schematic PCB + Schematic/StratoSoar-MK2.0/samdFlightController.kicad_sch. PCBKit opens the board in the browser, with nothing to install.

Can I use the StratoSoar MK2.2 design in my own project?

Its repository states no licence, so its author keeps all rights: ask crnicholson before reusing the design.