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FIRST® Robotics Competition (FRC®)

Control System 2009-2014

Control System Hardware Components

National Instruments is the manufacturer and donator of the Compact RIO (cRIO) hardware/firmware that forms the backbone of the FIRST Robotics Competition control system beginning in 2009.

The control system/electronics consist of:

National Instruments cRIO
- The FRC controllers run VxWorks 6.3
- FIRST is limited to three (3) specific types of cRIO modules for Digital I/O, Analog input, and Solenoid outputs
FIRST custom Power Distribution Panel
Three types of cRIO module breakout boards-Digital, Analog, Solenoid
A specific make & model of 12v battery (17Ah)
Two specific models of speed controllers to control up to 40A continuous variable speed motors
A specific type of relay to control up to 20A motors, pneumatic solenoids, and custom electronics
Pneumatic solenoids
A specific WiFi bridge/AP
User selectable Win7 netbook/laptop to command the robot by custom controls or up to four USB joysticks/game controllers (must run the FIRST Driver Station application)

Shortcuts

Control System Components:
cRIO FRC II | cRIO FRC I | Digital Sidecar | Analog Breakout | Solenoid Breakout | Power Distribution Panel | Jaguar | Victor | Talon | Spike | HiTec Servo | Driver Station-2012 | Driver Station-2011 | Driver Station-2010 | Joysticks | Cypress I/O | WiFi-2013 | RSL | Main Breaker | Breakers | Battery |
Sensors:
Camera | Camera Gimbal | Rotary Encoder | Photosensor | Gyro | Accelerometer | Rotary magnetic encoder | Potentometer | Linear Encoder | Pressure Switch | Limit Switch | Sonar |
Outdated But Usable at Home:
WiFi-2009 | Driver Station-2009 |

cRIO FRC II

Briefing on new cRIO
In 2012 a new version of the cRIO is introduced, the cRIO FRC II. On introductory sale to veteran teams in the Fall of 2011, a bare chassis will cost ~$300, while the chassis with three modules (Analog, Digital, and Solenoid) will cost ~$550.

Based on the NI cRIO-9076, this smaller, lighter model has only 4-slots, one each for analog/digital/solenoid modules, plus an additional slot that will be hardcoded for a second module of FIRST's choice. The cRIO FRC II has twice as much memory and RAM as the original FRC cRIO, with a newer Freescale 5125 processor running at 400MHz, but with a bigger cache and higher memory bandwidth. In comparison, it will probably appear to otherwise deliver similar performance as the original FRC cRIO. The mounting holes through the base are smaller than the original. It will continue to run even if the voltage drops as low as 9v. It's still intended to be powered through the protected regulation of the 24v Power Distribution Panel source in competition, but can be powered by something else for bench testing.
FRC Live @ Championship

Holding down the reset button long enough will reboot the cRIO into safe mode. Other settings that used to be done by DIP switches are set through software.
Screw-terminal wiring - use 24 to 12 AWG copper conductor wire with 0.39 in. of insulation stripped from the end.

Specs.

(4) module slots
512MB nonvolatile storage
256MB DRAM system memory
Spartan-6 LX45 FPGA (Xilinx Virtex-6 LX 45) (43,661 logic cells, 58 multipliers, 2088Kb RAM, 5 DMA channels, 1Mb/s transfer rate,)
400MHz Freescale MPC5125
(1) 10/100Base-TX Ethernet port
(1) RS232 port
9-30v power supply input range
15w maximum power consumption
22.7oz (1.42 lbs) chassis weight without modules
7"(l) x 3.5"(w) x 2.3"(h)

Slot 1 - Analog module (required)
Slot 2 - Digital module (required)
Slot 3 - Solenoid module
Slot 4 - any of the three types (Analog, Digital, or Solenoid)

NI-cRIO FRC II Operating Instructions (2012-) Specs: NI cRIO-9076 Operating Instructions
NI-cRIO FRC II Processor (2012-) Specs: Freescale MPC5125
NI-cRIO Model Comparisons: cRIO-907x model comparison
NI-cRIO FRC II Insides (2012-) Specs: NI cRIO-9076
NI-cRIO FRC II Chassis (2012-) Specs: NI cRIO-9075
NI-cRIO FRC II Processor Core (2012-) Specs: Processor core
NI-cRIO FRC I (2009-2010) Specs: NI cRIO-9074
NI-cRIO FRC FPGA Comparison Specs: Spartan3 vs Spartan6
NI-cRIO FRC I FPGA (2009-2010) Specs: Spartan3 family
NI-cRIO FRC II FPGA (2012) Specs: Spartan6 family

cRIO source: National Instruments cRIO ordering info.

