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Electrical Layout and Construction Techniques for FRC

Electrical Layout and Construction Techniques for FRC. Overview. Electrical System Major Electrical Components Layout Guidelines Construction Techniques. Electrical System. Major Electrical Components. RoboRio Power Distribution Panel Voltage Regulator Module Pneumatic Control Module

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Electrical Layout and Construction Techniques for FRC

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  1. Electrical Layoutand ConstructionTechniques for FRC FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  2. Overview • Electrical System • Major Electrical Components • Layout Guidelines • Construction Techniques FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  3. Electrical System FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  4. Major Electrical Components • RoboRio • Power Distribution Panel • Voltage Regulator Module • Pneumatic Control Module • New Motor Controllers FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  5. Major Electrical Components • RoboRio • Replaces Crio. • Different footprint with lower profile. • Enclosure is self-isolating. • Integrates functions of Digital Sidecar and Analog Breakout. FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  6. Major Electrical Components • Power Distribution Panel (PDP) • Replaces Power Distribution Board. • Slightly smaller footprint. • Able to read parameters via CAN Bus interface: • Temperature • System Voltage • Output Current per channel FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  7. Major Electrical Components • Voltage Regulator Module (VRM) • Replaces Converter module. • Provides regulated 12V and 5V for: • Wi-Fi Radio/Bridge • Camera (s) • Sensors • Other custom circuits FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  8. Major Electrical Components • Pneumatic Control Module (PCM) • Replaces Solenoid Breakout. • Can have multiple PCM’s in system. • Controlled by RoboRio via CAN Bus interface. • Powers compressor directly, Spike relay not needed. FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  9. Major Electrical Components • New Motor Controllers • Can be used in place of existing Jaguar, Victor and Talon controllers. • More compact. • Integral input power and signal wires. • No fan needed and sealed against debris. • Victor SP • Use like Victor and Talon Controllers. • Talon • Use like Jaguar via CAN Bus interface. FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  10. Layout Guidelines • Layout Considerations and Recommendations • Documentation • Examples FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  11. Layout Guidelines • Layout Considerations and Recommendations • Mechanical Constraints • Documentation • Power Flow • Signal Flow • Avoiding Electrical Noise/Interference • Manufacturability and Serviceability • Review and iterate FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  12. Layout Guidelines • Mechanical Constraints • Allow sufficient space around components for wiring • Use pre-defined “wiring channels” between major components or groups of components • Locate control components away from sources of heat such as large motors and compressor • Eliminate sharp edges that may chafe through wire insulation • Locate Wi-Fi radio/bridge away from large metal parts in a protected area, preferably in the upper structure of the robot • Ensure that components such as the radio/bridge, RoboRio, PDP, VRM, PCM etc. are easily accessible to allow wiring work, modification, repair and verification by Robot Inspectors FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  13. Layout Guidelines • Documentation • Start with the documentation; connection tables or schematic drawing • Enables easy troubleshooting • Enables easy duplication (practice robot) • The documentation methods and tools for the electrical system can easily be adapted to document the pneumatic system • Best to use Google Docs or FIRST provided tools (SolidWorks Electrical or AutoCAD Electrical) that are optimized for electrical drawings • Assign names to wires in tables or schematic drawings FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  14. Layout Guidelines • Power Flow • Follow current paths from the source (battery) to the load (RoboRio, camera, motors, etc.) • Prioritize minimizing the length of the power wiring • Refer to Game Manual to determine wire sizes and colours to use for each connection • Connections between battery, circuit breaker and PDP should use red and black 6 AWG, or larger, wire • Other connections between PDP and loads above 20 A should use red and black 12 AWG or 10 AWG wire • Other connections between PDP and loads of 20 A, or below should use red and black 18 AWG wire • Give priority to minimizing lengths of connections carrying the highest currents • Consider location of motor controllers; longer input wiring vs. longer motor wiring. Usually closer to PDP is best FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  15. Layout Guidelines • Signal Flow • Run signal wires of the same type together where possible (PWM, analog, relay control) • CAN Bus interface wiring is “daisy chained” from the RoboRio to each device in turn, ending at the PDP • Avoiding Electrical Noise/Interference • Avoid grouping signal wires with power wires and running them in parallel, keep them at least 2~3 inches apart • Acceptable for signal wires and power wires to cross at 90° • Try to keep power wires for motors circuits at least 3 inches away from RoboRio and radio/router FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  16. Layout Guidelines • Manufacturability and Serviceability • Determine which components or subsystems will likely need to be serviced or repaired in normal usage • Simplify the design to minimize the need for direct access to verify proper operation • Where possible, use clear panels to allow easy visual inspection of as many systems as possible. Inspectors will appreciate this • Determine how much space would be necessary and the method of access for testing, repairing or replacing a component or sub-system • Where possible, avoid the need to remove other components or subsystems to gain access • Determine what tools would be necessary to gain access to the component or subsystem. Minimize the number of tools and fasteners needed to gain access FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  17. Layout Guidelines • Review and Iterate • Review the design with other team members and mentors, taking into account the design objectives • Typically, the best designs have gone through 3~4 major iterations, each taking different approaches FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  