{"id":145,"date":"2026-04-03T17:40:44","date_gmt":"2026-04-03T17:40:44","guid":{"rendered":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/?page_id=145"},"modified":"2026-11-13T20:31:21","modified_gmt":"2026-11-13T20:31:21","slug":"payload-versions","status":"publish","type":"page","link":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/system-summary\/payload-versions\/","title":{"rendered":"Payload Versions"},"content":{"rendered":"\n

Payload 1.0 – Handle Style<\/h2>\n\n\n\n

The initial iteration of our project, Payload 1.0, features a handheld, handle-style design<\/sup><\/sup><\/sup><\/sup>. It is a modular unit that allows for simple wiring and assembles all the necessary sensors, including a Boson camera<\/sup>. For thermal management, the system utilizes louver and honeycomb heat dissipation structures alongside integrated fans<\/sup><\/sup><\/sup><\/sup><\/sup><\/sup><\/sup><\/sup><\/sup>. This version establishes a wireless connection between the command station and the payload<\/sup>. Internally, the payload is powered by a battery and contains a radio, an Orin and camera capture card, and a radar capture card<\/sup><\/sup><\/sup><\/sup>. The sensor suite includes ZEDX, thermal cameras, and radar<\/sup><\/sup><\/sup><\/sup>.<\/p>\n\n\n\n

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Payload V1.2 – Handle Style<\/h2>\n\n\n\n

Payload V1.2 continues with the handle-style design but introduces several key enhancements for durability and performance during fast motion. We upgraded the camera system by changing to a Boson+ equipped with an environmental enclosure. Additionally, this version features integration with a printed circuit board (PCB) that includes both power and debugging capabilities. To better withstand harsh environments, the design incorporates heat-resistant materials and specialized damping.
( this is the versition aim to integrate with PCB but failed , therefore switvh to the next version)<\/p>\n\n\n\n

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Payload V1.3 – Handle Style (SVD)<\/h2>\n\n\n\n

The V1.3 handle-style payload, also noted as the SVD version, focuses heavily on structural material improvements<\/sup>. Specifically, we switched to using ASA as a heat-resistant material and integrated TPU material to enhance the system’s damping characteristics<\/sup>.<\/p>\n\n\n\n

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Payload V1.4 \u2013 Handle Style (Fall)<\/h2>\n\n\n\n

Payload V1.4 builds on the V1.3 handle-style architecture. It focuses on sensor protection, power distribution, and thermal reliability under sustained load.<\/p>\n\n\n\n

Assembly and testing:<\/strong> The payload was fully assembled, wired, and integrated for system testing. Sealed-enclosure tests with MAC-VIO running showed the SSD stalling and then dropping out under sustained load. To fix this, we added an M.2 SSD heat sink, moved to a higher-capacity battery, and ran the Jetson in its 50 W power mode. With these changes, the payload holds a reliable operating window of about 25\u201330 minutes under the tested conditions.Payload V1.4 – Handheld with thermal resistance<\/p>\n\n\n\n

Sensor protection:<\/strong> The Boson+ thermal cameras sit behind ZnSe protective windows, and the TI radar sits behind an Ultem PEI radome. Bench tests showed that neither material noticeably degrades the thermal image or adds noise to the radar range and Doppler outputs. ZnSe conducts heat well, so an air gap between the window and the camera adds insulation.<\/p>\n\n\n\n

Power box:<\/strong> A redesigned compact power box holds the DC\u2013DC converters, fuses, reverse-voltage protection, and connectors.<\/p>\n\n\n\n

Enclosure:<\/strong> The CAD adds a dedicated radar mounting structure, thermal shielding, and an integrated switch power solution, all inside a compact enclosure.<\/p>\n\n\n\n

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Payload V1.4 CAD design showing the radar mounting structure, thermal shielding, and integrated enclosure layout.<\/figcaption><\/figure>\n\n\n\n
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Assembled Payload V1.4 during integration, showing the internal hardware arrangement and wiring.<\/figcaption><\/figure>\n\n\n\n
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M.2 SSD heat sink installed to improve storage reliability inside the sealed enclosure.<\/figcaption><\/figure>\n\n\n\n

