HSI Mk1 Electrical Design Guide

This guide defines the electrical design standards and practices for the HoverStop project. It ensures consistency, reliability, and maintainability across all electrical systems.

Wiring Standards

• Use white 26AWG hook-up wire for all harnesses.
• Label wires with heatshrink labels for clear identification.
• Maintain a small gap between insulation and solder joints to prevent melting into the wire.

Connector Standards

• Standardize on DSUB connectors with crimped terminals as the primary option.
• Use solder cup DSUB connectors as an alternative when crimped terminals are not feasible.

Soldering Guidelines

• Follow the soldering procedures outlined in the Soldering Wires onto the 23794 Angle Sensor, Hall Effect guide.
• Ensure all solder joints are shiny and show a slightly concave fillet.
• Clean away flux residue after soldering.

Additional Soldering Guidelines

• For general wire-to-component soldering (e.g., switches, buttons), refer to the General Wire-to-Component Soldering Guide.
• Ensure all soldered connections have 12–18mm of heatshrink tubing applied for insulation and strain relief.

Harness Design

• Group wires logically and bundle them with cable ties or spiral wrap.
• Avoid sharp bends or excessive strain on wires.
• Test harnesses for continuity and proper connections before installation.

PCB Design

• Use standard footprints for connectors and components.
• Include test points for critical signals.
• Label all connectors and test points clearly on the silkscreen.

Wire Lacing

• Follow the Wire Lacing Guide for organizing and securing wire bundles.
• Use lacing cord as per FAA AC 43.13-1B, Chapter 11 standards.
• Avoid overtightening to prevent damage to wire insulation.

Testing and Validation

• Perform continuity tests on all harnesses and PCBs.
• Use a multimeter or oscilloscope to verify signal integrity.
• Document all test results and include them in the project repository.

Communication

• All major changes, releases, and decisions are posted in Discord.
• Thread-based discussions encouraged per part or topic.
• New part numbers and assignments are coordinated via GitHub or Discord.