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![Page 1: Team 358 Hauppauge High School Electrical Workshop October 2010 1 FIRST® For Inspiration and Recognition of Science and Technology.](https://reader035.fdocuments.net/reader035/viewer/2022062321/56649da05503460f94a8bfda/html5/thumbnails/1.jpg)
Team 358Hauppauge High School
Electrical Workshop
October 20101
FIRST®For Inspiration and Recognition of Science and Technology
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Robotics Subsystems
• Major Subsystems– Mechanical– Pneumatic– Electrical – Software
This workshop will cover the Electrical Subsystem
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Electrical Subsystem Topics
• Presentation– Electrical Theory– Block Diagram and Major Components– Wiring Basics– Safety– Electrical Tools
• Hands-On Demonstrations– Wire Stripping and Crimping– Soldering– PWM Motor Speed Control– Parts Identification
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Electrical Theory
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Basic Electrical Theory
• Ohm’s LawE = Voltage (Volts) Symbol: VI = Current (Amps) Symbol: AR = Resistance (Ohms) Symbol: Ω
I = E / RP = Power (Watts) Symbol: W
P = E * I
We use a Positive Current convention(Current flows from + to -)
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The Water Analogy
Battery Pump + is the High Pressure Side - is the Low Pressure Side
E = Voltage (Volts) Water PressureI = Current (Amps) Water Volume FlowrateR = Resistance (Ohms) Flow Restriction
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Resistance Rules
• Resistor Symbol
• Series ResistanceR = R1 + R2
• Parallel ResistanceR = (R1 * R2) / (R1 + R2)
R1
R1 R2
R1
R2
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Electrical Circuit Example
• What is the combined resistance of R1, R2 and R3?
• What is the current being supplied by the battery?
• What is the voltage across R3?
• What is the power dissipated by R3?
R18 Ω
R28 Ω
12 V
R38 Ω
+
-Battery
Current (I)
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Kirchhoff's Voltage LawThe sum of voltage sources and voltage
drops in a circuit must equal zero
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Electrical Circuit Challenge
• What is the polarity and magnitude of the voltage that would be measured between points A and B?
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Hint: Kirchhoff's Voltage LawThe sum of voltage sources
and voltage drops in a circuit must equal zero
R18 Ω
R28 Ω
R38 Ω
+
-
A B
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Digital vs. Analog
• Digital Signal– Binary values (0 or 1)– Each value represented by a specific voltage
• Analog Signal– Continually variable– Random or waveform (sawtooth, sine, etc)
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Electrical Block Diagram and Major
Components
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Robot Electrical Block Diagram
CONTROLLER
POWERDISTRIBUTION
CIRCUITBREAKER
POWERSOURCE
SPIKERELAYS
DIGITALADAPTERMODULE
SOLENOIDCONTROLMODULE
ANALOGINPUT
MODULE
MOTORSPEED
CONTROLS
DIGITALI/O
WIRELESSBRIDGE
PNEUMATICSOLENOIDS
DIGITALSENSORS
ANALOGSENSORS
MOTORS COMPRESSOR12
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Power Source and Power Distribution
POWERDISTRIBUTION
CIRCUITBREAKER
POWERSOURCE
Power Distribution Panel12 Volt Power DistributionCircuit Breaker protection
24 Volt source5 Volt source
12 Volt BatteryLead Acid
18 Ah
Circuit BreakerHigh Current (120A)Used to enable and
disable Robot Power13
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cRIO Controller cRIO with Interface Modules Analog Digital Solenoid
Contains an industrial 400 MHz Freescale MPC5200 processor that supports the execution of code on the Wind River VxWorks real-time operating system
Interface Modules can be added or removed depending on the application Shown with Analog Input, Digital I/O and Solenoid Control Modules
Wiring can be via Bumper (blue/red card on Solenoid Module) or Cable & Sidecar Expansion Module
CONTROLLER
DIGITALADAPTERMODULE
SOLENOIDCONTROLMODULE
ANALOGINPUT
MODULE
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Controller and Digital I/O
cRIOController
NI-9403 Digital Sidecar Handles PWMs, Digital I/O, Relays w/standard
3-pin connectors
NI-9403 Digital I/OInterface to Digital
Sidecar
CONTROLLER
DIGITALADAPTERMODULE
SOLENOIDCONTROLMODULE
ANALOGINPUT
MODULE
DIGITALI/O
WIRELESSBRIDGE
Inter-connecting Cable 15
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Controller and Analog Input
cRIOController
NI-9201 Analog Input(w/Analog Bumper)Analog inputs also w/standard 3-pin
connectors
CONTROLLER
DIGITALADAPTERMODULE
SOLENOIDCONTROLMODULE
ANALOGINPUT
MODULE
DIGITALI/O
WIRELESSBRIDGE
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Controller and Solenoid Control
cRIOController
CONTROLLER
DIGITALADAPTERMODULE
SOLENOIDCONTROLMODULE
ANALOGINPUT
MODULE