Payload V2.0 \u2013 SCBA Wearable (Fall)<\/h2>\n\n\n\n

Payload V2.0 is a compact, firefighter-wearable unit. It mounts to the harness of a firefighter\u2019s self-contained breathing apparatus (SCBA), so it rides on the firefighter\u2019s chest instead of being carried by hand. The design goals are a small size and low weight, secure mounting, a clear field of view for the sensors, and compatibility with existing firefighter gear.<\/p>\n\n\n\n

Current state:<\/strong> V2.0 currently streams sensor data to the command station. The mounting harness, cable management, and mechanical stability are still being refined for firefighter use.<\/p>\n\n\n\n

Sensors:<\/strong> The front face exposes the thermal camera window and the radar aperture.<\/p>\n\n\n\n

Field demo:<\/strong> The wearable configuration was demonstrated with ACFA instructor Bob Vita.<\/p>\n\n\n\n

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Payload V2.0 wearable enclosure.<\/figcaption><\/figure>\n<\/figure>\n\n\n\n
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Payload V2.0 worn by ACFA instructor Bob Vita.<\/figcaption><\/figure>\n<\/figure>\n\n\n\n

Payloads and Command Station<\/h2>\n\n\n\n

FireSense runs two payloads, and each one works as its own system. Each one connects to the command station on its own, and the command station shows each payload\u2019s thermal view, map, and position separately.<\/p>\n\n\n\n

FireSense Payload 1 (V1.4, handle style) is built around an NVIDIA Jetson AGX Orin. It carries two Boson+ thermal cameras behind ZnSe protective windows, a ZEDX camera that provides the IMU and benchmarking data, and a ZEDX capture card. It also has a TI radar with a TI capture board behind an Ultem PEI radome, a WiFi HaLow STA bridge, and a custom PCB. MAC-VIO runs onboard, and data is recorded to an SSD with an M.2 heat sink. Payload 1 runs in the Jetson\u2019s 50 W power mode, which gives a reliable operating window of about 25\u201330 minutes in a sealed enclosure.<\/p>\n\n\n\n

FireSense Payload 2 (V2.0, SCBA wearable) is a compact unit that mounts to a firefighter\u2019s SCBA harness. It has two Boson+ thermal cameras, a MicroStrain IMU, a TI radar with a capture board, a WiFi HaLow STA bridge, and a PCB. Its connecting cables are wrapped in two heat-resistant layers. Right now, Payload 2 streams sensor data to the command station, and its mounting harness and cable management are still being refined.<\/p>\n\n\n\n

FireSense Command Station uses a WiFi HaLow AP router to receive data from each payload over its own link. It runs the firefighter-facing GUI, built in Foxglove. For the selected payload, the GUI shows a live thermal stream with estimated temperatures, a 3D map with full-map, per-floor, and follow modes, and a 2D floor map built from occupancy mapping.<\/p>\n","protected":false},"excerpt":{"rendered":"

Payload 1.0 – Handle Style The initial iteration of our project, Payload 1.0, features a handheld, handle-style design. It is a modular unit that allows for simple wiring and assembles all the necessary sensors, including a Boson camera. For thermal management, the system utilizes louver and honeycomb heat dissipation structures alongside integrated fans. This version […]<\/p>\n","protected":false},"author":458,"featured_media":0,"parent":2,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"page-with-sidebar","meta":{"footnotes":""},"class_list":["post-145","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/pages\/145","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/users\/458"}],"replies":[{"embeddable":true,"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/comments?post=145"}],"version-history":[{"count":8,"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/pages\/145\/revisions"}],"predecessor-version":[{"id":348,"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/pages\/145\/revisions\/348"}],"up":[{"embeddable":true,"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/pages\/2"}],"wp:attachment":[{"href":"https:\/\/mrsdprojects.ri.cmu.edu\/2026teamf\/wp-json\/wp\/v2\/media?parent=145"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}