Build a Solar-Powered FANET Wind Station (Breezedude Project)

(An Instructable based on the open-source Breezedude Project)

Introduction: Know the Wind, Live from the Launch Site!

For paraglider pilots, drone flyers, and outdoor adventurers, real-time wind data from a remote site is the ultimate safety and planning tool. Commercial stations are pricey and often don't work off-grid. The Breezedude Wind Station is the community-driven, open-source solution.

This project guides you through building a low-power, solar-charged wind station that broadcasts live weather data using FANET. This data is picked up by pilots' instruments and forwarded by ground stations to the Open Glider Network (OGN), appearing on the live Breezedude Map for everyone to see.

While pre-made kits appear occasionally, they sell out fast. This guide focuses on the reliable method: building it yourself from the open-source files.

Estimated cost 180-300$ depending on soldering skills

(more images on the github and breezedude website as well)

1. PCB & Components:
2. https://www.tindie.com/products/29424/
3. (Note: This is a marketplace for small producers and is often out of stock. Ordering the PCB directly via the project's GitHub files is the most reliable alternative.)
4. Sensor:
5. https://www.ecowitt.com/shop/goods_detail?id=38
6. Enclosure:
7. https://www.voelkner.de/products/89390/Spelsberg-Installationsgehaeuse-TK-PC-99-6-o-95x95x60-Polycarbonat-Lichtgrau-RAL-7035-1St..html
8. (Note: This is a German supplier. You can search for the model "Spelsberg TK PC 99-6-o" or a similar IP65-rated enclosure from industrial or electronics suppliers in your region.)
9. 868Mhz Antenna:
10. Description: 868MHz antenna with an SMA connector.
11. Where to find: Search for "868MHz SMA antenna" at general electronics suppliers like Digi-Key, Mouser, or at maker-focused stores like Adafruit or SparkFun.
12. Solar Cell:
13. Description: Small 5V solar panel, approximately 60x60mm.
14. Where to find: Search for "5V solar panel" at maker stores like Adafruit, SparkFun, or from general electronics suppliers.
15. Battery:
16. Description: One 16340 (also known as CR123a size) Li-Ion battery, or a larger 18650 Li-Ion battery for external use.
17. Where to find: Available from specialist battery stores or major electronics component distributors.
18. Cable Glands:
19. Description: PG7 type cable glands.
20. Where to find: Available from most electronics or industrial hardware suppliers.
21. 48mm Pipe Clamps:
22. Description: Two hinged pipe clamps for a 48mm (approx. 1.5-inch) diameter mast.
23. Where to find: Available at general hardware stores, plumbing suppliers, or online industrial suppliers.
24. 15mm x 50cm Aluminum Crossbar Tube:
25. Description: A short aluminum tube with a 15mm outer diameter.
26. Where to find: Available at most hardware stores or metal supply shops.
27. Adapter Plate (3D Print files):
28. https://github.com/breezedude/breezedude-mini
29. Screws:
30. Description: An assortment of M3 screws.
31. Where to find: Available at any local hardware store, home improvement center, or electronics supplier.
32. 48mm PVC Cover Cap:
33. Description: A 48mm (approx. 1.5-inch) friction-fit pipe cap, often called a "lamella plug" or end cap.
34. Where to find: Available at hardware or plumbing supply stores.
35. Mast Pipe:
36. Description: A 6-meter (or desired length) pipe with a 48.3mm outer diameter, typically made of galvanized steel.
37. Where to find: Available at large hardware stores, fencing suppliers, or construction material suppliers.

The first and most important step is to familiarize yourself with the project's home base. All the design files, firmware, and documentation are stored on GitHub.

1. Primary Resource: Go to the official Breezedude GitHub Repository.

This repository contains:

1. Gerber Files: The design files to get the circuit board manufactured.
2. Bill of Materials (BOM): A complete shopping list of every electronic component you'll need.
3. Firmware: The software that runs the station.

Take a moment to browse the repository. You don't need to understand everything, but knowing where to find the files is key.

You can't buy(*) the Breezedude PCB off the shelf, but you can easily have it professionally made.

1. Download the Gerber Files: From the Breezedude GitHub, navigate to the pcb folder and download the latest Gerber file (it will be a .zip file).
2. Choose a PCB Fabricator: Services like JLCPCB or PCBWay are very popular with hobbyists.
3. Upload and Order: Go to one of these sites, click "Order Now" or "Get a Quote," and upload the .zip Gerber file. The default settings are usually fine. The cost to get 5 boards made is often surprisingly low (around $5-10 plus shipping).

(*) Ready made PCB Kits might be available here

With your PCBs on the way, it's time to go shopping for the parts that will bring it to life.

1. The Shopping List: The full list is in the Bill of Materials (BOM) on GitHub. You can buy these individual components from large electronics distributors like Digi-Key or Mouser.

Key Parts to Source:

1. Wind Sensor: The Ecowitt WS85 ultrasonic sensor is highly recommended.

Purchase this directly from Ecowitt's website.

1. Electronics (refer to BOM for exact part numbers):
2. SAMD21 Microcontroller
3. LoRa Module (e.g., RFM95W or SX1262)
4. Pressure Sensor (e.g., BMP280)
5. Capacitors, Resistors, and Connectors

1. Power System:
2. 5V Solar Panel (a small 60x60mm panel works well)
3. 1S Li-Ion Battery (16340 or a larger 18650) and holder

1. Housing & Hardware:
2. IP65-rated Weatherproof Enclosure
3. Mast mounting hardware and waterproof cable glands

This is the most hands-on part of the process. Time to break out the soldering iron!

1. Solder the Components: Using the BOM and the PCB silkscreen as a guide, carefully solder all the surface-mount and through-hole components onto your freshly delivered PCB. Start with the smallest components first.
2. Connect the Antenna: Attach the SMA connector and screw on your 868 MHz antenna.
3. Add the Battery Holder: Solder the battery holder in place.

Now you'll upload the "brain" to the station.

1. Download the Firmware: Go to the Releases section of the Breezedude GitHub and download the latest firmware file (usually a .uf2 file).
2. Enter Bootloader Mode: Connect the station to your computer via USB-C. Quickly double-press the "Reset" button on the PCB. The station should now appear on your computer as a USB drive.
3. Flash the Firmware: Drag and drop the downloaded .uf2 firmware file onto this new USB drive. The device will automatically flash and restart.
4. Configure: Follow the instructions on the GitHub page to create a settings.txt file on the device to input your station's GPS coordinates and altitude.

Let's put it all together and get it outside.

1. Prepare the Enclosure: Drill holes for the sensor's cable gland and mount the solar panel to the lid, sealing any holes.
2. Mount Everything Inside: Secure the completed PCB inside the enclosure. Feed the wind sensor cable through the gland and connect it to the terminals. Connect the solar panel and insert the battery.
3. Deploy! Choose a location with a clear view of the sky and minimal wind obstruction. Securely mount the station and sensor to a mast.
4. Check the Map: After a few minutes, your station should begin transmitting. Go to the Breezedude Live Map, find your location, and enjoy seeing your station report live data to the world