Assembly Instructions
Version 24 (Jeremy Wright, 02/12/2014 04:10 pm) → Version 25/29 (Jeremy Wright, 03/17/2014 06:42 am)
h1. Ground Sphere Prototype Assembly Instructions v0.1 (OUTDATED)
{{toc}}
h2. Introduction
Version 0.2 is the second prototype, which sacrifices some of the flexibility of v0.1 in order to move toward a more polished kit version of the ground station. The overall design is the same between v0.1 and v0.2, but the details and several components have changed. Below are the assembly instructions for v0.2.
h2. Structural Component Pre-assembly The Antenna Base
h3. Tools
* Hacksaw or chop saw
* Sharp knife
* Drill or drill press
* Ruler or caliper
* Pen or pencil
* Optional: The first component to build is the antenna base. Centering jig for drill press
h3. Materials
* 1ea (ANT01) ¾” sched 40 PVC coupler
* 1 ea It is made from plumbing components available at any large hardware store. The diameter and length of ¾” the PVC sched 40 pipe 3” or longer. was chosen to allow the preamp to fit inside the base and give the antenna a weighted base for stability. Makes (ANT02) coupling sections
* 1ea (ANT05) ¾” PVC sched The use of press fit and threaded connections makes the antenna easy to assemble, disassemble, and tune.
1. Screw the schedule 40 to ½” 1/2" NPT male adapter
* 1ea (ANT06) ¾” PVC sched 40 end cap
* PVC cement primer (purple solvent)
* PVC pipe cement
* Optional: PVC safe spray paint in a desirable color. (ANT05) into the base adapter (ANT03).
h3. Safety issues !http://opendesignengine.net/dmsf_files/428?download=! !http://opendesignengine.net/dmsf_files/429?download=!
* Care must be taken when working with powertools, sharp blades, or saws.
* When h2. The Ground Plane
The Ground Plane is sizes using a chop saw, drill, or drill press, eye protection should be worn.
* PVC solvent and cement must be used the dimensions in well ventilated areas.
* Spray paint must be used in a well ventilated area, and should be done in a paint booth or outdoors.
h3. Product or Outcome
All plastic components for the Ground Sphere Mk2 upper structure.
h3. Procedure
"GScalc spreadsheet available here":http://opendesignengine.net/dmsf_files/271?download=.
# Using a chop saw or hack saw, cut 2 sections Cut out round pieces of ¾” PVC sched 40 pipe 1¼” long. conductive fabric (ANT14) and cotton muslin (ANT15) 7” in diameter
# Using Cut out with a sharp knife debur 1” diameter hole in the inside center of the fabric disks (ANT14 and outside ANT15)
# Quilt fabric discs together using conductive thread (ANT18). Ensure all of the sections. quilting threads end at common location near the center opening of the ground plane so that this may be connected to the ground line
# These become coupling sections (ANT02).
# Using Attach a small gauge ring terminal (ANT09) to the PVC cement primer (purple solvent), lightly coat quilting threads with about 2” of slack between the whole outside top of both coupling sections. the ground plane and the crimp
# Without dipping Sew 6 small pockets on the applicator back into muslin side of the primer, lightly coat Ground Plane to create the inside ground plane strut sleeves (ANT16); the pockets should extend from the center of the ¾” PVC sched 40 ground plane disk directly to ½” NPT male adapter. (ANT05). the outer edge at 45 degree intervals like spokes on a wheel
# Without dipping Fabricate the applicator back ground plane supports (ANT17)
## Cut 6 sections of 1/8" steel rod into 3" lengths
## Bend the primer, lightly coat the inside 6 sections of the ¾” PVC sched 40 18" steel rod to 90 degree angles 2" from one end cap (ANT06).
# Lightly coat Insert the inside long side of the unthreaded side Ground Plane Supports (ANT17) into the 6 ground plane strut sleeves (ANT16) on the bottom of the ¾” ground plane assembly
h2. The Antenna Body
The Antenna Body is made from a 6" long section of 1" PVC sched 40 to ½” NPT male adapter (ANT05) with PVC cement.
electrical conduit.
# Quickly insert one Cut a 6" long section of the coupling sections (ANT02) 1" PVC electrical conduit and set aside debur it to cure.
form the antenna body (ANT01);
# Lightly coat Test fit the inside sides Antenna Body (ANT01) into the non-threaded portion of the ¾” PVC sched 40 end cap Coupler (ANT04); ensure it fits fully and snugly
# Temporarily place the ground plane assembly on the antenna body so the support struts (ANT16) are flush against Antenna Body (ANT01) and the Coupler (ANT04).
# Attach the Aerial Terminals (ANT06) with PVC cement.
# Quickly insert ## Take one of the remaining coupling section (ANT02) Aerial Terminals (ANT06) and set aside to cure.
# As accurately as possible drill a 3/16” position it so that the mounting hole is toward the ground plane assembly with the long portion in line with the exact center Antenna Body (ANT01).
## Adjust the distance from the top (screw side) of the side on Aerial Terminal (ANT06) to the ¾” sched 40 PVC coupler (ANT01). The use top of a drill press and centering jig is recommended.