DIGITALI/O
WIRELESSBRIDGE
NI-9472 Relay Controller(w/Pneumatic Bumper)Solenoid outputs directly
controls pneumatic valves without spikes
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Motor Speed Controllers and Spikes
884 Victor Motor ControllerPWM Motor speed control
Bi-directional, variable speed40 Amp load
Jaguar Motor ControllerPWM Motor speed control
Bi-directional, variable speed40 Amp load
Spike Relay ControllerHigh current power switching Compressor, Motor Control
On/Off only40 Amp load
MOTORSPEED
CONTROLS
SPIKERELAYS
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BATTERY(12 VOLTS)
+12V
-12V
ROBOT CONTROLLER(PROCESSOR)
MOTOR
CIRCUITBREAKER
PWM CONTROL
MOTOR SPEEDCONTROLLER
(VICTOR)+-12V
+-12V
MOTORCONTROLLER
BLOCKDIAGRAM
Pulse Width Modulation (PWM)
PWM Motor DriveSwitches the motor on and off with a series of pulses of different duty cycles
Provides high torque at low speedsPulses are always 0 to 12 volts
The polarity can be changed to reverse motor direction
Fast
Medium
Slow
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PWM Waveforms
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Analog and Digital Sensors
ExamplesLimit switches
IR sensorsDigital Encoders
Digital Accelerometers
ExamplesPotentiometers (variable resistors)
Analog EncodersAnalog Multi-position Switches
Gyroscopes
DIGITALSENSORS
ANALOGSENSORS
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Wiring Basics
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Wire Characteristics
• Basic types– Solid (single wire)– Stranded (multiple smaller wires twisted together)– Jacketed (multiple insulated wires with an outer
cover)• The size (diameter) of a wire is referred to as
the “gauge” of the wire– The smaller the gauge, the larger the wire– The larger the wire, the lower the resistance per foot– The larger the wire, the more current it can handle– Undersized wire can produce excess heat
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Wire Gauge Table
AWG Stranded Wire Table
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Wire Gauge Rules
Typical First Robotics Wiring Rules
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Wire Color Codes
• Wire Insulation Colors– Colors are used to indicate the use– Typical (past First Robotics rules):
Constant + Voltage : red, white, brownConstant - Voltage: black, blueSignal wires: user selectable
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Safety
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Electrical SafetyVoltage Levels
• Voltage Levels– Robot components operate at a maximum
voltage of 24 Volts– Most circuits operate at 12 Volts– Safe to the touch, but the power sources can
generate sufficient current to damage the robot or cause fires if shorted
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Electrical SafetyRobot Construction
• Circuit Breakers & Fuses– Limit current by interrupting (opening ) the
electrical circuit– Circuit breakers can be reset, fuses must be
replaced
• Appropriate Wire Size (wire guage)– Wire must be of the appropriate size to handle
the current in the circuit– Undersized wire generates excess heat
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Electrical SafetyRobot Construction (continued)
Typical First Robotics Wiring Rules
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Electrical SafetyESD
• Electro-Static Discharge (ESD)– The human body can generate static charge on the
order of several thousand volts– This can damage electronic circuits and components
(semiconductors)– Failure may be immediate or at some time in the
future
• Prevention– Anti-Static mats– Wrist straps
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Electrical Tools and Instrumentation
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Electrical Tools
Wire Cutters
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Electrical Tools
Wire Strippers
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Electrical Tools
Wire Terminals and Crimping Tools
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Electrical Tools
Tie Wrap Gun and Tie Wraps
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Electrical Tools
Soldering Iron
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Electrical Tools
Digital Multi-Meter or Digital Volt Meter (DVM)
Measures:Voltage
ResistanceCurrent
Continuity
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Electrical Tools
Clamp-On Current Meter (Amprobe)
Measures:Current
(Also Resistance & Voltage with
probes)
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Electrical Tools
Oscilloscope
Measures:Voltage
Vs.Time
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Demonstrations
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Hands-On Demonstrations
• Wire Stripping and Crimping• Soldering• PWM Motor Speed Control• Parts Identification using an existing Robot
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