cRIO FRC I

(2009-2011) legal for use in 2012 as well

Briefing on original cRIO
The original FRC cRIO consists of a metal chassis with integrated controller and 8 slots for plug-in modules-(2) analog input modules, (2) digital I/O modules, (2) solenoid modules. By FRC rules there must be an analog module in slot 1 to provide robot battery voltage feedback, and a Digital module in slot 4 for the robot status light.
Additional modules are optional, but all modules must go in these specific positions if they are used at all (slot 1 is closest to the cRIO panel of lights, DIP switches, Ethernet and serial connectors, and 24v power connector):

Slot 1 - Analog module (required)
Slot 2 - Digital module (required)
Slot 3 - Solenoid module
Slot 4 - unused
Slot 5 - Analog module
Slot 6 - Digital module
Slot 7 - Solenoid module
Slot 8 - unused

NI recommends mounting this on it's side to better protect the modules and breakouts and so condensation doesn't pool on the circuit board behind the module connectors.

~ 2 lb, 11" x 3.5" x 6" (w/modules and breakouts)
400 mHz PowerPC 32-bit processor
64MB DRAM (about half goes to the operating system)
128MB non-volatile flash memory
2M gate FPGA for all digital I/O and hardware level support for quadrature encoders and analog oversampling (not user programmable)
Mounting on side recommended by NI for protection and so condenstation doesn't pool on FPGA.

How to Clean the cRIO-FRC and Install Gaskets.pdf
These gaskets to keep metal dust and shavings out of the cRIO innards came in some KOPs or they can be purchased through AndyMark.

cRIO Breakout Boards

Source: AndyMark
Wago connectors source: AndyMark

Digital Sidecar

This breakout board is connected to the cRIO Digital I/O Module (NI 9403) via a long cable.

~ 0.25 lb, 3" x 5" x 1"
12V input via WAGO connector
(10) Ten PWM outputs with selectable 6V power for servos
PWM connectors have friction lock connector
(14) Fourteen GPIO (TTL 5V Digital Input/Output) can be used for SPI interface
(8) Eight forward/reverse relay outputs
All connections are three-pin 0.100" PWM-style headers
GPIO & relay outputs connectors have positive retention clip
I2C interface - all 7-bit addresses are available, Standard I2C connector or alternate .1" header pins are available
Local 5V switching power supply for GPIO power
2-pin output for robot status light & board mounted LED (fast blink=no communication, slow blink=disabled, solid=enabled teleop or autonomous)

2010 improvements (can be identified by the red PCB) added reverse voltage protection
Digital Sidecar Description
Digital Sidecar specs

Source: AndyMark
DB37 ribbon cable source: AndyMark (a regular DB37 cable is also available)

Analog Breakout

This breakout board is connected directly to the cRIO Analog Input Module (NI 9201) , or extended with a ribbon cable and placed in a more protected spot.

There is a 2009 (red PCB) and a 2010 (blue PCB) version of this board with slightly different characteristics.

~0.4 lb, 3.5" x 5.5" x1"
(8) Eight channel analog input
+/- 10V input range
12-bit resolution
500 kHz aggregate sampling rate
Plugs into Analog Input Module (NI 9201) or can be extended by 25-pin cable and housed in a protective enclosure
12V input via WAGO connector
1A 5V switching power supply
Input #8 can be jumpered to monitor battery voltage if desired

2010 improvements (can be identified by the red PCB):

Significantly improves on the accuracy and the noise of the 2009AB, except in two corner cases not found in FRC. Noise is now well below a single-count on the ADC
Reverse voltage protection to handle cross-wired input power
Greatly reduced maximum output current - 2010AB ~0.5 amp / 2009AB ~3 amps
Added low pass filters, so noise coupled in, e.g. from motors, should be somewhat reduced.
Limits the usefulness of any analog sensors that operate in the kilohertz plus range

Analog Breakout Description
Analog Breakout Specs

Source: AndyMark

Solenoid Breakout

This breakout board is connected directly to the cRIO Solenoid Module (NI 9472) , or extended with a ribbon cable and placed in a more protected spot.
It is similar in appearance to the Analog Breakout above.