# Rotating the part 180 degrees, drill a 3/16” hole Ground Plane assembly so that it matches the D Plane figure in the exact center "GScalc spreadsheet":http://opendesignengine.net/dmsf_files/271?download=
## Mark the position of the opposite side Aerial Terminal (ANT06) on the ¾” sched 40 PVC coupler Antenna Body (ANT01).
# Rotating
## Draw a line around the part Antenna Body (ANT01) at the position of the first Aerial Terminal (ANT06)
## Along this line mark 3 additional positions 90 degrees, drill degrees apart starting at the first Aerial Terminal (ANT06) mark.
## Drill a 3/16” hole in the exact center each of the ¾” sched 40 PVC coupler (ANT01) between the first two holes. 4 position (a drill press is recommended)
# Rotating the part 180 degrees, drill a ## Drill another 3/16” hole in the exact center ½” below one of the remaining side on mounting holes from the ¾” sched 40 PVC coupler (ANT01).
# The holes should previous step. This will be at for the 12 o’clock, 3 o’clock’ 6 o’clock, RF line (coax) to exit the Antenna Body (ANT01) and 9 o’clock positions when sighting down the ¾” sched 40 PVC coupler (ANT01).
# If it is desirable connect to paint the ground station components, this is a good time to do so. Aerial Terminals (ANT06)
# Set ## Attach the units aside Aerial Terminals (ANT06) at each of the first four holes with #10 nut and bolt (ANT07, ANT08) hand tight. Note - these are temporary connections as these bolts are used for integration with electrical connections in future steps
# Place the antenna body.
h2. Assembling End Cap (ANT05) on top of the Phasing Loop
h3. Tools
* Needle nose pliers
* Wire cutters
* Wire strippers
* X-acto knife
* Terminal crimper
* Ruler Antenna Body (ANT01), but do not secure it with pipe cement or caliper
* Dental pick or needle any other adhesive
h3. Materials h2. Antenna Line
* 3ea (ANT10) Insulated crimp ring terminal Red (22-18 AWG)
* 1ea # Fabricate the Antenna Line (ANT11) Insulated crimp ring terminal Blue (16-14 AWG)
* 1ea (ANT13) by cuttin an arbitrary length of 50 ohm coax cable; Note - the Antenna line, SMA female connector Line should be long enough to pigtail go all the way around the antenna body, down the hole drilled for it, and out the bottom of the antenna body with 3” to spare
* 1ea (ANT15) Tuned length # Carefully strip back 2” of RG62u 90ohm the outer cladding of the coaxial cable
h3. Safety issues
* Care must be taken when working with hand tools, sharp blades, or sharp points.
* Coaxial and gently pull it free without damaging the braided shield below.
# Gently push the braided shield back along the coax cable wires, both toward the center conductor insulation. This will gather and shield wire can easily pierce expand the skin.
* Should braid like a shield wire pierce the skin, remove Chinese finger trap; allow it carefully since it can break off well below to expand.
# Gently widen a gap in the surface side of the skin, requiring painful removal
h3. Product braid near the insulation and fish the center conductor out this hole with a fine screwdriver or Outcome
All radio frequency (RF) components for dental pick, taking care not to unbraid the Ground Sphere Mk2 upper structure.
h3. Procedure
braided shield or breaking wires unnecessarily. Inevitably one or two may break, but this is okay.
# Cut Gently pull the RG62u 90ohm cable (ANT15) braid from the end in order to precisely 2.775”. collapse it back down... help it a bit by smoothing it with your fingers.
## Note: # Gently remove any broken wires from the braid. Once thin and smooth, you may wish to place the RG62u 90ohm cable (ANT15) should already be cut to length. section of coax insulation you previously removed over the exposed coax braid. Without the center conductor in the braid, the insulation will slide over the braid easily protecting and insulating the ground from inadvertent contact.
# Verify Strip back about ¼” from the length.
# Using the X-acto knife, strip ¾” from each end of the RG62u segment (ANT15) center conductor and retain crimp a ring terminal (ANT09) on it. Use the insulation tube. smallest wire rating for this ring terminal that will accept #10 hardware (red jacket). You may wish to put a small loop in the end of the exposed wire before inserting it into the ring terminal in order to give the crimp more to hold on to.
## Note: # Crimp a second ring terminal (ANT09) to the ground side. If something goes wrong For this you will need a larger lug (yellow jacket).
# Slide the ground plane assembly over the bottom of the antenna body with the RG62u segment (ANT15), do not cut off the messed conductive fabric side up end and retry. It is a specific length and must remain so. the struts on the bottom.
# In Thread the event unstripped side of breakage, use another segment the coax through the lower hole in the antenna body from the outside to the inside of the correct length.
antenna body (ANT01), leaving ½” or so and the stripped and crimped ends hang out of the hole.
# Using Mount the dental pick or needle, gently Coupler (ANT04) on the Antenna Body (ANT01). Secure these parts with PVC cement if you wish.
