1. Robot Design Workshop: VEX Hardware & Robot Building Basics Elliot Eid Minnesota BEST Robotics Copyright © 2010 BEST Robotics, Inc. All rights reserved. 1

2. Basics  Only use parts supplied in the consumable and returnable kits, or on the approved optional items list  Do not modify returnable parts  No paint, tape (except non-residue tape), glue, etc. may be placed on these parts  Robot must fit into a two-foot cube (initially) and weigh less than 24 pounds  Arms may extend outside two-foot cube after game starts  All machines will be inspected for compliance prior to competing Copyright © 2010 BEST Robotics, Inc. All rights reserved. 2

3. Servos Controller Analog Motors/ Servos Battery Digital i/o WiFi key USB/Tether Serial Joystick (2) Servo Horns Return Kit Items Copyright © 2010 BEST Robotics, Inc. All rights reserved. 3 (2) Servo Extensions (2) USB A-A cable AAA Battery Charger (4)

4. (2) Motors Drive Components Return Kit Items Copyright © 2010 BEST Robotics, Inc. All rights reserved. 4 Motor Controller (4) Screw Terminal Motor i/f Cable (4) Screw Terminal Sensor i/f Cable (8) 7.2V Battery 7.2V Battery Charger Battery Adapter (2)

5. VEX Cortex Battery Connection Robot Design Workshop 2011 Copyright © 2010 BEST Robotics, Inc. All rights reserved. 5 leave connected here connect/disconnect here

6. VEXnet Control System Copyright © 2010 BEST Robotics, Inc. All rights reserved. 6 VEX Cortex Microcontroller Dual ARM Cortex CPUs Programmable WiFi Radio Technology

7. VEXnet Cortex M3 Controller Copyright © 2010 BEST Robotics, Inc. All rights reserved. 7 System Status Indicators WiFi 802.11 Proprietrary Comm 8 Analog inputs 12 Digital Inputs or Outputs 10 Motor/Servo Ports (Built-In ESC on 2 ports) Standard Serial Interfaces (UART, I2C) Speaker Output

8. VEXnet Joystick Copyright © 2010 BEST Robotics, Inc. All rights reserved. 8 2 XY Analog Joysticks 8 Buttons on Top Plug-in USB/ WiFi Key 4 Buttons on Front-Side Programming Interface  “Playstation” Game-Style Controller 3 Axis Accelerometer (XY Tilt, XYZ Accel, Shake) Power Switch 6 AAA Rechargeable Batteries

9. VEX Cortex Connectors Copyright © 2010 BEST Robotics, Inc. All rights reserved. 9 USB Analog In Digital In/Out 2-wire motor Standard Serial Interfaces (UART, I2C) Speaker Out 1 12 1 8 SP 1212 9 10 2-wire motor 3-wire PWM Servo/Motor Ctrl Gnd (Blk) +5v (Red) Sig (Wht) Sig (Wht) +5v (Red) Gnd (Blk)

10. VEX Cortex Connectors Copyright © 2010 BEST Robotics, Inc. All rights reserved. 10 Backup Battery Port for WiFi Communications (9V) 75MHz Crystal Interface Ports (not used by BEST) On/Off Switch Main Battery Port (7.2V) Configuration Switch (used for special procedures)

11. VEX Cortex Pinouts Copyright © 2010 BEST Robotics, Inc. All rights reserved. 11 Ground + 5V Signal/Control + Battery Power (for + control input) + Battery Power (for – control input)

12. DC Motors  Four Motors are Supplied in the Kit  Two large motors and two small motors  Motors can be used to power wheels, lifting arms or mechanisms, grippers, etc.  Motors may be mounted using the Brackets and Screws supplied in the Consumable Kit. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 12

13. Mounting DC Motors  Use of motor mounting plates to mount the motors is no longer required. HOWEVER, if they are not used when face mounting the small motor, it is easy to damage the internal gear plate. Robot Design Workshop 2012 Copyright © 2010 BEST Robotics, Inc. All rights reserved. 13