~0.4 lbs, 3.5" x 5.5" x 1"
(8) Eight 1A 12V solenoid outputs (double solenoids will require 2 outputs unless a Spike is used)
Plugs into Solenoid Module (NI 9472)
12V input via WAGO connector or 24v from the Power Distribution Panel's cRIO connector
Two pin 0.100" header outputs
Output connectors have positive retention clip

Solenoid Breakout Description
Solenoid Breakout specs

Source: AndyMark

Power Distribution Panel (PD)

<i>FIRST</i> 2009 Power Distribution Panel

~1.6 lbs, 9" x 5.75" x 1.75"
(12) Twelve 20A/30A circuit breaker power connections
(8) Eight 40A circuit breaker power connections
LED indicators for blown or missing circuit breakers (NOT enabled for 2009)
24V output for cRIO controller (unique connector)
12V output for wireless access point (white WAGO connector)
5V output for Axis Ethernet camera (built-in WAGO connector)
12V input via metric M6 terminal lugs (BEWARE of attempting to use 1/4-20 nuts)
All output connectors via WAGO terminal blocks (requires no crimping or soldering)
- Important: strip 1/2" of wire insulation for the big 40amp WAGO block (745-85X)
- Important: strip 1/3" of wire insulation for the smaller 20-30amp WAGO block (745-38X)

2010 improvements (can be identified by the red PCB):

Red LEDs under any wired Wago connections that have pulled breakers
Self-resetting fuse (5-10 sec) in the camera return path. The PD now protects itself, the camera, the cRIO, and the router when cross-wired.
In an extreme situation when shorted a third line of PD defense will kick in. This takes 20-40 minutes of resting unpowered to recover entirely
A tiny bit of extra power supply conditioning

Power Distribution Panel specs
Power Distribution Panel circuit design

Source: AndyMark

Speed Controller-Jaguar

<i>FIRST</i> 2009 Luminary Micro Speed Controller

<i>FIRST</i> 2009 Luminary Micro Speed Controller Diagram

<i>FIRST</i> 2010 Luminary Micro Speed Controller

One Page Intro., Jaguar Getting Started document

This Jaguar H-bridge speed controller from Texas Instruments (formerly Luminary Micro) comes in two types that can be told apart by their covers: grey/tan or black. The original 2009 release was gray/tan and had a few issues with static electricity, as well as back EMF from the motor that caused their destruction. The replacement in 2010 was black and redesigned using Texas Instruments components (after TI acquired the company that made the Jags - Luminary Micro). There are some minor electrical differences, but the major difference is the grey has two CAN connectors for daisy chaining, but the black has one RS232 and one CAN to act as a communications bridge between the cRIO and a chain of Jaguars.
Details
2011 CAN Getting Started.pdf

20 kHz PWM frequency
5ms update rate
40 amps continuous w/over-current self-protection: 100 amp for .2 sec/60 amps for 2 sec
Standard R-C Servo type (PWM) interface
CAN interface as well
Status LED indicates run, direction, and fault conditions
Limit switch inputs for forward and reverse directions (MUST have jumpers or limit switches connected for the Jaguar to operate in forward or reverse)
Brake/coast mode selection
Larger than an IFI Victor 884 Speed Controller
Calibration feature
NOT reverse polarity protected

cRIO Jaguar PWM specs (and test measurements using a run-of-the-mill digital voltmeter):

Period: 5ms
Reverse: .67ms (measured voltage: 0.67v)
Neutral: 1.5ms (measured voltage: 1.49v)
Forward: 2.33ms (measured voltage: 2.33v)

The Jaguar provides smoother control and is especially valuable at fine-tuned low speed control and it self-protects against over-current/temp. The Victor can handle some higher current stress for longer periods of time, but in a severe over-current case it would fail catastrophically. There are also reports of the Jaguar not working well with the Denso window motors. In any case new applications should be throughly tested to see which speed controller is more appropriate.

Fault Conditions

A slow flashing Red LED indicates that the MDL-BDC detected one of the following fault conditions:

Power supply under-voltage
Over temperature
Over current
Limit switch activated in the current direction of motion

When a fault condition occurs, the motor shuts down and the LED indicates a fault state during the fault condition and for 3 seconds after the fault cause is cleared (except for the limit switch fault, which is cleared instantly). A slow flashing Yellow LED indicates that the MDL-BDC is not receiving a valid control signal.