# Strip ½” of insulation from the coax and unbraid the shield from both ends the coax hanging out the bottom of the RG62u segment, twisting Coupler (ANT04)
# Gather the strands into a single strand.
# Some breakage shield on either side of the shield strands is unavoidable. center conductor and twist to form two ground leads.
# Remove any broken strands.
# Using Strip the X-acto knife, strip ¼” of center conductor back about ¼" to 3/16”, ensuring that the center conductor has enough insulation to prevent the ground wires from making contact with some margin.
# Solder the center conductor from both ends to the input side of the RG62u segment (ANT15).
preamp (RAD02) and the ground leads to the ground shield on either side of the input line on the PC board
h2. Phasing Loop
# With the needle nose pliers, form Cut a hook section of 90ohm cable to a little over 2 ¾” in length to make the end Phasing Loop (ANT12); Note - the math comes to 2.77456 or about 2 199/256”, but don’t sweat the accuracy... just measure 2 ¾” precisely and add the width of an Xacto knife blade. The more accurately you can make this cut, the higher gain the antenna will have at the desired frequency.
# Strip the cable ¾” back on both of ends and push the insulation back and fish the center conductors conductor out as small as possible, a 1/32” across.
you did before on the RF line.
# Slip a red ring terminal (ANT10) over one Strip back about ¼” from the end of the center conductors. conductor on each end and crimp ring terminals (ANT09) on the ends. The hook should just fit into Use the hole smallest wire rating for this ring terminal that will accept #10 hardware (red jacket). You may wish to put a small loop in the end of the exposed wire before inserting it into the ring terminal (ANT10).
in order to give the crimp more to hold on to.
# Crimp larger ring terminals (yellow jacket) to the ring terminal (ANT10) ground braids.
h2. Preamp Line
# Fabricate Preamp Line (ANT12) by take the antenna assembly which came with the crimper.
SDR (RAD01) and cutting it close to the antenna
# Trim Take the insulation tubes removed from cut end (not the RG62u segment (ANT15) in step 2 into ½”.
# Slip one side of the cable terminated with the MCX connector) and strip ½” of insulation tubes over from the coax and unbraid the shield.
# Gather the shield wires twisted in step 3 on the same either side as of the terminal we just terminated in step 7.
center conductor and twist to form two ground leads.
# Insert a red ring terminal (ANT10) over Strip the exposed twisted shield wire insulated with center conductor back about ¼" to 3/16”, ensuring that the center conductor has enough insulation tube in step 9. to prevent the ground wires from making contact with some margin.
# Allow a small amount Solder the center conductor to the output side of play in the length (the insulation tube should not be tight)
preamp (RAD02) and the ground leads to the ground shield on either side of the output line on the PC board.
h2. Preamp Power Connector
# Crimp Fabricate the ring terminal with power jack (RAD03), by soldering the crimper
red lead to the input side of the preamp (RAD02) voltage regulator to a pre-wired barrel connector . This can be best accomplished by soldering it to the pad labeled L5 on the side closest to IC1, the voltage regulator.
# Cut Solder the antenna line (ANT13) black lead to the ground shield at six inches a convenient point around the outside of the preamp (RAD02) PCB.
This connection scheme will allow any standard power supply with a center positive barrel connector to be used, as the regulator can handle any voltage from 6V to 18VDC. In a pinch, the end power supply can be connected directly to the preamp PCB (RAD02). The expected current draw of the connector and strain relief.
preamp is around 35mA, so a good value for a fuse would be 1/4A, though most “wall wart” power supplies rated at 100mA will fail before then, so there is little point in putting a fuse inline, but plenty of reasons to double check your work.
h2. Assembly
# Use Remove the wire strippers hardware (ANT07, ANT08) connecting the four Aerial Terminals (ANT06) to the Antenna Body (ANT01).
# As you look at the 14ga setting antenna body with the top up and gently strip ¾” from the hole where the wire exits facing you, arrange the antenna line ( ANT13) (ANT11) coax so that the ground shield goes to the right and retain the insulation tube.
# Using center conductor to the dental pick or needle, gently unbraid left. These are somewhat arbitrary, but it is necessary to know where things are in order to connect the shield from phasing loop correctly.
# Connect the stripped end ground of the antenna line (ANT13), twisting them into a single strand.
# Some breakage (ANT11), the ground of the shield strands is unavoidable.
# Remove any broken strands.
# Using ground plane assembly (the conductive thread pigtail), and the X-acto knife, very carefully strip ¼” ground of insulation from one of the exposed center conductor ends of the phasing loop together by stacking the ring terminals on the #10 screw (ANT07). Ensure the antenna line (ANT13).
## Note: If something connector angles toward the antenna line hole in the antenna body, the ground plane ground goes wrong with straight down, and the phasing loop’s angles away from the antenna line (ANT13), you may cut off hole.
# Place the messed up end and retry, beginning ground lug (ANT06) on the screw (ANT07) last with the screw terminal at step 11. the top
# There is enough extra to correct one mistake Insert the screw into the hole in this manner.
# In the event of a second mistake antenna body (ANT01) on the same antenna line, discard right side as viewed with the shortened antenna line and use another beginning at step 10.
hole facing you.