14. DC Motors Copyright © 2010 BEST Robotics, Inc. All rights reserved. 14  Four External Motor Controllers Supplied this Year  Connect via 3-wire external motor controller and 2-wire screw terminal cable (red/black)  Use motor ports 2 thru 9 only!  Do NOT Use the Built-In Motor Controllers  Motor ports 1 and 10  Motor amperage may damage circuitry

15. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 15 DC Motors  Servo/Motor Ports are Divided into 2 Banks  Bank 1 = Ports 1 - 5  Bank 2 = Ports 6 – 10  Use only ports 2 – 9  Each bank can support a maximum of 4 amps of current  BEST large motor stall current can reach 3.5 amps  For Power Reasons, Spread Motors among Ports  No more than 2 motors plugged into ports 2 – 5  No more than 2 motors plugged into ports 6 – 9  Otherwise you risk overcurrent and shutdown of the processor  Sheet Metal Shield around the Large Motors IS Needed and Should NOT be Removed

16. DC Motors Copyright © 2010 BEST Robotics, Inc. All rights reserved. 16  Connect Wires to Motor Terminals  Quick-disconnect terminals (Strongly Preferred!)  Solder  Polarity is NOT Marked on Motors: positive (+), negative (-)  Wiring (and Programming) will Determine Clockwise or Counter Clockwise Rotation for Positive Stick Movement  Its recommended that you mount motors using supplied Brackets and 8-32 Machine Screws Machine screws must be cut to proper length to avoid motor damage (use screws supplied in kit)! Max screw depth= ~1/8” (small motor) ~1/4” (large motor)

17. 3-Wire Motor Connection Copyright © 2010 BEST Robotics, Inc. All rights reserved. 17 External Motor Controller Standard 2-wire Motor Cable Standard 3-wire PWM connector Suggest using a 4” wire tie, heat shrink tubing, or RESIDUE FREE painter’s tape here Screw Terminals for attaching motor leads

18. 3-Wire Motor Connection Copyright © 2010 BEST Robotics, Inc. All rights reserved. 18  Connectors are not keyed  Connect red to red, black to black

19. Servos  Servos produce a specified rotational movement when activated  Possible Uses  Activation of micro- switches  Operation of grabber mechanisms  Release of a spring- loaded latch Copyright © 2010 BEST Robotics, Inc. All rights reserved. 19

20. Servos Copyright © 2010 BEST Robotics, Inc. All rights reserved. 20  Futaba S3003 or S3004 Series  Maximum 120 Degree Rotation (+60, -60)  Connection to Cortex Controller  Via 3-wire Servo Power Adapter Cable  Prevents damage to servos  Use motor ports 2 thru 9 only  Servo Horns may be Modified Servo Horns (2) (1) Do not overtighten mounting screws!

21. Example Hookup Copyright © 2010 BEST Robotics, Inc. All rights reserved. 21 Servo Motor Controller DC Motors Battery Motor Screw Terminal Cortex Controller There are 3 things wrong here

22. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 22 Motor/Servo Connectors  Placement of Servo Connectors  VEX motor controller can be placed adjacent to a Futaba servo or extension connector 1)Keyed differently; will work but a tighter fit. 2)Recommend keeping motor controller in a higher numbered port; may lose one servo port due to this.  Futaba servo & extension connectors ARE keyed BUT they will still fit in backwards. Pay attention to the keying and wire orientation (white wire to the inside). 12

23. Digital Input Connections Copyright © 2010 BEST Robotics, Inc. All rights reserved. 23  Use for Limit Switches, Microswitches  Connect to Cortex Digital Inputs using 2-wire Sensor Screw Terminal Cables (white/black wires) Sensor Screw Terminal Cable Connect to Switch Connect to Cortex Digital Input Port

24. Digital Input Connections Copyright © 2010 BEST Robotics, Inc. All rights reserved. 24  Must program Digital Port for proper direction (input)  Open = reads as ‘1’ ; Closed = reads as ‘0’ Use Digital Ports 1 thru 12 Sensor Cable Connector is keyed

25. Analog Input Connections  New last year: POTENTIOMETERS! Robot Design Workshop 2011 Copyright © 2010 BEST Robotics, Inc. All rights reserved. 25 5V Pin Signal Pin Ground Pin Signal Terminal on CK Pot

26. Re-Syncing (Pairing) VEXnet Copyright © 2010 BEST Robotics, Inc. All rights reserved. 26 If VEXnet does not connect, you may need to re-sync the joystick/controller pair by simply connecting a USB cable and powering on both units.