CALIBRATION PROCEDURE

To calibrate the servo-style PWM input for a specific range, connect a PWM source, then:

1. Hold down the USER switch with a straightened paperclip.
2. After 5 seconds, the LED flashes Red and Green quickly to indicate Calibration mode.
3. Instruct the controller to send a full-forward signal.
4. Instruct the controller to send a full-reverse signal.
5. Instruct the controller to return to a neutral signal.
6. The LED flashes Green and Yellow quickly to indicate a successful calibration. (Red & yellow means failure to calibrate)
7. Release the USER switch.

The MDL-BDC samples these signals and centers the speed range and neutral position between these limits. A calibration failure will be signaled if an out-of-range signal is detected.
To reset the servo-style PWM input to the default factory range:

1. Disconnect the power to the MDL-BDC.
2. Hold down the USER switch with a straightened paperclip.
3. Reconnect power to the MDL-BDC
4. After 5 seconds, the LED flashes Red and Green slowly to indicate a successful calibration reset to factory settings.
5. Release the USER switch.

Source: Digikey usually has a special FRC price during the season (~$85) or AndyMark

Speed Controller-Victor

Victor 884 Users Manual ( Adobe PDF

, 60 KB)
This has been around longer than the Jaguar and has different characteristics. Both speed controllers can be used. The Victor allows high current for longer than the Jaguar, while the Jaguar permits finer control. The Jaguar also does not seem to work well with the Window motors under certain circumstances, causing the Window motors to heat up unusually and be shutdown by the Window motor's thermal overload protection.

IFI Victor 884 Callout

120 Hz switching frequency (PWM output chop rate)
Standard R/C type PWM (red wire is unused-open circuit), Input pulse 1-2ms, rate 15-30ms
40 amps continuous (conservatively rated for FRC application)
6-15v min/max
3% minimum throttle
handles higher current applications than the Jaguar, but doesn't have the self-protection features that the Jaguar does
Standard R-C Servo type (PWM) interface
Brake/coast mode selection (checked 60 times per second)
much smaller footprint than a Jaguar
Status LED indicates power, neutral control signal, forward full, backward full
Calibration feature
cooling fan rated for 6-16v
Cannot be used with Brushless motors
NOT reverse polarity protected
Less linear output than the Jaguar

cRIO victor PWM specs (and test measurements using a run-of-the-mill digital voltmeter):

Period: 10ms
Reverse: 1ms (measured voltage: 0.5v)
Neutral: 1.5ms (measured voltage: 0.75v)
Forward: 2ms (measured voltage: 1.0v)

Source: VexPro (usually offers a special discount to FRC teams during the season)

Speed Controller-Talon

Brushed DC motor speed control featuring a sealed design with passive cooling and a footprint slightly smaller than a Victor. Without the optional fan it is also much shorter.
From Cross the road electronics

Input voltage: 6-28 VDC
Continuous current: 60 A
Peak current: 100 A
Input PWM signal: 0.9-2 ms @ 333 Hz
Input resolution: 10-bit (1024 steps)
Output resolution: 10-bit (1024 steps)
Output switching frequency: 15 kHz
Locked-antiphase rectification
Smart LED, blinks proportional to throttle
Simple calibration
User selectable brake/coast
4% neutral dead band
Linear throttle response

Talon Users Manual ( Adobe PDF

, 287 KB)

Source: AndyMark
Cross the road electronics

Spike Relay

The Spike is not a PWM device although it is controlled by a PWM-style cable. It can not be connected to an R/C hobby type receiver. The Spike is designed to plug into special Relay Ports.