# Slide Tighten the remaining ½” insulation tube over screw securely with a nut (ANT08) on the remaining shield wires inside of the RG62u (ANT15) segment twisted antenna body making sure the ground lug (ANT06) remains in step 3. line with the axis of the antenna body (ANT01) and the ring terminals (ANT09) do not rotate causing strain on the wire crimp connections.
# Trim Do the insulation tube removed from same with the center conductor on the antenna line (ANT11) and the center conductor from the same side as the ground used in the previous steps on the phasing loop (ANT13) bolting them and another ground lug (ANT06) to a length the hole on the left of ½” the antenna body (ANT01) when viewed with the antenna line hole facing you. What this should look like is the antenna line (ANT11) conductors straddle the antenna body (ANT01) on one side, while the phasing loop (ANT13) conductors straddle the antenna body (ANT01) on the other.
# Carefully slide Rotate the insulation tube over antenna body 180 degrees so that the shield strands of the antenna line (ANT13) twisted together hole in step 12. the antenna body (ANT01) is facing away from you
# Insert Take the phasing loop (ANT13) and gently turn it to the right wrapping it around the antenna body (ANT01). Heating it a blue ring terminal (ANT11) over little with a heat gun or placing the exposed twisted shield wires assembly in sunshine may help it the phasing loop proves to be stiff.
# Connect the ground wire on both the phasing loop (ANT13) to the ground lug (ANT06) directly above the antenna line (ANT13) hole and the RG62u segment (ANT15) insulated center conductor to the ground lug (ANT06) in the remaining hole 180 degrees opposite of the antenna line’s exit hole. Tighten as before, making sure the ground lug remains in line with the insulation tubes axis of the antenna body (ANT01) and the ring terminals (ANT09) do not rotate causing strain on the wire crimp connections.
h2. Fabricating and Installing the Aerials
Note, in steps the "GScalc spreadsheet":http://opendesignengine.net/dmsf_files/271?download= the aerials (ANT10) are defined as loops 13.71 inches long.
# Cut two pieces of romex house wiring, leaving at least one piece insulated, to a length of 14 and 16. ¼”.
# Allow Strip off ¼” of insulation on both ends of the insulated arial(s).
# Position a small amount pair of play pliers to grip on the bare wire directly against the insulation, and bend the end 90 degrees. Do the same for the other end, taking care to bent them in the length (the insulation tube should not same direction. To be tight) clear: If the wire is placed on the ground with one stripped end pointing up, the other would be pointing upward also.
# Repeat this process with the second aerial.
# Crimp Take one of the ring terminal aerials between thumb and forefinger clamping with a bit of pressure and pull it through with your other hand in order to curve the crimper wire, As you do so, ensure that the stripped ends end up on the outside of the curve. To be clear: when the wire comes full circle, so that the ends touched, the stripped ends point away from the center of the circle.
# Repeat this process with the second aerial taking care with both to form a smooth arc.
# Partially unscrew the set screws from the Aerial Terminals (ANT06) on the side of the antenna body (not the ground lug mounting screws). Insert a red ring terminal (ANT10) over both the loops into opposite ground lugs and tighten, taking care not to torque the lugs off true. A large amount of torque is not required. If the remaining exposed Aerial Terminals are numbered 1 thru 4, one loop would connect 1 and 3, while the other would connect 2 and 4.
# Once tightened, arrange the loops to be circular and when viewed from the top, cross at the center conductors, on of the antenna body (ANT01) and at right angles.
h2. Installation and Testing
# Secure the ground plane struts (ANT17) to the antenna body (ANT01) with a zip tie or two, making sure the ends are in contact with the Coupler (ANT04) under them and are in line (ANT13) with the antenna body (ANT01).
# Arrange the struts to make the ground plane as flat as possible.
# Thread the preamp output line (ANT12) and preamp (RAD02) through the RG62u segment (ANT15) steel pipe and crimp pipe flange base.
# Without torquing the ring terminal tightly.
preamp, thread the base on the antenna body. At this point you may wish to cover the preamp with electrical tape or heat shrink tubing to insulate it, but any part of the preamp PCB that can touch the sides of the pipe should be a ground anyway.
# Set Gently push the preamp assembly into the base of the pipe.
# Place some rubber or felt feet on the base of the antenna base (ANT03) to keep from scratching paint or furniture.
# Plug the amplifier (RAD02) into a 12VDC source. Current draw should measure about 35mA +/-5mA. If not, inspect the unit aside for integration with damage or poor solder connections.
# Connect the MCX connector on the preamp line (ANT12) to the SDR dongle (RAD01) and tune the SDR software to 900 MHz.
# Using a cordless phone or other 900 MHz source verify that the antenna is receiving and amplifying signals. Further testing of the preamp (RAD02) is out of the scope of the average hobbyist.
Tuning the antenna is a trial and error process, adjusting the length of the aerials (ANT10), phasing loop (ANT013), and distance between the aerials and the ground plane assembly by adjusting the position of the ground plane struts. Remember that larger components and dimensions tune for lower frequencies and smaller components and dimensions tune higher frequencies. Tweaking and replacing parts while observing the effects will allow you to tune the antenna body
!http://opendesignengine.net/dmsf_files/428?download=! !http://opendesignengine.net/dmsf_files/429?download=! and align your GroundSphere satellite ground station to peak performance.
