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2009 Control System Workshop

2009 Control System Workshop . January 10, 2009 Farmingdale State College SPBLI - FIRST. Mark McLeod Advisor Hauppauge Team 358 Northrop Grumman Corp. Mark.McLeod@ngc.com. Agenda. FIRST Control System Overview Team Assembly Benchtest Firmware Updates Wireless Setup Re-Benchtest

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2009 Control System Workshop

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  1. 2009 Control System Workshop January 10, 2009 Farmingdale State College SPBLI - FIRST Mark McLeod Advisor Hauppauge Team 358 Northrop Grumman Corp. Mark.McLeod@ngc.com

  2. Agenda • FIRST Control System Overview • Team Assembly • Benchtest • Firmware Updates • Wireless Setup • Re-Benchtest • Download Programs & Test

  3. FIRST Control System

  4. Hardware Gather around demo robot • Driver • Driver Station (DS) • Router (for non-competition use only) • Disable/Enable Competition Port switch • Joysticks (HID compatible only) • Robot • cRIO • Bumpers (Analog, Pneumatic) • Digital Sidecar • Power Distribution Panel (PD) • Wireless Bridge • Jaguar (or Victor) Speed Controllers • Spike (primarily for compressor or other motors)

  5. cRIO • 400mHz, 64MB/128MB • Fixed positions for: • (2) Analog modules • (2) Digital Modules • (1) Pneumatic Module • (2) Ethernet ports • (1) serial port (console) • 24v power

  6. Driver Station (DS) • 50Hz update rate • (4) USB ports-joysticks • (2) Ethernet ports • (1) Competition Port • (8) Digital Inputs • (4) Analog Inputs • (8) Digital Outputs • Auto/Teleop toggle • No hot-swapping joysticks • Joysticks must be centered at bootup • Will run off 9v batteries Dongle • MUST be attached for DS to run • Connects pin 8 to 9

  7. Power Distribution Panel (PD) • (8) 40A connectors • (12) 20/30A connectors • (2) Power-Safe Connections • 24V output for cRIO • 12V for WiFi • 5V for camera • Power input uses metric M6 nuts-don’t over torque • LEDs for 3 special connectors

  8. Digital Sidecar • 12V via Wago connector • DB-37 cable to cRIO • (10) PWM outputs • Jumper for servo use • (14) Digital IO (GPIO) • (8) Relays • I2C Interface (connector & pins) • 2-pin status light output • Power status LEDs 5v, 6v, 12v • Need to add cable nuts

  9. Analog Bumper/Breakout • (7) Inputs • (1) Special Input Jumper controlled • Battery voltage • Standard Input • 12V Wago power • Green power LED • CANNOT survive reversed polarity

  10. Pneumatic Bumper/Breakout • (8) Outputs • 12V Wago power • Green power LED • ONLY board with reverse power polarity protection • Test white Wago connectors for other devices/boards here

  11. Axis Ethernet Camera • Ethernet Web-ready camera • Connects to cRIO port 2 • Requires special crossover cable (orange) • Black lens turns to focus • Reset button on back • Use “Setup Axis Camera” on PC to configure it for FRC competition use

  12. Wireless Bridge/Wireless Router • Bridge • On robot • 12V power from PD • Ethernet to cRIO port 1 • Disconnect to tether in pits • Router • For DS and PC • NOT for competition • AC power • Ethernet to DS ETH1 port

  13. Jaguar Speed Controller • 20kHz PWM frequency & 5ms update rate (Victors are 17ms) • Limit switch inputs (forward/reverse) • Coast/Brake (jumper or DIO) • PWM cable retention clips • 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 • Fan runs only when needed

  14. What We’ll Do Today Follow step-by-step directions in the 2009 Control System manual at: usfirst.org/frccontrolsystem • Connect everything • Bench test • Update the firmware (DS & cRIO) • Bench test • Setup wireless networking • Bench test • Download LabVIEW & Wind River programs

  15. Wiring-Power

  16. Wiring-Data

  17. Assembly Steps • Wiring • Battery w/ Anderson Connector (6 awg) • 120amp breaker w/ Anderson Connector w/ Power Distribution (PD) Board (6 awg) • cRIO to PD (18 awg) • Digital Sidecar • DB37 cable to cRIO (attach cable nuts to Sidecar first) • White Wago connector to PD (18 awg) • Attach test servo to Digital Sidecar & add power jumper • Analog & Solenoid Bumpers • Directly attach to cRIO • White Wago connector to PD (18 awg) • Wireless Bridge (requires cutting the cord off the adaptor) • Camera power (requires cutting the cord off the extra adaptor) • Wire Jaguars/Victors to PD

