How to make our own DLP projector

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Posted by Peter Liu1

on May 24 2012 08:10 AM

Hello,

I am from Huazhong University of Science & Technology,China.our team are concentrating on 3D measure .We decided to make a special DLP projector for our equipment,but we have been faced with some problems.We need your help,the following are the background info.

We choose DLP technology in 3D measurement.We have our own 3D measurement technology and We have used the technology in industrial measurement.(for more details ,you can see the video: http://kejiao.cntv.cn/C24907/classpage/video/20120405/106065.shtml It' s a pity that it is a Chinese video.).Our 3D measurement devices have got the gold medal at Geneva International Exhibition of Inventions.Also,our team has won a second prize in 2011 National Science and Technology Awards in China.As the development of our own 3D measurement technology,we need to make a new projector with faster frame rate, more accuracy light control and flexibility in optics design.That is the reason we choose DLP lightcommder and have purchased a new DLP lightcommder（http://www.ti.com/tool/dlplightcommander）.Recently,We have achieved 3D measurement in a high frame rate.So we decided to use 0.55 XGA Chipset to make our own projector for special needs in our equipment.

The following is our special needs:

1.Use 0.55 XGA Chipset (http://focus.ti.com/paramsearch/docs/parametricsearch.tsp?family=analog&familyId=1746&uiTemplateId=MDLP_PARMSRCH_T)

2.Resolution:1024*768

3.500hz at 8bit gray-scale

4.We don't need RGB lights,we only need a white light LED

5.Interchangeable lens mount (Nikon f-mount)

6.Have a suitable shape for our special shell

After reading the materials (datasheets application notes...) ,we have some problems:

1.If we have developed the hardware successfully,how to download the programs and firmware into the chips and flash?

2.The hardware design is so difficult,could TI give the original PCB（not pdf）to us?So we can develop our instrument more faster and with less risk.

3.Supplement to the first problem:How to download programs into DLPR200?How to download the hex file into the CYPRESS USB control chip?

That is to say:if we face a new hardware,what are the steps to configure the chips?

Look forward to your reply.

All Replies

Posted by Sanjeev

on May 26 2012 22:08 PM

Expert5745 points

Dear Peter Liu,

Welcome to DLP&MEMS forum.

We are more than happy to assist you in this regard. Thank you for considering DLP technology for your 3D measurement application. We are glad to know that you have sucessfully completed proof-of-concept on DLP LightCommander(TM) Kit and moving forward to building your own hardware.

Response to your querries:

After reading the materials (datasheets application notes...) ,we have some problems:

1.If we have developed the hardware successfully,how to download the programs and firmware into the chips and flash?

[Sanjeev] The DLPC200 firmware resides in Serial Flash. To program a blank or corrupt flash we will provide a new DLPC200 firmware .hex file which you can program it via standard PROM programmers. Another good option will be consider putting small FPGA or Microcontroller in your design which can directly interface to DLPC200 configuration Serial Flash. By this approach whenever DLPC200 flash corrupt or is blank on a new board you could easily program it.

2.The hardware design is so difficult,could TI give the original PCB（not pdf）to us?So we can develop our instrument more faster and with less risk.

[Sanjeev] If I understood correctly you are looking for ordering PCB directly instead of building a PCB. Yes this is possible. We have few recongized design house they will be able to help you with building custom boards. I will send you friend request, we can discuss it offline.

3.Supplement to the first problem:How to download programs into DLPR200?How to download the hex file into the CYPRESS USB control chip?

That is to say:if we face a new hardware,what are the steps to configure the chips?

[Sanjeev] We understand the problem you are facing. We already received many queries in this regard. We are working on putting a white paper or appnote on the web. The short response to your question, for the CYPRESS USB control chip we have developed custom program on this chip that will interface to DLPC200. We plan to put the .hex file of this firmware on the web soon. You can use CyConsole program from Cypress program this file on EEPROM.

Regards,

Sanjeev

Posted by Peter Liu1

on May 28 2012 02:43 AM

Prodigy80 points

Hi，Sanjeev

Thanks to your reply,I have understood most of it.But there are still some questions and sths to be comfirmed.

For the first response,there are three devices needed to be configurated.They are Cypress USB controller(51 core),Serial flash(DPLR200,store DLPC200 firmware)and Parallel flash(store DLPC200 config + images),right?

There are somethings to be comfirmed.

1.For Cypress USB controller,TI supplied its hex file.and i have downloaded it(DLP LightCommander Cypress USB firmware),i can download the firmware into the controller by using CyConsole program.The configuration of this chip is finished,right?

2.For Serial flash(DLPR200),it stores the DLPC200's firmware.The firmware has been supplied in the web,named DLP LightCommander DLPC200 Firmware.And it is a bin file(DLPC200_HW1_0_363_MCU2_1_5.bin).We can download it to the Serial Flash by using standard PROM programmers.BTW,could you recommend a PROM programmer to us?if we use microcontroller to do this,Which chip is better?Could TI give us some supports in technology,we wil be glad to use TI's microcontroller.

3.For Parallel flash ,it stores DLPC200 config + images.what is the config means?A batchfile?or sth else?The batch file will be downloaded in the Parallel flash,right? Or if we run the Run batchfile API,then we can build the config in the flash? what are the differences between the images in Parallel Flash and DDR2?