18. Layout Guidelines • Examples • Octanis, the Good and the Bad • Standard Practice in Industry FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  19. Layout Guidelines • Octanis Electronic Panel, bottom view FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  20. Layout Guidelines • Octanis Electronic Panel, bottom view FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  21. Layout Guidelines • Octanis Electronic Panel, close-up view • Digital I/O connection points are inaccessible on Digital Side Car DIO terminals DIO cables FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  22. Construction Techniques • Standard Practice in Industry • Use the correct materials • Use the correct tools for the task at hand • Use the tools correctly • Secure wires, with sufficient slack, to resist vibration and eliminate strain on connections • Wire labels, can also be used for pneumatic circuits • Verify the work, immediately after it is done is CRITICAL to your success on the playing field • The person doing the work checks their work, immediately • A second person checks the work afterward FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  23. Construction Techniques • Check wire size and color requirements in current rules • See “Resources” section for explanation of wire gauge sizes • Can use wires of larger size if connectors allow • For simplicity and ease of stocking, use 3 wire sizes plus PWM cables • Use 10 or 12 AWG for all power wiring (PDP to motor controllers/relays to motors) • Use 16 or 18 AWG wire in colors other than red and black for signal wires • Use 22 AWG wire for low current and signal circuits • Use twisted pair or shielded cable for analog sensor connections to avoid electrical noise/interference FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  24. Construction Techniques • Use the correct tools for the task • Use the correct size and type screwdrivers to avoid stripping screw heads • Use the correct cutters for the wire size for 6 AWG for 10 AWG and smaller for 18 AWG and smaller FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  25. Construction Techniques • Avoid using “adjustable” wire strippers • Will often be set for wrong wire size • Best to use “gauged” or “automatic” wire strippers • Avoids cutting too deep and cutting some of the conductor strands • Many can be set to strip a particular length of insulation off the wire • Easier to train team members to get good results and to be more productive and efficient FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  26. Construction Techniques • Use correct “slot” in jaws to avoid damaging conductors • Start with properly stripped wire. Check each one, every time insulation cut unevenly conductor damaged • Improperly stripped wire • Best to cut it off and start over conductors cut unevenly wire cut at angle FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  27. Construction Techniques • Use the correct lugs for the application • Use the correct size crimp lug for the wire • Red – for 22 ~ 18 AWG • Blue – for 16 ~ 14 AWG • Yellow – for 12 ~ 10 AWG • Use fork-lugs for terminals that already have screws installed, i.e. older motor controller types FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  28. Construction Techniques • Use ring lugs for connections where you install the screw • Up to two lugs can be installed on one terminal FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  29. Construction Techniques • Use the correct (ratcheting) crimpers!!! • It is CRUCIAL to your teams success to do a pull test immediately after each and every crimp to ensure every one is good and reliably holds up over time • A different team member should do a pull test on every crimp afterward for PWM cable contacts for 6AWG lug size color code dots for Anderson contacts FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  30. Construction Techniques • Crimping wires properly • Ensure stripped section of the wire is the correct length • Put the lug into the crimping tool and squeeze tool 1 ~ 2 clicks • Insert wire and start squeezing until tool stops clicking and opens 0.5 ~ 1 mm longer than lug barrel lug, insulation removed • Insert wire and start squeezing until tool stops clicking and opens FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  31. Construction Techniques crimped areas crimped areas • Example of a good crimp • Examples of bad crimps crimped on wire insulation strands sticking out back of lug exposed conductor incomplete crimp conductor too long conductor too short crimp misaligned FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  32. Construction Techniques • Labeling • Use peel and stick wire marker booklets or label printer • Soldering • Not needed often in FRC • Soldering is a manual skill that requires a lot of practice • See tutorial in “Resources” section • If a mentor or student knows how to solder, consider just having them do all the soldering FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  33. Resources • American Wire Gauge (AWG) • https://en.wikipedia.org/wiki/American_wire_gauge • WPI “Wiring the 2015 FRC Control System” • https://wpilib.screenstepslive.com/s/4485/m/24166/l/144971-wiring-the-2015-frc-control-system • Sparkfun “Working With Wire” Tutorial • https://learn.sparkfun.com/tutorials/working-with-wire • FRC 3476, Code Orange, “How To Crimp Wires For FRC” video • www.youtube.com/watch?v=UcOv1a2rK2g • One Tesla, “The Basics of How to Solder” tutorial • http://onetesla.com/tutorials/how-to-solder • Electronics Parts Outlet • Stocks many of the tools describe and linked on next pages • Offers discount on tools and parts to FRC teams • http://epohouston.com FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  34. Resources • Wire marker booklets • http://www.homedepot.com/p/Ideal-Wire-Marker-Booklets-10-Pack-44-102/100118882 • http://www.homedepot.com/p/Ideal-Characters-1-45-10-Pack-Wire-Marker-Booklet-Legend-44-103/100118633 • Wire cutters for smaller wires, 26~18 AWG • http://hansenhobbies.com/products/connectors/tools/cut_fct/ • Wire cutters for larger wires, 26 ~ 10 AWG • http://www.craftsman.com/craftsman-professional-6-in-diagonal-pliers/p-00945762000P?prdNo=47&blockNo=47&blockType=G47 • http://www.oreillyauto.com/site/c/detail/CTI0/86258/N0221.oap?ck=Search_wire+cutter_N0221_-1_850&keyword=wire+cutter&pt=N0221&ppt=C0371 • http://www.harborfreight.com/8-inch-offset-diagonal-cutter-66277.html • Cable cutter for 6 AWG wire • http://www.harborfreight.com/10-in-cable-cutters-61422.html • Automatic wire strippers • http://www.homedepot.com/p/Ideal-Stripmaster-10-22-AWG-Wire-Stripper-45-292/202819657 • http://www.homedepot.com/p/Klein-Tools-Katapult-Wire-Stripper-Cutter-11063W/204660476 FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

