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2. A guide to wiring your robot. Jerry Skene Past mentor – Chantilly Robotics Email: mrskene@chantillyrobotics.org

3. 3 www.chantillyrobotics.org/wiring Presentation available online at:

4. 4 Overview of the major electrical components Agenda

5. 5 Overview of the major electrical components Power Distribution Agenda

6. 6 Overview of the major electrical components Power Distribution Signal Distribution Agenda

7. 7 Overview of the major electrical components Power Distribution Signal Distribution Where to get electrical parts & tools Agenda

8. 8 Overview of the major electrical components Power Distribution Signal Distribution Where to get electrical parts & tools Questions Agenda

9. 9 Overview of Major Components - note some components may change for 2014 season Driver Control System

10. 10 Major Components

11. 11 Major Components Battery & Connector

12. 12 Major Components High Amp Circuit Breaker

13. 13 HIGH – AMP CIRCUIT BREAKER

14. 14 Major Components Power Distribution Panel

15. 15 Major Components Power Distribution Panel Power Distribution Panel - ensures safe distribution of power to various components on your robot ensures safe distribution of power to various components on your robot - supports 20 – 40 amp resettable circuit breakers supports 20 – 40 amp resettable circuit breakers - includes voltage regulators for main processor and camera includes voltage regulators for main processor and camera

16. 16 Power Distribution Module

17. 17 Major Components ROBOT CONTROLLER

18. 18 National Instruments Compact RIO Robot Controller Ethernet to Wifi Radio & cameraAnalog, Digital and Solenoid Interface modules

19. 19 CRIO 400mHz CPU, 64MB/128MB

20. 20 CRIO 400mHz CPU, 64MB/128MB Fixed positions for: (2) Analog modules – can read potentiometer input

21. 21 CRIO 400mHz CPU, 64MB/128MB Fixed positions for: (2) Analog modules – can read potentiometer input (2) Digital Modules – input and output modes: Input - reads switches, digital sensors, etc. Output - turns on/off relays, lights, etc. - controls motor speed controllers

22. 22 CRIO 400mHz CPU, 64MB/128MB Fixed positions for: (2) Analog modules – can read potentiometer input (2) Digital Modules – input and output modes: Input - reads switches, digital sensors, etc. Output - turns on/off relays, lights, etc. - controls motor speed controllers (1) Pneumatic Module - connects to pneumatic solenoids

23. 23 CRIO 400mHz CPU, 64MB/128MB Fixed positions for: (2) Analog modules – can read potentiometer input (2) Digital Modules – input and output modes: Input - reads switches, digital sensors, etc. Output - turns on/off relays, lights, etc. - controls motor speed controllers (1) Pneumatic Module - connects to pneumatic solenoids (2) Ethernet ports (1) serial port (console) 24v power

24. 24 Major Components Analog Module

25. 25 Requires analog header plug

26. Analog Module 26 Requires analog header plug Uses 3-wire PWM cable

27. Analog Module 27 Requires analog header plug Uses 3-wire PWM cable Can measure robot’s battery voltage

28. Analog Module 28 Requires analog header plug Uses 3-wire PWM cable Can measure robot’s battery voltage can measure analog voltage from various sensors, such as a potentiometer or a rangefinder

29. 29 Major Components Digital Sidecar

30. 30 Digital Sidecar Used to connect digital devices to cRio processor

31. 31 Digital Sidecar Used to connect digital devices to cRio processor Gets 12V from Power Distribution panel

32. 32 Digital Sidecar Used to connect digital devices to cRio processor Gets 12V from Power Distribution panel DB-37 cable to cRIO

33. 33 Digital Sidecar Used to connect digital devices to cRio processor Gets 12V from Power Distribution panel DB-37 cable to cRIO (10) PWM outputs for motor controllers –Jumper for servo use

34. 34 Digital Sidecar Used to connect digital devices to cRio processor Gets 12V from Power Distribution panel DB-37 cable to cRIO (10) PWM outputs for motor controllers –Jumper for servo use (14) Digital IO (GPIO)

35. 35 Digital Sidecar Used to connect digital devices to cRio processor Gets 12V from Power Distribution panel DB-37 cable to cRIO (10) PWM outputs for motor controllers –Jumper for servo use (14) Digital IO (GPIO) (8) Relays

36. 36 Digital Sidecar Used to connect digital devices to cRio processor Gets 12V from Power Distribution panel DB-37 cable to cRIO (10) PWM outputs for motor controllers –Jumper for servo use (14) Digital IO (GPIO) (8) Relays Power status LEDs 5v, 6v, 12v

37. 37 Solenoid Breakout Major Components

38. Solenoid Breakout 38 Used to connect to higher power devices, such as pneumatic solenoid control valves

39. 39 Major Components VICTOR & JAGUAR SPEED CONTROLLERS

40. 40

41. 41 Jaguar Motor Speed Controller Converts signal from CRIO/Sidecar to power motors

42. 42 Jaguar Motor Speed Controller Converts signal from CRIO/Sidecar to power motors Limit switch inputs (forward/reverse)

43. 43 Jaguar Motor Speed Controller Converts signal from CRIO/Sidecar to power motors Limit switch inputs (forward/reverse) Coast/Brake (jumper or DIO)

44. 44 Jaguar Motor Speed Controller Converts signal from CRIO/Sidecar to power motors Limit switch inputs (forward/reverse) Coast/Brake (jumper or DIO) Slow flashing Yellow LED indicates no valid pwm signal