  18. Assembly Steps • Triple check wiring polarity • Unplug Analog Bumpers to test in Solenoid Bumper first • Add circuit breakers • Add jumpers to Analog Bumpers (battery feedback vs normal) • Power it up • One at a time plug the wago connectors into the Solenoid Bumper (a green light means is wired correctly) • (2) for the Analog bumpers • (2) for the Digital Sidecars • (1) for the Solenoid • Connect the verified power lines to the Sidecars & bumpers • All lights should be green (or Jaguars blinking yellow) • Connect Servos to Digital Sidecar – add jumpers

  19. Driver Station (DS) Connections • Connect joysticks to USB1 & 2 • Connect ETH1 port to cRIO port 1 • Attach Disable/Enable switch • Plug in power

  20. Bench Test I • Verify green power status LEDs on PD, Bumpers and Digital Sidecar • Basic objective is to move a joystick at the DS end and have a motor respond at the cRIO end • Default is Arcade (1 joystick) while a top button is pushed

  21. DS Firmware Update • Both DS & cRIO must be updated together • Driver Station (DS) (Manual 5.1.1) • USB memory stick (some do not work) • Firmware update & detailed directions at http://www.usfirst.org/frccontrolsystem • Rename update file to: “dsud_pkg.bin” (make sure file extensions are not hidden on your PC) • Copy to top level of USB memory stick • Plug USB stick into DS • Hold both up & down arrow buttons for ~8sec • Follow further directions on DS LCD screen quickly – if the DS screen goes back to normal then you’ve either been too slow or your memory stick/update file was rejected. • Do NOT interrupt the loading process once it puts up the big warning • Set team number (Manual 5.3.2)

  22. cRIO Firmware Update • Confirm PC LabVIEW update • Manual 5.1.2 • Watch for laptop issues • Power up the cRIO and connect your PC through the DS ETH2 port • Firmware update at http://www.usfirst.org/frccontrolsystem as part of the LabVIEW FRC software update • Start the “FRC cRIO Imaging Tool” • Choose Development Environment • Click “Format Controller” • Select Image: FRC_2009_v7.zip • Device Name: FRC-cRIO-team# • Team ID: team#

  23. Bench Test II • With new firmware behavior will differ • USB1 joystick throttle selects arcade or tank drive

  24. Wireless Setup • Bridge (Manual 5.6.1) • Connect PC to Bridge via Ethernet • Set laptop IP to DHCP • Browse to 192.168.1.250 (admin/admin) • Basic -> Wireless • Basic -> Network Settings • Connect to cRIO port 1 (disconnect DS Ethernet cable) • Router (Manual 5.6.2) • Set laptop IP to DHCP • Connect PC to Router via Ethernet • Browse to 192.168.1.1 (blank/admin) • Wireless -> Manual • Setup -> Basic Setup • Set laptop IP to 10.XX.YY.6, Mask: 255.0.0.0, Gateway: 10.XX.YY.4 • Connect to DS ETH1 port • Connect PC to DS ETH2 port

  25. Bench Test III • Same behavior as Bench test II • Start LabVIEW Dashboard project

  26. Cautions • The cRIO and camera cases must be electrically isolated. Don’t mount on metal. • The DS must NOT lose power or be interrupted while the firmware is being updated • Don’t reverse polarity anywhere! Triple Check! • Don’t mixup the voltage (24v,12v,5v) requirements • Test all 12v white Wago power cables on the pneumatic bumper first. It alone has reverse power protection and a green light means your cable is good. • Don’t over-torque the Power Distribution M6 nuts (10mm wrench) • Don’t confuse the (2) Analog bumpers with the (1) Solenoid Bumper • The robot WiFi MUST be powered by the special connector on the PD. That connector is protected against sudden power drops while the regular 12v connections will be shutdown momentarily to conserve power. • The cRIO modules and bumper power connectors can be shaken loose

  27. Notes • The DS inputs have a value if nothing is attached • The orange Ethernet cable is a special crossover cable for use with the camera. • Servos require a jumper on the Digital Sidecar • The system takes a long time to startup. • The cRIO and WiFi will operate at 4.5V and survive transients down to ~3.5V • The Digital Sidecar will shutdown the PWMs when battery voltage hits ~5V, so they’d start dropping out as the voltage dips below 5V • Joysticks must be centered when the DS is powered up. Similar to N64 or Gamecube.

  28. Oddities • The DS LCD can blank out from a static discharge, but the DS keeps working fine. • Some Power Distribution 5v LEDs don’t work, but the power is fine. • The PD will squeal at times from the 12 & 24V boost supplies cycling • Some redundant loose parts found in PD and Digital Sidecar should be removed.

  29. Links to Further Information • Firmware Updates & Control System Manuals: http://www.usfirst.org/frccontrolsystem • Jaguar Getting Started: http://www.luminarymicro.com/index.php?option=com_remository&func=download&id=1127&chk=ed03ce56ed47704071431b33a1fe7e20&Itemid=591

  30. Presentation slides at: Team358.org • Questions/Help please email Mark.McLeod@ngc.com

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