The Welcome To Nigeria Challenge was conceived to give Nigeria’s busiest airport a much-needed emotional touch. After the first round, one team was selected by the judges to develop their concept, named Super Display into a full-fledged product. In order to design a physical interface that lists ‘Welcome’ in every Nigerian language, the interface would need to be clearly visible from a distance and may incorporate other signals (such as audio, etc) as it would be displayed in Nigerian international airports or other locations. The product should also have the ability to be updated with new languages.
This documentation provides the instructions for anyone to build a Super Display of their own. It is licensed CC BY-SA 4.0; attribution should be made to the team members as well as Hardware Things.
|WTN-M001||40mm Aluminum Angle bar (1 qt = 18ft)||1.36||Buy|
|WTN-M002||Fabricated Parts||27||Make (3D Printing)|
|WTN-M004||Mesh Adhesive Tape||1||Buy|
|WTN-M005||M2.5 Cross Head 14mm||108||Buy|
|WTN-M006||M3 Cross Head 8mm||52||Buy|
|WTN-M007||M4 x32 Anchor Drywall Screw||8||Buy|
|WTN-M008||M3 Acrylic (Bolt & Nut)||4||Buy|
|WTN-E001||80mm PWM Fan||2||Buy|
|WTN-E002||9V 30A SMPS||1||Buy|
|WTN-E003||P5 RGB matrix display||20||Buy|
|WTN-E005||300w bulk converter||5||Buy|
|WTN-E006||18650 battery pack||2||Buy (from local assembler)|
|WTN-E007||BMS 2S 40A||2||Buy|
|WTN-E008||5v 2A buck converter||1||Buy|
|WTN-E011||DF Mini MP3 Player||1||Buy|
|WTN-E012||Soldering Lead 60/40 Size||1||Buy|
|Pin headers (female and male), Resistors (1k and 10k), Terminal Blocks (2, 6, and 8 pins), Tip 41c transistor.|
NOTE: While the product can be built with the PCB file attached above, the current version does not use this. It uses the ESP 32 for its control. We describe how the PCB may be used in the Extensions section.
To make the frame you will need the following aluminium parts (see the mechanical design files), note that the last two are assembly hardware:
|S1, S2||1 of each||[324x40x40mm]|
|T1, T2, T7, T8||1 of each||[802x40x40mm]|
|T3, T5, T4, T8||1 of each||[800x40x40mm]|
|J1, J2, J3, J4||1 of each||[40x40x40mm]|
|M2.5 Cross Head 14mm||108||see BOM|
|M3 Cross Head 8mm||52||see BOM|
Use LINK to fasten T3 to T1, then T5 to T3, then T7 to T5, then T4 to T2, then T6 to T4, and T8 to T6. See Figures 3 and 4 for layout.
Next, Use J1 to fasten S1 to T1, then use J2 to fasten S1 & T2, then use J3 to fasten T7 to S2, then use J4 to fasten T8 to S2, and use M1 to brace T3, T5, T4, & T6 together. See Figure 5 for the layout and Figures 6 and 7 for the assembly process.
- Fabrication of the display frame will require 24.41ft of 40mm Aluminum angle.
- Holes in some 3D printed parts may not fit accurately. Print without holes, drill after.
- The Aluminum angles available locally are in several colloquially named variants. Use parts with 2mm thickness (see Figure 8 below). Thicker ones are heavier, and may overload the mount.
Assembling the display requires 9 bulk to display mounts. Each mount requires three 3D printed parts (see Mechanical Design files for this) as shown below. 2 DP1 parts are requires, while 1 DP2 part is also required.
To assemble one bulk to display mount, join two DP1 parts together and then fit DP2 on, as shown below in Figure 10.
After that, use the assembled mount pieces to fasten the P5 Matrix LED panels together as shown in the Figure 11 animation.
To make the battery pack you will need the following parts:
|P5 LED matrix display||20|
|300w bulk converter||5|
|4mm wire cable||5 yards|
Take the following steps:
Figure 12 also shows the electronic connection when completed.