{{toc}}
h2. Introduction
Version 0.2 is the second prototype, which sacrifices some of the flexibility of v0.1 in order to move toward a more polished kit version of the ground station. The overall design is the same between v0.1 and v0.2, but the details and several components have changed. Below are the assembly instructions for v0.2.
h2. Structural Component Pre-assembly The Antenna Base
h3. Tools
* Hacksaw or chop saw
* Sharp knife
* Drill or drill press
* Ruler or caliper
* Pen or pencil
* Optional: The first component to build is the antenna base. Centering jig for drill press
h3. Materials
* 1ea (ANT01) ¾” sched 40 PVC coupler
* 1 ea It is made from plumbing components available at any large hardware store. The diameter and length of ¾” the PVC sched 40 pipe 3” or longer. was chosen to allow the preamp to fit inside the base and give the antenna a weighted base for stability. Makes (ANT02) coupling sections
* 1ea (ANT05) ¾” PVC sched The use of press fit and threaded connections makes the antenna easy to assemble, disassemble, and tune.
1. Screw the schedule 40 to ½” 1/2" NPT male adapter
* 1ea (ANT06) ¾” PVC sched 40 end cap
* PVC cement primer (purple solvent)
* PVC pipe cement
* Optional: PVC safe spray paint in a desirable color. (ANT05) into the base adapter (ANT03).
h3. Safety issues !http://opendesignengine.net/dmsf_files/428?download=! !http://opendesignengine.net/dmsf_files/429?download=!
* Care must be taken when working with powertools, sharp blades, or saws.
* When h2. The Ground Plane
The Ground Plane is sizes using a chop saw, drill, or drill press, eye protection should be worn.
* PVC solvent and cement must be used the dimensions in well ventilated areas.
* Spray paint must be used in a well ventilated area, and should be done in a paint booth or outdoors.
h3. Product or Outcome
All plastic components for the Ground Sphere Mk2 upper structure.
h3. Procedure
"GScalc spreadsheet available here":http://opendesignengine.net/dmsf_files/271?download=.
# Using a chop saw or hack saw, cut 2 sections Cut out round pieces of ¾” PVC sched 40 pipe 1¼” long. conductive fabric (ANT14) and cotton muslin (ANT15) 7” in diameter
# Using Cut out with a sharp knife debur 1” diameter hole in the inside center of the fabric disks (ANT14 and outside ANT15)
# Quilt fabric discs together using conductive thread (ANT18). Ensure all of the sections. quilting threads end at common location near the center opening of the ground plane so that this may be connected to the ground line
# These become coupling sections (ANT02).
# Using Attach a small gauge ring terminal (ANT09) to the PVC cement primer (purple solvent), lightly coat quilting threads with about 2” of slack between the whole outside top of both coupling sections. the ground plane and the crimp
# Without dipping Sew 6 small pockets on the applicator back into muslin side of the primer, lightly coat Ground Plane to create the inside ground plane strut sleeves (ANT16); the pockets should extend from the center of the ¾” PVC sched 40 ground plane disk directly to ½” NPT male adapter. (ANT05). the outer edge at 45 degree intervals like spokes on a wheel
# Without dipping Fabricate the applicator back ground plane supports (ANT17)
## Cut 6 sections of 1/8" steel rod into 3" lengths
## Bend the primer, lightly coat the inside 6 sections of the ¾” PVC sched 40 18" steel rod to 90 degree angles 2" from one end cap (ANT06).
# Lightly coat Insert the inside long side of the unthreaded side Ground Plane Supports (ANT17) into the 6 ground plane strut sleeves (ANT16) on the bottom of the ¾” ground plane assembly
h2. The Antenna Body
The Antenna Body is made from a 6" long section of 1" PVC sched 40 to ½” NPT male adapter (ANT05) with PVC cement.
electrical conduit.
# Quickly insert one Cut a 6" long section of the coupling sections (ANT02) 1" PVC electrical conduit and set aside debur it to cure.
form the antenna body (ANT01);
# Lightly coat Test fit the inside sides Antenna Body (ANT01) into the non-threaded portion of the ¾” PVC sched 40 end cap Coupler (ANT04); ensure it fits fully and snugly
# Temporarily place the ground plane assembly on the antenna body so the support struts (ANT16) are flush against Antenna Body (ANT01) and the Coupler (ANT04).
# Attach the Aerial Terminals (ANT06) with PVC cement.
# Quickly insert ## Take one of the remaining coupling section (ANT02) Aerial Terminals (ANT06) and set aside to cure.
# As accurately as possible drill a 3/16” position it so that the mounting hole is toward the ground plane assembly with the long portion in line with the exact center Antenna Body (ANT01).
## Adjust the distance from the top (screw side) of the side on Aerial Terminal (ANT06) to the ¾” sched 40 PVC coupler (ANT01). The use top of a drill press and centering jig is recommended.