Control Signal Hi: 3V min @ 4mA; Lo: open or ground.
Operating Voltage 6V to 16V
Maximum Current 20A continuous
Surge Current 100A for < 2 second
Max Switching Rate 20 operations per second no load, 6 operations per minute for rated life at rated load
Initial Operate Time 5 ms typical
Initial Release Time 2 ms typical
Expected Mechanical Life 10 million operations
Expected Electrical Life 100K operations at 20A, 14VDC, 1mH
Power Connector 1/4" blade connectors
Signal Connector Uses a standard non-shrouded PWM cable (3 wires)
Typical Application Power one motor with variable speed forward, reverse, or off (shunt brake)

Blue Spike Guide

Source: VexPro

HiTec Servo

The HiTec servo is a small motor that can be commanded to rotate to a particular position in a range of ~270 degrees. It has a varied of "horns" or the white part in the accompanying photo that are interchangeable, and are often used with homegrown mechanical linkages to increase their effectiveness.
This attaches to the Digital Sidecar PWM outputs, BUT also requires the use of a jumper beside the PWM output, because it runs on the 6v power from the PWM connection,

HiTec Servo HS-322HD

Source: AndyMark

Driver Station (DS) (2012/2013/2014 version)

<i>FIRST</i> 2012/2013/2014 Classmate Driver Station

Any laptop is now legal with only the Driver station application a requirement.
Rookies are still provided with a newer model Classmate (E12). FIRST provides new (optional) Classmate images to update older Classmates to Windows 7 (if necessary) and pre-install the current year's programming environment(s). Especially important with the oldest E09 because the very limited disk space does not leave enough room to perform the normal installation process. The 2012 Classmate power adaptor produces 2.1 amps @ 19v with center positive on the barrel connector.

Classmate E12 Specs

Driver Station (DS) (2011 version)

<i>FIRST</i> 2011 Classmate Driver Station

Any laptop is now legal with only the Driver station application a requirement.

Come cautions:
Run the Driver Station application as administrator, so it can adjust network settings.

Triple check that your IP settings are exactly what is required by the playing field:

Ethernet port IP - 10.te.am.5, netmask - 255.0.0.0
Disable wireless and all other unused network cards.

Turn off firewalls and anti-virus, because they can block or otherwise interfere with field network traffic.

Keep your laptop charged at ALL times. Many failures are due to a lack of laptop battery power - USB ports brown-out, laptops slow down or sleep to conserve power or shutdown altogether while a match is in progress.

Laptop USB is notorious for cutting power to USB ports while the laptop is on battery or after hibernating/sleeping.

Make sure your laptop battery is fully charged and preferably plugged in.
Check your power saver settings to avoid power cutbacks when the battery is low.
- Open the Device Manager. Win 8, hold the Windows key and press the 'x' key to open a menu in the lower-left and select "Device Manager." Using Win 7, open the Start Menu, type "Device Manager" in the search field, and click it.
- Expand "Universal Serial Bus controllers"
- Right-click each entry titled "USB Root Hub" and select "Properties"
- Change to the "Power Management" tab
- Uncheck the check box next to "Allow the computer to turn off this device to save power"
- Press "OK"
- Repeat this for each "USB Root Hub" entry
- Reboot the computer
If using more than one USB device, i.e., multiple joysticks, distribute the USB load across all the laptop USB ports that you have. Keep critical joysticks on their own USB port.
Avoid ganging multiple USB devices up on a single USB hub. Bigger hubs are worse, because larger hubs and more devices require more power and USB has a 500mA limit. If used, small hubs are best.
Avoid complicated joysticks that draw an excess of USB power. Power hungry fancy sticks or ones with glittery LEDs require more power and won't fare as well as plain vanilla generic joysticks when a brown-out occurs.

The 2011/2012/2013 Classmate power adaptor produces 2.1 amps @ 19v with center positive on the barrel connector.
E10 classmate power adaptor

Classmate E10 Specs

Driver Station (DS) (2010 version)

In 2010 FRC introduced a small netbook laptop as the Driver Station. This netbook continued to be used in subsequent years.

Classmate E09 - special edition for FRC
Cypress FirstTouch USB breakout for custom controls, digital/analog inputs
USB Disable button
F1/Space Bar = Enable/Disable robot
Standard USB hub to connect multiple joysticks and the other USB devices
Classmate & "Driver" user account is the only one recognized by the FMS, but outside field competition the DS application can be run on any PC

As with new technology applications everywhere unexpected problems arose when 1,808 Classmates went into competition.

Sleep/hibernate mode sometimes caused connected USB devices to be lost. Game controllers would re-sort themselves so your drive stick might wake up to be your kicker controller.
While on battery the Classmate might refuse power to high draw devices such as the Cypress FirstTouch breakout for user buttons.
On rare occasions the Classmate would refuse to connect to FMS. There were quick fixes to this, but sleep mode might bring it on again.
Teams got a Restore USB memory stick that could be used to restore the Classmate to the FRC delivered OS. DS Restoration Instructions.doc
The built-in Ethernet port could get damaged with rough handling. The cable retention clip broke on many machines, but usb-Ethernet adaptors worked as a substitute.