27. Out of the Box Configuration Copyright © 2010 BEST Robotics, Inc. All rights reserved. 27  Cortex Controller comes pre-installed with a default program.  Allows a team to hook up the Cortex and have it work without having to program it.  Referred to as the “BEST default” program.  This is NOT the only configuration for the Cortex!  Good for initial checkout, but we want teams to load a unique configuration.

28. BEST Default Program Motor/Servo Port Joystick Channel Motor Limits Positive Direction Negative Direction Motor 1 (Arcade Right) Channel 1 (Lt, Rt) Channel 2 (Fwd/Rev) None Motor 2Channel 1Digital Input 1Digital Input 2 Motor 3Channel 2Digital Input 3Digital Input 4 Motor 4Channel 3Digital Input 5Digital Input 6 Motor 5Channel 4Digital Input 7Digital Input 8 Motor 6Channel 3None Motor 7Channel 3 InversedNone Motor 8Channel 4None Motor 9Channel 4 InversedNone Motor 10 (Arcade Left) Channel 1 (Lt, Rt) Channel 2 (Fwd/Rev) None Copyright © 2010 BEST Robotics, Inc. All rights reserved. 28

29. BEST Programming Options Copyright © 2010 BEST Robotics, Inc. All rights reserved. 29  Three different programming environments available  easyCv4 http://www.intelitekdownloads.com/easyCV4http://www.intelitekdownloads.com/easyCV4  RobotC http://www.robotc.net/download/cortexhttp://www.robotc.net/download/cortex  Mathworks MATLAB/SIMULINK http://www.mathworks.comhttp://www.mathworks.com  easyC is a block programming environment (similar to software for Lego Mindstorms)  RobotC programs in C with a text editor, but it has runtime debugging (can step through program line by line and see what the results are)  SIMULINK is graphical programming/modeling environment with simulation capability (see what your program will do before you download it to the Cortex)

30.  Direct USB Download Copyright © 2010 BEST Robotics, Inc. All rights reserved. 30 Downloading a Program Uses only the A-A USB cable. Battery is not needed

31. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 31 Testing Tips  Ensure your robot is ‘safe’ to operate:  Can’t move or fall off table (use a jack-stand)  All team members clear of moving parts  Connect either WiFi keys or tether cable between the joystick and the Cortex controller.  Make sure Cortex switch is in OFF position.  Attach a charged battery.  Turn on joystick (if not using tether).  Turn Cortex switch to ON position.  For WiFi comm, link should establish in ~10 sec.  Test robot operations with transmitter.

32. LED Status Lights Copyright © 2010 BEST Robotics, Inc. All rights reserved. 32 Joystick Battery Status Robot Battery Status Communication Link Status Game Status (not used by BEST) Green Battery – good charge Yellow Battery - dying Red Battery – dead Green VEXnet – communication established Yellow VEXnet – searching Lights on the controller and the joystick are the same

33. Team Tips  Use quick-disconnect terminals to attach wires to motor terminals (preferred). If using solder, tin motor wires before attaching to screw terminals since frayed stranded wires can cause a short.  Do NOT solder wires to Cortex connectors!  Sensor cables, servo wires, and servo extensions are all keyed in correct orientation; insert and remove carefully to avoid destroying connectors (pin connectors are very delicate).  Tighten screws on motor and sensor connector cables so that wires are not loose and do not pull out.  Mount Cortex to robot using #8 screws through holes provided; be careful not to over tighten.  Avoid “hot insertion” of USB Keys.  You may operate tethered by removing the USB WiFi key and connecting a USB A-A cable between joystick and Cortex. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 33

