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! Certification process 1. 2. 3. 4. Attend training session Study supplied materials Take written exam Interview with electrical mentor and demonstrate proper wiring technique 5. Receive cool skill badge upon successful completion! 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 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 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 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 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 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 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 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 cRIO NI 9403 module 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 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 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 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 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 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 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 Electrical Power Diagram Electrical Signal Diagram Wiring 101 1. Use the correct wire gauge for the load 2. Determine the routing path prior to measuring and cutting the wire to length plus some extra 3. Crimp and mount the wire on the component side first, using a lock washer 4. Route the wire back to the Power Distribution Board using tie-downs along the way 5. Cut the wire to the final length 6. Crimp a ferrule on the end of the wire and insert it into the appropriate Wago connector 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) Wire routing examples Ad hoc Planned Example pictures taken from Team 2338 cable management guide Crimping for success 1. 2. 3. 4. 5. 6. 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 Crimping tools Ratcheting crimper for insulated connectors Self adjusting crimper for wire ferrules Wire strippers Used for medium/large gauge wire Used for small gauge wire Anatomy of a good crimp Measuring crimp resistance Use Ohms Law to calculate the resistance of a crimped connection 1. Apply 5 - 10 amps through the wire 2. Measure the voltage across the crimp 3. Use V / I to calculate the resistance Ohms Law Formula Wheel