4.As for the PCB,it is the best that we can get the original PCB,so we can buy the chips and design our Optical path.We can build the Projector for our use as fast as possible.We are considering to buy the original PCB file if the price is proper.

At last,my email is liuxingjian1990@gmail.com , we can talk about sth in business(for example:the price of PCB) through the email.

Look forward to your reply.

THx so much!

Peter

Posted by Sanjeev

on Jun 03 2012 01:50 AM

Expert5745 points

Hi Peter,

Sorry for delayed response, I was on business travel.

1. No. Cypress USB controller binary file is yet to be put on the web. We are also thinking if a direct programmable EEPROM file image can generated so that you can directly put it on the EEPROM device without needing use CyConsole tool. So if the programmed EEPROM is put on the board the Cypress USB controller would automatically work.

2. DLPR200 firmware is for uprgade only. For the blank flash part we will put another binary file which ~8MB size. Sure, we can recommend TI microcontrollers for you. Please allow some time for it.

3. Yes config file is 'batch file'. If you open a 'batch file' you would see many register configuration details also the images it referring to. Yes, batch file will be stored into the flash. Ideally there is no difference in the images stored in Parallel Flash and DDR2 memory. Parallel Flash as configuration information in addition to the images. So when DLPC200 start configuring from the parallel flash, it will first configure its internal registers then transfers the images from parallel flash to DDR2 memory.

4. For the pricing details you can contact to TI sales people based in China. Based on your need you can consider building a custom board or use the LightCommander(TM) standard PCB .

Regards,

Sanjeev

Posted by Peter Liu1

on Jun 04 2012 06:40 AM

Prodigy80 points

Hi Sanjeev，

Thanks so much for your reply.

We are desiring to finish the system as quick as possible.Could you give us a method that we can build it up right now?

1.For Cypress USB, we are preparing to use CyConsole tool becaue we have used it in the last project.It will be easier for us.So we have sloved this problem.

2.For a blank DLPR200,how to program it?We can use TI microcontrollers to program the configuration,Could you give us some reference codes in the microcontrollers?Could TI give us a program design as fast as possible?

If we don't use the microcontrollers ,is there another way to program the DLPR200(DLPC200 configuration Serial Flash)?

where is the binary file which ~8MB?Can we download it in the website?

3.For the batchfile,we have some problems.

We have successfully change the frame rate,and other parameters through the batchfile.But we can't change the LED IIIumination time(camera exposure time).

Because if we changed the exposure time,there were so many register's values changing.

But i found the batchfile was created by Texas Instruments DLP Seq Compiler DLL,could TI provide us the DLL and the API? It will help us a lot.

4.As for the board,we will contact the sales in China,but we still want to buy the original file.Could you help us to contact related people?

Best wishes to you!

Peter

Posted by Adam Kunzman

on Jun 05 2012 10:28 AM

Intellectual265 points

Dear Peter,

Our firm has a similar control solution that uses the DLP5500 chipset we call the X3-PM55. You can get some additional detail on it by clicking here. It is backward compatible with LightCommander tools and also supports additional dynamic pattern generation the beyond existing DLPC200 capabilities. We would be happy to discuss possible business solutions with you.

Regards,

Adam Kunzman, Keynote Photonics

Posted by Sanjeev

on Jun 19 2012 18:19 PM

Expert5745 points

Hi Peter,

Here are answers to your questions.

1. OK.

2. I will be putting this shortly on the TI web. Since I have your email id let check if i can share the earlier version for you to try.

3. Unfortunately the DLP Sequence Compiler DLL cannot be shared outside. I suggest you to use the GUI to generate batchfile for different exposure timing and have one big project with several solution in it with each solution having one exposure timing setting.

4. Let me know if you are still waiting for TI China sales response.

Regards,

Sanjeev

Posted by Peter Liu1

on Jun 25 2012 06:22 AM

Prodigy80 points

I'm so sorry to reply to you so late ,because I have a series of classes these days.
Now we are preparing to layout the PCB of the project.

We still have some problems:

1.we don't know how to download the binary file to the DLPR200 and where is the 8MB binary file?

2.since you said the DLP Sequence Compiler DLL cannot be shared outside,we have to use your method,but i hope there is another way better than it.

Posted by Peter Liu1

on Jun 25 2012 06:22 AM

Prodigy80 points

I'm so sorry to reply to you so late ,because I have a series of classes these days.
Now we are preparing to layout the PCB of the project.

We still have some problems:

1.we don't know how to download the binary file to the DLPR200 and where is the 8MB binary file?

2.since you said the DLP Sequence Compiler DLL cannot be shared outside,we have to use your method,but i hope there is another way better than it.

Regards

Peter

Posted by Sanjeev

on Jun 25 2012 09:27 AM

Expert5745 points

Hi Peter,

1. Since it is still in the process of putting on the extranet. I will check here if an early beta version can be released to you. I have your email id with me.

2. Unfortunately that is the only method we have at present. That is build the configuration data from the GUI, create the flash image, put on the flash then use UINT8 DLP_RegIO_InitFromParallelFlashOffset (UINT32 offset, UINT8 reset) to switch between configurations.

Regards,

Sanjeev