Helios-6 Parametric Solar Tracker & KiCad Telemetry Node REV A / CAD + EDA

Involute worm-wheel gimbal synthesis, Spencer 1971 solar position math, Euler-Poincare manifold verifier, and RP2040 + INA219 PCB netlist

Manifold: 6/6 Watertight .kicad_sch .kicad_pcb

Hardware Metrology & Fabrication Readiness

Every parameter change recomputes the involute tooth flanks, rebuilds the 6 watertight triangle meshes in browser memory, checks Euler-Poincare topology, and updates the gimbal pose to track the sun vector.

Worm Reduction & Self-Lock
OpenSCAD WASM Volume Match
Tracker Gain, Selected Day, Clear-Sky Beam Only
Telemetry Node BOM

01 Parametric Synthesis & Ephemeris

Exploded Assembly Stack 0.0 mm offset

0%

Involute Gear & Frame Geometry α = 20 deg

1.50 mm
24 teeth
3.00 mm

Solar Ephemeris (Spencer 1971)

38.9 deg N
Day 172 (Jun 21)
13:30 (13.50 h)

02 3D Parametric CAD Viewport & Kinematics

Az 224.8 deg / El 68.5 deg
Pitch Dia: 36.00 mm | OD: 39.00 mm | Bore: 8.00 mm
Yaw 45 deg / Pitch 35 deg / Scale 1.00x
Drag to orbit, scroll or +/- to zoomSwipe sideways to orbit, use + / - to zoom V=1698 E=5100 F=3400 (Euler χ=0, Watertight)
Wheel Pitch / Outside Dia 36.00 / 39.00 mm Root 32.25 mm | Backlash 0.160 mm
Worm Lead vs Friction Angle 5.71 deg < 9.07 deg Self-locking (margin +3.36 deg, η=37.4%)
Stepper Angular Resolution 0.00469 deg / ustep Az: 38,357 steps | El: 13,547 steps
Printed Part Volumes (PLA) 33.42 cm3 total Base 16.5 / Gear 5.5 / Yoke 11.4 cm3
Assembly Bounding Envelope 59.0 x 47.6 x 76.2 mm Worm center distance: 25.50 mm
Gimbal Pointing Incidence cos(θ) = 1.0000 Pointing error: 0.00 deg (within limits)

03 Stereographic Sky Dome & Yield

δ = +23.44 deg
Active Day Jun 21 Mar 21 Dec 21

Ephemeris & Clear-Sky Beam Yield 14.84 h daylight

Dual-Axis Tracker (Helios-6) 10.92 kWh/m2
Fixed Latitude Tilt (38.9 deg) 7.58 kWh/m2
Fixed Horizontal Surface 7.81 kWh/m2
Equation of Time (Spencer) -1.48 min
Air Mass Attenuation (Meinel) 0.681 beam factor
Solar Noon Peak Altitude 74.54 deg

04 KiCad 8 Telemetry Node (80 x 56 mm, 2-Layer)

RP2040 + INA219

U1 / RP2040 (Raspberry Pi, LCSC C2040)

Dual-core Cortex-M0+ microcontroller, QFN-56. Placed at (32.0, 28.0) mm on F.Cu.

Connected nets: +3V3, GND, VDD_CORE, I2C_SDA, I2C_SCL, STEP_AZ, DIR_AZ, STEP_EL, DIR_EL, LDR_NE..SE, USB_DP/DN

05 BOM, RP2040 Pinout & OpenSCAD Source Inspector

Static cad/helios_gimbal.scad
Ref Qty Value Manufacturer & MPN LCSC Mouser Function / Placement