# Rotating the part 180 degrees, drill a 3/16” hole Ground Plane assembly so that it matches the D Plane figure in the exact center "GScalc spreadsheet":http://opendesignengine.net/dmsf_files/271?download=
## Mark the position of the opposite side Aerial Terminal (ANT06) on the ¾” sched 40 PVC coupler Antenna Body (ANT01).
# Rotating
## Draw a line around the part Antenna Body (ANT01) at the position of the first Aerial Terminal (ANT06)
## Along this line mark 3 additional positions 90 degrees, drill degrees apart starting at the first Aerial Terminal (ANT06) mark.
## Drill a 3/16” hole in the exact center each of the ¾” sched 40 PVC coupler (ANT01) between the first two holes. 4 position (a drill press is recommended)
# Rotating the part 180 degrees, drill a ## Drill another 3/16” hole in the exact center ½” below one of the remaining side on mounting holes from the ¾” sched 40 PVC coupler (ANT01).
# The holes should previous step. This will be at for the 12 o’clock, 3 o’clock’ 6 o’clock, RF line (coax) to exit the Antenna Body (ANT01) and 9 o’clock positions when sighting down the ¾” sched 40 PVC coupler (ANT01).
# If it is desirable connect to paint the ground station components, this is a good time to do so. Aerial Terminals (ANT06)
# Set ## Attach the units aside Aerial Terminals (ANT06) at each of the first four holes with #10 nut and bolt (ANT07, ANT08) hand tight. Note - these are temporary connections as these bolts are used for integration with electrical connections in future steps
# Place the antenna body.
h2. Assembling End Cap (ANT05) on top of the Phasing Loop
h3. Tools
* Needle nose pliers
* Wire cutters
* Wire strippers
* X-acto knife
* Terminal crimper
* Ruler Antenna Body (ANT01), but do not secure it with pipe cement or caliper
* Dental pick or needle any other adhesive
h3. Materials h2. Antenna Line
* 3ea (ANT10) Insulated crimp ring terminal Red (22-18 AWG)
* 1ea # Fabricate the Antenna Line (ANT11) Insulated crimp ring terminal Blue (16-14 AWG)
* 1ea (ANT13) by cuttin an arbitrary length of 50 ohm coax cable; Note - the Antenna line, SMA female connector Line should be long enough to pigtail go all the way around the antenna body, down the hole drilled for it, and out the bottom of the antenna body with 3” to spare
* 1ea (ANT15) Tuned length # Carefully strip back 2” of RG62u 90ohm the outer cladding of the coaxial cable
h3. Safety issues
* Care must be taken when working with hand tools, sharp blades, or sharp points.
* Coaxial and gently pull it free without damaging the braided shield below.
# Gently push the braided shield back along the coax cable wires, both toward the center conductor insulation. This will gather and shield wire can easily pierce expand the skin.
* Should braid like a shield wire pierce the skin, remove Chinese finger trap; allow it carefully since it can break off well below to expand.
# Gently widen a gap in the surface side of the skin, requiring painful removal
h3. Product braid near the insulation and fish the center conductor out this hole with a fine screwdriver or Outcome
All radio frequency (RF) components for dental pick, taking care not to unbraid the Ground Sphere Mk2 upper structure.
h3. Procedure
braided shield or breaking wires unnecessarily. Inevitably one or two may break, but this is okay.
# Cut Gently pull the RG62u 90ohm cable (ANT15) braid from the end in order to precisely 2.775”. collapse it back down... help it a bit by smoothing it with your fingers.
## Note: # Gently remove any broken wires from the braid. Once thin and smooth, you may wish to place the RG62u 90ohm cable (ANT15) should already be cut to length. section of coax insulation you previously removed over the exposed coax braid. Without the center conductor in the braid, the insulation will slide over the braid easily protecting and insulating the ground from inadvertent contact.
# Verify Strip back about ¼” from the length.
# Using the X-acto knife, strip ¾” from each end of the RG62u segment (ANT15) center conductor and retain crimp a ring terminal (ANT09) on it. Use the insulation tube. smallest wire rating for this ring terminal that will accept #10 hardware (red jacket). You may wish to put a small loop in the end of the exposed wire before inserting it into the ring terminal in order to give the crimp more to hold on to.
## Note: # Crimp a second ring terminal (ANT09) to the ground side. If something goes wrong For this you will need a larger lug (yellow jacket).
# Slide the ground plane assembly over the bottom of the antenna body with the RG62u segment (ANT15), do not cut off the messed conductive fabric side up end and retry. It is a specific length and must remain so. the struts on the bottom.
# In Thread the event unstripped side of breakage, use another segment the coax through the lower hole in the antenna body from the outside to the inside of the correct length.
antenna body (ANT01), leaving ½” or so and the stripped and crimped ends hang out of the hole.
# Using Mount the dental pick or needle, gently Coupler (ANT04) on the Antenna Body (ANT01). Secure these parts with PVC cement if you wish.
# Strip ½” of insulation from the coax and unbraid the shield from both ends the coax hanging out the bottom of the RG62u segment, twisting Coupler (ANT04)
# Gather the strands into a single strand.
# Some breakage shield on either side of the shield strands is unavoidable. center conductor and twist to form two ground leads.