The classmate power adaptor produces 2amps @ 20v with center positive on the barrel connector.

Classmate spare parts
Classmate E09 Manual

Joysticks

FRC Logitech F310 Game Controller Mapping

FRC Extreme 3D Pro Game Controller Mapping

Logitech Attack 3, xBox 360, Logitech F310-Flight Mode or Sports Mode Extreme 3D Pro
(click on game controllers for FRC mapping of buttons & axes)

To control the robot the Kit of Parts includes a pair of the classic Attack3 Joysticks. Any USB wired game controller can be used, such as Xbox 360 or Playstation 3 compatible game controllers. It just has to be recognizable by the Windows OS with an appropriate hardware driver on the Driver Station laptop as a game controller. Non-game controllers such as keypads are not recognized by the Driver station application.

Note: Some game controllers have mode buttons and switches that change how the buttons and axes are mapped. This can inadvertently lead to a mysterious loss of control if the driver hits the button/switch accidentally. Controllers without such a switch are more foolproof to use.

Warning: power hungry controllers may brown out during competition. Basic controllers connected directly to the laptop USB ports are safest. When the driver station laptop battery gets low it begins to cut power to USB ports starting with the ports with the highest power drain. Usually, that means starting with ports connected to bigger drain USB hubs that have several devices hanging off them.
Changing Windows USB Power Settings

Source: Game console retailers like Best Buy, GameStop, Target, Walmart

Texas Instruments Stellaris Launchpad Evaluation Kit LM4F120 (2014)

FRC TI Stellaris Launchpad Evaluation Kit

The Stellaris requires custom firmware provided by TI to set it up to behave like a standard HID joystick (or two joysticks), making buttons and dials available for user custom designed control board extensions. The unit is stackable with other breakout boards to add capability or simplify screw terminal connections.

The Stellaris is powered by and communicates through a USB connection to the laptop/netbook running the Driver Station application.
User Manual

Source: Digikey

First Touch DS I/O Breakout

FRC Cypress First Touch I-O Board Pinout

The Cypress First Touch requires special FRC-specific firmware to be used with and recognized by the Driver Station. NOTE: there have been three versions of the Cypress board released over the years. There are two FRC Cypress firmware versions that match changes in the board FRC_IO.2009.v3.hex & FRC_IO.2012.v3.hex come with the FRC river Station Update and after installation is located on your PC at: C:\Users\Public\Documents\FRC\
Boards manufactured between 2009-2011 use the 2009 version of the firmware, later boards use the 2012 version. If you are unsure you can just try each and the PSoC software will simply tell you if the firmware doesn't match the board.

If you see Cypress FirstTouch firmware update error:
ERROR!---> | The hex file was built for silicon revision ES3, but the acquired device is revision **
then PSoC version 3.17 must be used to apply new firmware.

The Cypress board is powered by and communicates through a USB connection to the laptop/netbook running the Driver Station application. The 9v battery is not used in our application.
How_To_Configure_Your_I-O_Module.pdf

Source: Special Mount (an enclosure is also for sale)

Wireless

2013 Version

In 2013 the D-Link DAP-1522 Rev B AP/bridge is used. It replaces the previously used Rev A.

<i>FIRST</i> 2012 Robot Radio DAP-1522 Rev B

<i>FIRST</i> 2013 Robot Radio Power Converter

12v-5v Power Converter_CLL.pdf
WARNING: This is a 5 volt device and requires the use of a 12v-to-5v power converter for use on the robot.

Source: DAP-1522 Rev B
Source: Voltage Regulator (12v to 5v)

D-Link DAP-1522 Rev B manual (2012)
D-Link DAP-1522 Rev B Firmware for FRC (2012)

2011 Version

In 2011 the D-Link DAP-1522 Ap/bridge is used.
FIRST 2011 Robot Radio DAP-1522

How to Configure Your DAP-1522 Robot Radio (2011)
D-Link DAP-1522 Rev A manual (2011)
D-Link DAP-1522 Rev A Firmware 1.21 for FRC (2011)

Rockwell Robot Status Light

Wired one way it will flash forever, but wired correctly it will repeat exactly what the RSL LED on the Digital Sidecar does.
Ground, Power and most importantly-a jumper MUST be used.
RSL Wiring ( Adobe PDF