The battery is made of 96 2200mAh 18650 lithium ion cells made into two battery packs (48 cells each) 6 by 8 configuration. Each battery pack is connected to 40 Amps 2s BMS. The battery packs are charged with a 9V 30 Amps power supply. To make the battery pack you need the following:
|18650 2200mAh lithium ion cells||96|
|18650 combination bracket||96|
|0.15x8mm nickel strip||10 meters|
|40A 2s BMS||2|
|4mm wire cable|
Take the following steps to make the battery pack:
Interlock the 18650 combination bracket to form two 6 by 8 boxes.
Arrange 48 cells on each box as shown below.
Connect the battery together (2s 24p) with the spot welder and the nickel stripe (see Figure 14).
Connect the battery packs to the bms according to the diagram below.
Cut the insulating pad and attach to the battery packs top and bottom.
The HD 2020 software (see tutorial for more guidance) is used to design and program the screen display. The software has many features which enable graphics, animated characters, time and date settings, countdowns, U disk export and more.
Method: Click File -> New Display, and the setting dialog box pops up.
The control card already has the correct parameters (normal display text), create a new display screen, click OK, and complete the establishment of a display screen and a program. If the control card does not have the correct parameters (i.e., the text is not displayed normally), select the device, select the color, set the width, height, and gray level; then click to enter the hardware setting interface and set the display point method of the display, that is, commonly used smart settings such as: network cable, serial cable, or Wi-Fi for intelligent settings. Wi-Fi was used for Super Display.
Method: After selecting the program, click on the graphic, text, time, timing, counting, temperature and humidity, animated characters, Chinese calendar, etc. to create different types of partitions.
When the Wi-Fi card is connected, first connect the Wi-Fi signal sent by the control card (requires a computer with a wireless network card, if using a desktop computer, be sure to purchase a wireless network card; generally a laptop with a wireless network card is preferred).When connecting to a Wi-Fi signal, the default password is “88888888”. If you connect with the HD 2020 software, you need to enter the password of “88888888”, Click Connect, and the default password can also be modified. Once Wi-Fi is connected, the device can be found in the software. The information window will appear on the online bar of the control card and other information.
The text can be updated via wifi (mobile or PC) or physical flash drive. The app required for the mobile control is called LedArt, this application has the ability to switch programs, change text, increase and decrease brightness of the super display wirelessly. The app required for PC control is the HD2020, the app gives the user the ability to fully control the display both wirelessly and through a flashdrive.
For text-only content display, we use text areas to meet the requirements. The text supports left rotation, right rotation, and reverse. The table was customized, borders, and background were added.
The steps to change the text are:
To change the language:
To change the graphics on the display the new design can be uploaded wirelessly or via usb through the PC application. There was an instance where we wanted to display pictures instead of text. We took the following steps:
A custom PCB extension is available to wirelessly monitor the battery voltage and current consumption in real time. The board has 5 voltage sensors (voltage divider) that measures the voltage at each bulk converter and the battery and displayed on a localhost web server, the pcb is controlled by an ESP 32 microcontroller. To access the webserver connect the ESP 32 to your computer and open a serial port, copy the link and paste in your browser to view the life data.
The LED controller used is the WF2 LED controller which has the ability to display current time and date (CMOS) and this can be included in programs sent via the mobile or PC application. The time display on the display is similar to text and graphics. The steps are as follows:
An extension for the super display includes 5 voltage sensors to measure the voltage at bulk converters, current sensor to measure the display’s total current consumption, a PIR sensor to measure human proximity, an mp3 module and a speaker to send a verbal message, a temperature sensor to measure the device temperature and a 4 DC fans for cooling. The entire board is powered by an esp32 microcontroller and all measured data is displayed on a localhost webpage.
To use the electronic extension above, you’d need the elec. to disp. mount (see Mechanical Design files). Each mount requires three 3D printed parts.