# Remove any broken strands.
# Using Strip the X-acto knife, strip ¼” of center conductor back about ¼" to 3/16”, ensuring that the center conductor has enough insulation to prevent the ground wires from making contact with some margin.
# Solder the center conductor from both ends to the input side of the RG62u segment (ANT15).
preamp (RAD02) and the ground leads to the ground shield on either side of the input line on the PC board
h2. Phasing Loop
# With the needle nose pliers, form Cut a hook section of 90ohm cable to a little over 2 ¾” in length to make the end Phasing Loop (ANT12); Note - the math comes to 2.77456 or about 2 199/256”, but don’t sweat the accuracy... just measure 2 ¾” precisely and add the width of an Xacto knife blade. The more accurately you can make this cut, the higher gain the antenna will have at the desired frequency.
# Strip the cable ¾” back on both of ends and push the insulation back and fish the center conductors conductor out as small as possible, a 1/32” across.
you did before on the RF line.
# Slip a red ring terminal (ANT10) over one Strip back about ¼” from the end of the center conductors. conductor on each end and crimp ring terminals (ANT09) on the ends. The hook should just fit into Use the hole smallest wire rating for this ring terminal that will accept #10 hardware (red jacket). You may wish to put a small loop in the end of the exposed wire before inserting it into the ring terminal (ANT10).
in order to give the crimp more to hold on to.
# Crimp larger ring terminals (yellow jacket) to the ring terminal (ANT10) ground braids.
h2. Preamp Line
# Fabricate Preamp Line (ANT12) by take the antenna assembly which came with the crimper.
SDR (RAD01) and cutting it close to the antenna
# Trim Take the insulation tubes removed from cut end (not the RG62u segment (ANT15) in step 2 into ½”.
# Slip one side of the cable terminated with the MCX connector) and strip ½” of insulation tubes over from the coax and unbraid the shield.
# Gather the shield wires twisted in step 3 on the same either side as of the terminal we just terminated in step 7.
center conductor and twist to form two ground leads.
# Insert a red ring terminal (ANT10) over Strip the exposed twisted shield wire insulated with center conductor back about ¼" to 3/16”, ensuring that the center conductor has enough insulation tube in step 9. to prevent the ground wires from making contact with some margin.
# Allow a small amount Solder the center conductor to the output side of play in the length (the insulation tube should not be tight)
preamp (RAD02) and the ground leads to the ground shield on either side of the output line on the PC board.
h2. Preamp Power Connector
# Crimp Fabricate the ring terminal with power jack (RAD03), by soldering the crimper
red lead to the input side of the preamp (RAD02) voltage regulator to a pre-wired barrel connector . This can be best accomplished by soldering it to the pad labeled L5 on the side closest to IC1, the voltage regulator.
# Cut Solder the antenna line (ANT13) black lead to the ground shield at six inches a convenient point around the outside of the preamp (RAD02) PCB.
This connection scheme will allow any standard power supply with a center positive barrel connector to be used, as the regulator can handle any voltage from 6V to 18VDC. In a pinch, the end power supply can be connected directly to the preamp PCB (RAD02). The expected current draw of the connector and strain relief.
preamp is around 35mA, so a good value for a fuse would be 1/4A, though most “wall wart” power supplies rated at 100mA will fail before then, so there is little point in putting a fuse inline, but plenty of reasons to double check your work.
h2. Assembly
# Use Remove the wire strippers hardware (ANT07, ANT08) connecting the four Aerial Terminals (ANT06) to the Antenna Body (ANT01).
# As you look at the 14ga setting antenna body with the top up and gently strip ¾” from the hole where the wire exits facing you, arrange the antenna line ( ANT13) (ANT11) coax so that the ground shield goes to the right and retain the insulation tube.
# Using center conductor to the dental pick or needle, gently unbraid left. These are somewhat arbitrary, but it is necessary to know where things are in order to connect the shield from phasing loop correctly.
# Connect the stripped end ground of the antenna line (ANT13), twisting them into a single strand.
# Some breakage (ANT11), the ground of the shield strands is unavoidable.
# Remove any broken strands.
# Using ground plane assembly (the conductive thread pigtail), and the X-acto knife, very carefully strip ¼” ground of insulation from one of the exposed center conductor ends of the phasing loop together by stacking the ring terminals on the #10 screw (ANT07). Ensure the antenna line (ANT13).
## Note: If something connector angles toward the antenna line hole in the antenna body, the ground plane ground goes wrong with straight down, and the phasing loop’s angles away from the antenna line (ANT13), you may cut off hole.
# Place the messed up end and retry, beginning ground lug (ANT06) on the screw (ANT07) last with the screw terminal at step 11. the top
# There is enough extra to correct one mistake Insert the screw into the hole in this manner.
# In the event of a second mistake antenna body (ANT01) on the same antenna line, discard right side as viewed with the shortened antenna line and use another beginning at step 10.
hole facing you.
