Calibrator board v1 proposal (hardware, firmware, signal contract)

.github/workflows/ci.yaml

@@ -193,3 +193,26 @@ jobs:
             core/src/two_way.cpp core/src/timecode.cpp core/src/chirp.cpp core/src/detect.cpp core/src/g711.cpp \
             -framework Foundation -o /tmp/avsync-calibration-math
           /tmp/avsync-calibration-math
+
+  calibrator:
+    # Calibrator board: firmware build, host tests, KiCad ERC/DRC (hardware/calibrator).
+    runs-on: ubuntu-24.04
+    steps:
+      - uses: actions/checkout@v4
+      - name: packages
+        run: |
+          sudo apt-get update
+          sudo DEBIAN_FRONTEND=noninteractive apt-get install -y gcc-riscv64-unknown-elf picolibc-riscv64-unknown-elf make
+      - name: firmware (CH32X035, RISC-V)
+        working-directory: hardware/calibrator/firmware
+        run: |
+          make test
+          make CROSS=riscv64-unknown-elf- EXTRA_CFLAGS="-isystem /usr/lib/picolibc/riscv64-unknown-elf/include"
+      - name: ERC and DRC (KiCad 9.0.9)
+        working-directory: hardware/calibrator
+        run: |
+          docker run --rm -u "$(id -u):$(id -g)" -e HOME=/tmp -v "$PWD:/work" -w /work kicad/kicad:9.0.9 \
+            sh -c 'kicad-cli sch erc --severity-error --exit-code-violations -o /tmp/erc.rpt calibrator.kicad_sch &&
+                   kicad-cli sch export netlist --format kicadsexpr -o /tmp/cal.net calibrator.kicad_sch &&
+                   python3 scripts/check_netlist.py /tmp/cal.net &&
+                   kicad-cli pcb drc --severity-error --exit-code-violations -o /tmp/drc.rpt calibrator.kicad_pcb'

CHANGELOG.md

@@ -1,5 +1,16 @@
 # Changelog
 
+## Hardware (in development)
+
+- Calibrator board v0.3 under `hardware/calibrator/` (signal contract in
+  `docs/calibrator.md`): KiCad 9 project, JLCPCB files, CH32X035 firmware with host
+  tests. USB-C powered by the phone (no battery, no cables supplied); the firmware never
+  enables USB, so a phone only supplies power, and it can be updated over USB-C with the
+  BOOT button and open tools (wchisp, chprog). Comparator with hysteresis for the sensor
+  pair, 1 nF sensor filters. AVsync logo on both sides (gold ENIG copper, white silk,
+  black mask), QR code to the project site. Board files CERN-OHL-P-2.0, firmware MIT.
+  A first batch of 10 is ordered; not tested yet.
+
 ## Mobile (not released yet)
 
 - Test signal (iPhone and Android) no longer stops by itself about 5 minutes

docs/calibration.md

@@ -9,7 +9,7 @@ The rig is an LED and a piezo on one microcontroller pin. Parts and firmware are
 ## With the calibrator
 
 The calibrator is a small board with an LED, a buzzer and two light sensors
-([signal contract](calibrator.md)). The phone powers it over a USB-C cable.
+([signal contract](calibrator.md), [hardware](../hardware/calibrator/README.md)). The phone powers it over a USB-C cable.
 In the app: **Settings → With calibrator** (iPhone and Android; the clap
 calibration stays as it is). Three steps:
 

hardware/calibrator/.gitignore

@@ -0,0 +1,9 @@
+*.rpt
+*.dsn
+*.ses
+*-backups/
+fp-info-cache
+*.kicad_prl
+fab/gerbers/
+fab/calibrator-pos.csv
+__pycache__/

hardware/calibrator/3d/LED_reverse_1206.wrl

@@ -0,0 +1,3 @@
+#VRML V2.0 utf8
+Transform { translation 0.0000 0.0000 0.0551 children [ Shape { appearance Appearance { material Material { diffuseColor 0.9 0.9 0.85 } } geometry Box { size 1.2598 0.6299 0.1102 } } ] }
+Transform { translation 0.0000 0.0000 -0.1024 children [ Shape { appearance Appearance { material Material { diffuseColor 1 1 0.6 } } geometry Box { size 0.7323 0.5512 0.2047 } } ] }

