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CV Robotics Team 955

CV Robotics Team 955. Electrical Team Certification. Jamie Moore 2013. Why do we need a certification?. Many students are new to electrical work and need some help getting started Provides a standard way of doing things Wiring failures are a leading cause of dead robots and lost matches!.

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CV Robotics Team 955

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  1. CV Robotics Team 955 Electrical Team Certification Jamie Moore 2013

  2. Why do we need a certification? • Many students are new to electrical work and need some help getting started • Provides a standard way of doing things • Wiring failures are a leading cause of dead robots and lost matches!

  3. Certification process • Attend training session • Study supplied materials • Take written exam • Interview with electrical mentor and demonstrate proper wiring technique • Receive cool skill badge upon successful completion!

  4. Certification goals Be able to • Identify and describe the main electrical components used on the robot • Read and follow an electrical diagram • Properly wire components for safe, reliable operation

  5. 12V SLA Rechargeable Battery • Features • 18 Ah capacity • 150A max rated output • Rechargeable up to 250 times • Sealed lead acid chemistry • Can be used in any position • 3-5 year life expectancy The 12V SLA Rechargeable Battery is the sole source of electrical power for the robot

  6. Main Circuit Breaker • Features • 120A protection rating • Integrated switch • Insulated terminal caps The Main Circuit Breaker protects the entire electrical system and acts as the master power switch

  7. Power Distribution Board • Features • 8 40A protected outputs • 12 30A protected outputs • 24V 1.5A power supply • 12V 2A power supply • 5V 3A power supply • Reverse battery protection • Wago terminal blocks The Power Distribution Board supplies protected power from the battery to all the other electrical components

  8. cRIO-FRC II Controller • Features • Reconfigurable via plug-in modules • Built in Ethernet and serial ports • 400 MHz processor, 128 MB ram • Spartan 6 LX45 FPGA • 256 MB disk storage The cRIO-FRC II is a real time embedded controller chassis that runs the robot software and controls all of the I/O

  9. Analog Breakout Module • Features • 2 – 20 VDC input • 5V 0.25A supply for sensors • Standard 3 pin interface • Interfaces with NI 9201 The Analog Breakout Module is used to wire analog sensors to the cRIO NI 9201 module and to monitor the battery voltage

  10. Solenoid Breakout Module • Features • 6 – 30 VDC input • Interfaces with NI 9472 • Reverse polarity protection The Solenoid Breakout Module is used to wire pneumatic solenoid valves to the cRIO NI 9472 module

  11. Digital Sidecar • Features • 10 PWM outputs • 14 general purpose I/O • 16 relay outputs • Robot signal light header • 5V/3A power supply • Interfaces with NI 9403 • Reverse-battery protection The Digital Sidecar is a digital I/O breakout module for the cRIONI 9403 module

  12. Robot Signal Light • Features • Bright, wide angle • Panel mount The Robot Signal Light is used to indicate the status of the robot and is a required safety feature

  13. Talon Motor Controller • Features • PWM input • 60 amp rating • Small footprint • Passive cooling • Linear response • Simple calibration • Smart status indicator The Talon provides bidirectional speed control of CIM drive motors

  14. CIM Brushed DC Motor • Features • 12V DC • 5310 RPM • 343 oz-in torque • 375 Watts • 133 Amp stall current Multiple CIM DC motors are used to power the robot drive system

  15. Spike H-Bridge Relay • Features • 20 amp rating • Bidirectional control • Simple digital interface • Small footprint The Spike H-Bridge Relay provides bidirectional control of small motors such as an air compressor

  16. 5V Power Converter • Features • 5V @ 5A output • Overload protected • High efficiency (90%) • Integrated heat sink The 5V Power Converter is used to generate the power needed for the D-Link Wireless Bridge

  17. D-Link Wireless Bridge • Features • 2.4 and 5 GHz bands • Ethernet 10/100T base • Wireless access point The D-Link Wireless Bridge provides a communication link between the driver station and the robot

  18. Axis M1013 Network Camera • Features • 800 x 600 max resolution • 67 degree field of view • Adjustable focus • Video compression The Axis M1013 Network camera provides a live compressed video stream from the robot

  19. Electrical Power Diagram

  20. Electrical Signal Diagram

  21. Wiring 101 • Use the correct wire gauge for the load • Determine the routing path prior to measuring and cutting the wire to length plus some extra • Crimp and mount the wire on the component side first, using a lock washer • Route the wire back to the Power Distribution Board using tie-downs along the way • Cut the wire to the final length • Crimp a ferrule on the end of the wire and insert it into the appropriate Wago connector

  22. Selecting the correct wire gauge • Refer to FRC rules for wire gauge and color • Only three gauges typically needed • 6 gauge for up to 100 Amps • Battery connections • Main circuit breaker • 12 gauge for up to 40 Amps • Motor controller • Spike relay • 18 gauge for up to 20 Amps • Everything else (except PWM cables)

  23. Wire routing examples Ad hoc Planned Example pictures taken from Team 2338 cable management guide

  24. Crimping for success • Use the right tool for the job • Match the connector size to the wire gauge • Strip off the correct length of insulation • Crimp connector with ratcheting crimp tool • Test the crimp for mechanical strength • Test the crimp for electrical resistance

  25. Crimping tools Self adjusting crimper for wire ferrules Ratcheting crimper for insulated connectors

  26. Wire strippers Used for medium/large gauge wire Used for small gauge wire

  27. Anatomy of a good crimp

  28. Measuring crimp resistance Use Ohms Law to calculate the resistance of a crimped connection Apply 5 - 10 amps through the wire Measure the voltage across the crimp Use V / I to calculate the resistance Ohms Law Formula Wheel

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