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

3. FIRST Control System

4. Hardware Gather around demo robot Driver Driver –Driver Station (DS) –Router (for non-competition use only) –Disable/Enable Competition Port switch –Joysticks (HID compatible only) Robot 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 400mHz, 64MB/128MB Fixed positions for: Fixed positions for: –(2) Analog modules –(2) Digital Modules –(1) Pneumatic Module (2) Ethernet ports (2) Ethernet ports (1) serial port (console) (1) serial port (console) 24v power 24v power

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

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

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

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

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

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

12. Wireless Bridge/Wireless Router Bridge Bridge –On robot –12V power from PD –Ethernet to cRIO port 1 –Disconnect to tether in pits Router 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) 20kHz PWM frequency & 5ms update rate (Victors are 17ms) Limit switch inputs (forward/reverse) Limit switch inputs (forward/reverse) Coast/Brake (jumper or DIO) Coast/Brake (jumper or DIO) PWM cable retention clips PWM cable retention clips Slow flashing Yellow LED indicates no valid pwm signal Slow flashing Yellow LED indicates no valid pwm signal Slow flashing Red LED indicates limit switch, over temp/current, or under voltage <6V 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 Over-current protection can cause motors to cut out in pushing matches Fan runs only when needed 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 usfirst.org/frccontrolsystem Connect everything Connect everything Bench test Bench test Update the firmware (DS & cRIO) Update the firmware (DS & cRIO) Bench test Bench test Setup wireless networking Setup wireless networking Bench test Bench test Download LabVIEW & Wind River programs Download LabVIEW & Wind River programs

15. Wiring-Power

16. Wiring-Data

17. Assembly Steps Wiring 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) DB37 cable to cRIO (attach cable nuts to Sidecar first) White Wago connector to PD (18 awg) White Wago connector to PD (18 awg) Attach test servo to Digital Sidecar & add power jumper Attach test servo to Digital Sidecar & add power jumper –Analog & Solenoid Bumpers Directly attach to cRIO Directly attach to cRIO White Wago connector to PD (18 awg) 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 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 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 Analog bumpers (2) for the Digital Sidecars (2) for the Digital Sidecars (1) for the Solenoid (1) for the Solenoid –Connect the verified power lines to the Sidecars & bumpers All lights should be green (or Jaguars blinking yellow) All lights should be green (or Jaguars blinking yellow) Connect Servos to Digital Sidecar – add jumpers Connect Servos to Digital Sidecar – add jumpers

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

20. Bench Test I Verify green power status LEDs on PD, Bumpers and Digital Sidecar 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 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 Default is Arcade (1 joystick) while a top button is pushed

21. DS Firmware Update Both DS & cRIO must be updated together Both DS & cRIO must be updated together Driver Station (DS) (Manual 5.1.1) Driver Station (DS) (Manual 5.1.1) –USB memory stick (some do not work) –Firmware update & detailed directions at http://www.usfirst.org/frccontrolsystem 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) Set team number (Manual 5.3.2)

22. cRIO Firmware Update Confirm PC LabVIEW update Confirm PC LabVIEW update Manual 5.1.2 Manual 5.1.2 Watch for laptop issues Watch for laptop issues Power up the cRIO and connect your PC through the DS ETH2 port 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 Firmware update at http://www.usfirst.org/frccontrolsystem as part of the LabVIEW FRC software update http://www.usfirst.org/frccontrolsystem Start the “FRC cRIO Imaging Tool” 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 With new firmware behavior will differ USB1 joystick throttle selects arcade or tank drive USB1 joystick throttle selects arcade or tank drive

24. Wireless Setup Bridge (Manual 5.6.1) 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) 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 Same behavior as Bench test II Start LabVIEW Dashboard project Start LabVIEW Dashboard project

26. Cautions The cRIO and camera cases must be electrically isolated. Don’t mount on metal. 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 The DS must NOT lose power or be interrupted while the firmware is being updated Don’t reverse polarity anywhere! Triple Check! Don’t reverse polarity anywhere! Triple Check! Don’t mixup the voltage (24v,12v,5v) requirements 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. 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 over-torque the Power Distribution M6 nuts (10mm wrench) Don’t confuse the (2) Analog bumpers with the (1) Solenoid Bumper 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 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 The cRIO modules and bumper power connectors can be shaken loose

27. Notes The DS inputs have a value if nothing is attached The DS inputs have a value if nothing is attached The orange Ethernet cable is a special crossover cable for use with the camera. The orange Ethernet cable is a special crossover cable for use with the camera. Servos require a jumper on the Digital Sidecar Servos require a jumper on the Digital Sidecar The system takes a long time to startup. 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 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 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. 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. 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. 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 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. 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 Firmware Updates & Control System Manuals: http://www.usfirst.org/frccontrolsystem http://www.usfirst.org/frccontrolsystem Jaguar Getting Started: http://www.luminarymicro.com/index.ph p?option=com_remository&func=downlo ad&id=1127&chk=ed03ce56ed47704071 431b33a1fe7e20&Itemid=591 Jaguar Getting Started: http://www.luminarymicro.com/index.ph p?option=com_remository&func=downlo ad&id=1127&chk=ed03ce56ed47704071 431b33a1fe7e20&Itemid=591 http://www.luminarymicro.com/index.ph p?option=com_remository&func=downlo ad&id=1127&chk=ed03ce56ed47704071 431b33a1fe7e20&Itemid=591 http://www.luminarymicro.com/index.ph p?option=com_remository&func=downlo ad&id=1127&chk=ed03ce56ed47704071 431b33a1fe7e20&Itemid=591

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