  35. Resources • Crimpers for 22 to 10 AWG wires • http://www.andymark.com/product-p/am-2215.htm • www.harborfreight.com/ratcheting-crimping-tool-97420.html • www.fairradio.com/catalog.php?mode=viewitem&item=1689 • http://www.oreillyauto.com/site/c/detail/CTI0/86595/N0221.oap?ck=Search_crimper_N0221_-1_850&keyword=crimper&pt=N0221&ppt=C0371 • Crimper for 6 AWG wires • www.harborfreight.com/hydraulic-wire-crimping-tool-66150.html • http://www.andymark.com/product-p/am-0806.htm • Crimper for PWM cables and CAN wire connectors • http://hansenhobbies.com/products/connectors/tools/crimp_dx/ • http://www.andymark.com/product-p/am-2672.htm • Crimper for 15 A, 30 A & 45 A Anderson Powerpole contacts • http://www.andymark.com/product-p/am-2554.htm • http://www.powerwerx.com/crimping-tools/tricrimp-crimping-powerpole-contacts.html • Hemostat/forceps, “third hand” • http://www.harborfreight.com/5-1-2-locking-clamp.html • http://www.radioshack.com/radioshack-6-curved-forceps/6400065.html FRC 2587 Electrical Layout and Construction Guidelines Rev. 04

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