hardware/calibrator/3d/MLT-8530.wrl

@@ -0,0 +1,3 @@
+#VRML V2.0 utf8
+Transform { translation 0.0000 0.0000 0.5906 children [ Shape { appearance Appearance { material Material { diffuseColor 0.08 0.08 0.08 } } geometry Box { size 3.3465 3.3465 1.1811 } } ] }
+Transform { translation -1.7126 0.0000 0.5906 children [ Shape { appearance Appearance { material Material { diffuseColor 0.3 0.3 0.3 } } geometry Box { size 0.1181 0.4724 0.3937 } } ] }

hardware/calibrator/3d/QSOP-28.wrl

@@ -0,0 +1,31 @@
+#VRML V2.0 utf8
+Transform { translation 0.0000 0.0000 0.3346 children [ Shape { appearance Appearance { material Material { diffuseColor 0.12 0.12 0.12 } } geometry Box { size 1.5354 3.8976 0.5906 } } ] }
+Transform { translation -0.4528 1.6929 0.6378 children [ Shape { appearance Appearance { material Material { diffuseColor 0.6 0.6 0.6 } } geometry Box { size 0.1969 0.1969 0.0197 } } ] }
+Transform { translation -0.9646 1.6250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 1.6250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 1.3750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 1.3750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 1.1250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 1.1250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 0.8750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 0.8750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 0.6250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 0.6250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 0.3750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 0.3750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 0.1250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 0.1250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 -0.1250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 -0.1250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 -0.3750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 -0.3750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 -0.6250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 -0.6250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 -0.8750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 -0.8750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 -1.1250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 -1.1250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 -1.3750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 -1.3750 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation -0.9646 -1.6250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }
+Transform { translation 0.9646 -1.6250 0.0984 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4331 0.0984 0.0787 } } ] }

hardware/calibrator/3d/TS-1187A.wrl

@@ -0,0 +1,7 @@
+#VRML V2.0 utf8
+Transform { translation 0.0000 0.0000 0.2953 children [ Shape { appearance Appearance { material Material { diffuseColor 0.85 0.85 0.85 } } geometry Box { size 2.0079 2.0079 0.5906 } } ] }
+Transform { translation 0.0000 0.0000 0.6299 children [ Shape { appearance Appearance { material Material { diffuseColor 0.15 0.15 0.15 } } geometry Box { size 1.1811 1.1811 0.1181 } } ] }
+Transform { translation -1.1417 -0.7382 0.0394 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4724 0.2756 0.0787 } } ] }
+Transform { translation -1.1417 0.7382 0.0394 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4724 0.2756 0.0787 } } ] }
+Transform { translation 1.1417 -0.7382 0.0394 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4724 0.2756 0.0787 } } ] }
+Transform { translation 1.1417 0.7382 0.0394 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4724 0.2756 0.0787 } } ] }

hardware/calibrator/3d/VEMT2500X01_RGW.wrl

@@ -0,0 +1,5 @@
+#VRML V2.0 utf8
+Transform { translation 0.0000 0.0000 0.3150 children [ Shape { appearance Appearance { material Material { diffuseColor 0.75 0.8 0.85 } } geometry Box { size 0.9055 0.9055 0.6299 } } ] }
+Transform { translation 0.0000 0.0000 -0.2283 children [ Shape { appearance Appearance { material Material { diffuseColor 0.7 0.75 0.8 } } geometry Box { size 0.7087 0.7087 0.4606 } } ] }
+Transform { translation -0.9843 0.0000 0.0394 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4724 0.1575 0.0787 } } ] }
+Transform { translation 0.9843 0.0000 0.0394 children [ Shape { appearance Appearance { material Material { diffuseColor 0.8 0.8 0.8 } } geometry Box { size 0.4724 0.1575 0.0787 } } ] }