45. 45 Jaguar Motor Speed Controller Converts signal from CRIO/Sidecar to power motors Limit switch inputs (forward/reverse) Coast/Brake (jumper or DIO) Slow flashing Yellow LED indicates no valid pwm signal Slow flashing Red LED indicates limit switch, over temp/current, or under voltage <6V

46. 46 Jaguar Motor Speed Controller Converts signal from CRIO/Sidecar to power motors Limit switch inputs (forward/reverse) Coast/Brake (jumper or DIO) Slow flashing Yellow LED indicates no valid pwm signal Slow flashing Red LED indicates limit switch, over temp/current, or under voltage <6V Over-current protection can cause motors to cut out in pushing matches

47. 47 Major Components VIDEO CAMERA

48. 48 Axis M10112 Network Camera Ethernet Web-ready camera Requires special crossover cable (orange) Fixed focus Reset button on back Use “Setup Axis Camera” on PC to configure it for FRC competition use !!! Isolate this from the chassis (older Axis camera)

49. 49 Major Components RELAYS (SPIKES)

50. 50 Spike: - allows the cRIO to turn a motor or other high current load on/off

51. 51 Major Components WIRELESS BRIDGE

52. 52 Wireless Bridge -Allows wifi communications between the driver station and the robot -Must not be used in pit area during competition: use Ethernet cat5 tether cable instead

53. 53 Driver Station Provides remote control interface to cRIO Major Components

54. 54 Joysticks and controllers Two are provided in the Kit of Parts (KOP) any USB-based controller may be used: Xbox, etc.

55. 55 Connections & polarities – what goes where Power Distribution

56. 56 Connections & polarities – what goes where Legal wire gauge and color Power Distribution

57. 57 Connections & polarities – what goes where Legal wire gauge and color How to make reliable connections Power Distribution

58. 58 Power Distribution Battery: +12 volts: - RED wire: 6 AWG from battery to hi-amp breaker to power distribution panel GND: - BLACK or BLUE wire : 6 AWG from battery to hi-amp breaker to power distribution panel

59. 59 Other power connections: - use 12 AWG or larger diameter wire for all circuits protected by a 40A Circuit Breaker. Power Distribution

60. 60 Other power connections: - use 12 AWG or larger diameter wire for all circuits protected by a 40A Circuit Breaker. - use 14 AWG or larger diameter wire for all circuits protected by a 30A Circuit Breaker. Power Distribution

61. 61 Power Distribution Other power connections: - use 12 AWG or larger diameter wire for all circuits protected by a 40A Circuit Breaker. - use 14 AWG or larger diameter wire for all circuits protected by a 30A Circuit Breaker. - use 18 AWG or larger diameter wire for all circuits protected by a 20A Circuit Breaker.

62. 62 Power Distribution Power Distribution Panel Wireless Bridge Mobile Device Controller Digital Sidecar Camera Hi-amp Circuit Breaker Victor Motor Controller

63. 63 How to make reliable crimp connections: –Use a ratchet-type crimping tool on crimp connections: Power Distribution YES (Eclipse crimpers or equivalent) NO

64. 64 Simply strip wire and push into connector – do not tin wire first Power Distribution – WAGO connectors

65. 65 SIGNAL DISTRIBUTION Digital I/O & PWM motor control signals come from the Digital Sidecar

66. 66 Use 3-wire cables to connect PWM port on Robot Controller to Victor Speed controller Signal Distribution You can buy extras at InnovationFirst.com or robotmarketplace.com

67. 67 Try to keep your wiring neat – it will save you time! Compliments to Dave Lavery - Team 116

68. 68 Robotic Sensors

69. 69 Robotic Sensors Detect information about the physical world What do they do?

70. 70 Robotic Sensors Detect information about the physical world Convert this information into an electrical signal suitable for the robot’s computer controller What do they do?

71. 71 Robotic Sensors Simple Switch for sensing physical contact: Function: Consists of two electrical contacts – they make or break a connection when the switch is activated

72. 72 Robotic Sensors Optical Sensor for physical presence: interrupted & reflected type are available Function: Consists of light source (LED) and light detector (photocell); can sense by interruption or reflection of beam Optical Interrupter Optical Reflector

73. 73 Robotic Sensors Purpose: Measures distance to an object via infrared emitter/detector combo IR rangefinder

74. 74 Robotic Sensors Ultrasonic Rangefinder Function: Measures distance to an object by means of ultrasonic sound bursts, or pings

75. 75 Robotic Sensors Potentiometer Function: Measures rotary input, outputs an analog value

76. 76 Robotic Sensors Rotary or shaft encoder Purpose: For precisely measuring shaft angle using a light source (LED) and light detector (photocell) with an encoder disc Rotary Encoder Encoder Disc, read by optical sensors inside decoder

77. 77 Some recommended sources: –andymark.com – servos, PWM cables, Talon controller, crimp tool, etc. –Waytekwire.com – wire, etc. –Mouser.com –Allelectronics.com –Digikey.com – Jaguars, sensors, etc. –Sparkfun.com –Robotmarketplace.com Where to get electrical parts

78. 78 Some recommended sources: –www.Chiefdelphi.comwww.Chiefdelphi.com Unofficial source for information on all robotics topics –www.Forums.usfirst.orgwww.Forums.usfirst.org Official source Where to get answers:

79. 79 Questions ??? ? ? ? ? ? ? ? ? ? Some images borrowed from Cybersonics, Team 103

80. 80 Thank you. www.chantillyrobotics.org/wiring

81. 81 END

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