# Slide Tighten the remaining ½” insulation tube over screw securely with a nut (ANT08) on the remaining shield wires inside of the RG62u (ANT15) segment twisted antenna body making sure the ground lug (ANT06) remains in step 3. line with the axis of the antenna body (ANT01) and the ring terminals (ANT09) do not rotate causing strain on the wire crimp connections.
# Trim Do the insulation tube removed from same with the center conductor on the antenna line (ANT11) and the center conductor from the same side as the ground used in the previous steps on the phasing loop (ANT13) bolting them and another ground lug (ANT06) to a length the hole on the left of ½” the antenna body (ANT01) when viewed with the antenna line hole facing you. What this should look like is the antenna line (ANT11) conductors straddle the antenna body (ANT01) on one side, while the phasing loop (ANT13) conductors straddle the antenna body (ANT01) on the other.
# Carefully slide Rotate the insulation tube over antenna body 180 degrees so that the shield strands of the antenna line (ANT13) twisted together hole in step 12. the antenna body (ANT01) is facing away from you
# Insert Take the phasing loop (ANT13) and gently turn it to the right wrapping it around the antenna body (ANT01). Heating it a blue ring terminal (ANT11) over little with a heat gun or placing the exposed twisted shield wires assembly in sunshine may help it the phasing loop proves to be stiff.
# Connect the ground wire on both the phasing loop (ANT13) to the ground lug (ANT06) directly above the antenna line (ANT13) hole and the RG62u segment (ANT15) insulated center conductor to the ground lug (ANT06) in the remaining hole 180 degrees opposite of the antenna line’s exit hole. Tighten as before, making sure the ground lug remains in line with the insulation tubes axis of the antenna body (ANT01) and the ring terminals (ANT09) do not rotate causing strain on the wire crimp connections.
h2. Fabricating and Installing the Aerials
Note, in steps the "GScalc spreadsheet":http://opendesignengine.net/dmsf_files/271?download= the aerials (ANT10) are defined as loops 13.71 inches long.
# Cut two pieces of romex house wiring, leaving at least one piece insulated, to a length of 14 and 16. ¼”.
# Allow Strip off ¼” of insulation on both ends of the insulated arial(s).
# Position a small amount pair of play pliers to grip on the bare wire directly against the insulation, and bend the end 90 degrees. Do the same for the other end, taking care to bent them in the length (the insulation tube should not same direction. To be tight) clear: If the wire is placed on the ground with one stripped end pointing up, the other would be pointing upward also.
# Repeat this process with the second aerial.
# Crimp Take one of the ring terminal aerials between thumb and forefinger clamping with a bit of pressure and pull it through with your other hand in order to curve the crimper wire, As you do so, ensure that the stripped ends end up on the outside of the curve. To be clear: when the wire comes full circle, so that the ends touched, the stripped ends point away from the center of the circle.
# Repeat this process with the second aerial taking care with both to form a smooth arc.
# Partially unscrew the set screws from the Aerial Terminals (ANT06) on the side of the antenna body (not the ground lug mounting screws). Insert a red ring terminal (ANT10) over both the loops into opposite ground lugs and tighten, taking care not to torque the lugs off true. A large amount of torque is not required. If the remaining exposed Aerial Terminals are numbered 1 thru 4, one loop would connect 1 and 3, while the other would connect 2 and 4.
# Once tightened, arrange the loops to be circular and when viewed from the top, cross at the center conductors, on of the antenna body (ANT01) and at right angles.
h2. Installation and Testing
# Secure the ground plane struts (ANT17) to the antenna body (ANT01) with a zip tie or two, making sure the ends are in contact with the Coupler (ANT04) under them and are in line (ANT13) with the antenna body (ANT01).
# Arrange the struts to make the ground plane as flat as possible.
# Thread the preamp output line (ANT12) and preamp (RAD02) through the RG62u segment (ANT15) steel pipe and crimp pipe flange base.
# Without torquing the ring terminal tightly.
preamp, thread the base on the antenna body. At this point you may wish to cover the preamp with electrical tape or heat shrink tubing to insulate it, but any part of the preamp PCB that can touch the sides of the pipe should be a ground anyway.
# Set Gently push the preamp assembly into the base of the pipe.
# Place some rubber or felt feet on the base of the antenna base (ANT03) to keep from scratching paint or furniture.
# Plug the amplifier (RAD02) into a 12VDC source. Current draw should measure about 35mA +/-5mA. If not, inspect the unit aside for integration with damage or poor solder connections.
# Connect the MCX connector on the preamp line (ANT12) to the SDR dongle (RAD01) and tune the SDR software to 900 MHz.
# Using a cordless phone or other 900 MHz source verify that the antenna is receiving and amplifying signals. Further testing of the preamp (RAD02) is out of the scope of the average hobbyist.
Tuning the antenna is a trial and error process, adjusting the length of the aerials (ANT10), phasing loop (ANT013), and distance between the aerials and the ground plane assembly by adjusting the position of the ground plane struts. Remember that larger components and dimensions tune for lower frequencies and smaller components and dimensions tune higher frequencies. Tweaking and replacing parts while observing the effects will allow you to tune the antenna body
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