34. Joystick Calibration  If the motors hum or creep (sticks not returning to zero), the joystick may need to be recalibrated  Calibration procedure (as extracted from the easyC help file): Copyright © 2010 BEST Robotics, Inc. All rights reserved. 34 1) The Joystick must be "Linked" to the Cortex Microcontroller using the VEXnet Keys. 2) Hold the "6U" Back Switch depressed. 3) While the "6U" Back Switch is depressed, use a small Allen Wrench (1/16" or smaller) or similar small straight tool to depress and hold the CONFIG Switch. 4) Hold both Switches depressed until you see the Joystick LED Flash RED and GREEN - you can now release both Switches. a.There is a 10 second time limit to complete the following steps 5 and 6. 5) Now move both Joystick Pots to the maximum position desired in all 4 directions - Up, Back, Left, and Right. a.If a movement is not detected in all 4 directions, a timeout will occur after about 10 seconds and the Cal Mode will be discontinued and the VEXnet LED will briefly Flash Red. b.The Joystick LED will continue to Flash RED and GREEN during the calibration process. 6) After movement is detected in all 4 directions, the Joystick LED will be ON and Solid GREEN. a.To "Save" the Calibration, depress and release the "8U" Top Switch Button. b.If the calibration is accepted and Saved, the Joystick LED will start Flashing Fast GREEN for a few seconds. c. If the Calibration is not Saved, a timeout will occur after about 10 seconds and the Cal Mode will be discontinued and the VEXnet LED will briefly Flash Red. d.To cancel a calibration, depress and release the "7U" Top Switch Button. The Cal Mode will be discontinued and the VEXnet LED will briefly Flash Red. e.If the Cal Mode is discontinued or saved, the Joystick LEDs will resume their normal function after the VEXnet LED briefly Flashes.

35. Design Basics: Chassis  Use plywood or PVC to create a chassis. Other components will be mounted to the chassis.  Two large motors can be used to power drive wheels. Robot will move forward, backward, or turn by varying relative speed and direction of each motor.  Allow non-drive wheels to pivot to make robot maneuverable. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 35 Chassis (plywood or PVC) Wheels Motors

36. Wheel Attachments  Some proven techniques for mounting drive wheels to motor spindle.  Other techniques can be used. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 36

37. Wheel Size Experiment with size of wheels. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 37 Large wheels: Faster robot More difficult to control Small wheels: Slower robot Easier to control

38. Lifting Mechanisms Many mechanism designs can be created to lift or retrieve objects. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 38 Belt and Pulley Slide and Rail SystemScissors LiftParallel Arm Linkage

39. Linear Drive Mechanism Copyright © 2010 BEST Robotics, Inc. All rights reserved. 39 Rotational motion of motor can be used to create a linear drive using belts and pulleys.

40. Grabbing Mechanisms Simple grabbing mechanism can be operated by a servo, allowing motors to be used for lifting mechanisms. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 40 Servo with Servo Horn Wires attach arms to Servo Horn As Servo rotates, grabber arms open and close Pivot

41. Reminders  Read Generic Kit Notes  Read Generic Game Rules  Read Game-Specific Rules  Re-read all of the above! Copyright © 2010 BEST Robotics, Inc. All rights reserved. 41

42. Copyright © 2010 BEST Robotics, Inc. All rights reserved. 42 Where to find help?  Online documentation (BRI Site)  http://www.bestinc.org http://www.bestinc.org  BEST Public Message Board (for anyone)  http://tech.groups.yahoo.com/group/bestinc/ http://tech.groups.yahoo.com/group/bestinc/  Must register for login account  Share ideas, resolve issues, …  Official Q&A “Control System” Category  http://www.bestinc.org/cgi-bin/bestqna http://www.bestinc.org/cgi-bin/bestqna  Use “Official Q&A” page during contest for “rules specific” questions  Is this legal?  VEX Forum  http://www.vexforum.com/forum.php http://www.vexforum.com/forum.php  Technical questions about VEX equipment  easyC and RobotC dedicated forums included here  Robotevents BEST Forum  http://forum.robotevents.com/forumdisplay.php?f=51 http://forum.robotevents.com/forumdisplay.php?f=51  Dedicated user forum for BEST Robotics  Must register for a login account