, 101 KB)

The RSL blink pattern tells what state the robot is in. The patterns can be changed year-to-year but in 2011 they were:

Fast Blink = cRIO not communicating with Driver Station
Slow Blink = disabled
Short on/long-off Blink = either low battery or no code & disabled
Long on/short off blink = Teleop mode
Solid on = Autonomous mode

Main Breaker/Robot Power Switch

The battery connects through Anderson connectors to this 120 amp breaker used as the main robot power switch. It is very unlikely that this will ever trip under normal conditions as it withstands amperage much greater than 120a for some period of time before tripping. If it does trip you have a serious electrical problem, or ill designed overloaded power draws.

Squeeze the black lever to turn on.
Push the red button to turn off.

120amp Main Breaker/Robot Power Switch Spec.

Source: AndyMark

Snap Action Breakers

These mount in the Power Distribution Panel and are self-resetting 40/30/20 amp breakers for individual circuit protection. It's important to remember that these only safeguard the wiring, and it's critical that they each be used with the properly rated wire gauge (or better). They do not protect devices like the speed controllers.
Snap-Action 30/20a Breaker Spec.
Snap-Action 40a Breaker Spec.

Source: VexPro or AndyMark

EnerSys NP18-12 or MK ES17-12 Batteries

FRC robots are restricted to a specific 12v battery. One or two batteries are provided in the Kit and if they are the same past years batteries can be used as spares. It's a good idea to have several (4-5) batteries (and chargers) for competition.

Specs: EnerSys NP18-12 Datasheet
MK ES17-12 Datasheet

Source: AndyMark

Sensors

FRC 2011 Sensor Manual

Axis 206/M1011 Webcam

This optional network camera is connected either to the cRIO via port 2 (the 206 requires a crossover Ethernet cable to work, the M1011 does not), or to the DLink network bridge (any cable/camera model). For the default camera code to work with it there must be a special user account - username: FRC/password: FRC

Note: the screw mount on the camera back takes an M4 metric nut.

FIRST Axis M1011 Webcam Yellow status

<i>FIRST</i> Axis M1011 Webcam Yellow status

Camera Image Compression vs. image file size

Axis 206:
- Adjustable focus lense
- Manual
- Datasheet
Axis M1011:
- Fixed focus lense
- Manual
- Datasheet
- Installation Guide
Axis M1013:
- Adjustable focus lense
- Datasheet
- Axis M1013-14 Quick Guide
- Axis M1013 User Manual

Source: AndyMark

Camera Gimbal (aka, Pan & Tilt Assembly)

This comes in the KOP with the camera and can also be purchased through AndyMark
Camera Pan and Tilt Assembly Diagrams

KOP US Digital Encoders

The KOP encoders are 360 CPR (Counts Per Revolution), with 4X quadrature decoding, you get 1440 positions per revolution. Which gives you a unique position every 1/4 degree. 10,000 maximum RPM for these encoders. This encoder can be used directly with a Jaguar speed controller if you are using the alternate CAN bus.
For use directly by your cRIO code this connects to several of the Digital Sidecar digital inputs:

1. +5 VDC power -> 5v power
2. Quadrature A channel -> signal
3. Ground -> ground (-)
4. Quadrature B channel -> signal

US Digital site, YouTube Assembly Guide
US Digital Encoder EP4 Assembly Instructions ( Adobe PDF

, 101 KB)
US Digital Encoder Datasheet ( Adobe PDF

, 346 KB)

Source: AndyMark

Photosensor

FRC Photoswitch Installation

This is an Allen-Bradley RightSight, model 42EF-D1MNAK-A2.
There is an adjustment screw on the top that increases/decreases the sensitivity, but be careful not to over-turn it or it will break and it's not fixable.
In the 2011 rules had an exception for wiring the power for this particular sensor. It does not work below 11v, so the normal Power Distribution supply would not work as soon as the robot moved and the voltage dipped. The power for this was allowed to be taken from the Solenoid Breakout in turn wired to the 24v regulated port on the Power Distribution Panel. The signal wire still connects to a Digital Sidecar digital input. This avoids power dips even as the battery voltage drops.

Blue wire -> ground (-)
Brown wire -> 12v
Either White wire () or Black wire () -> Digital Sidecar DIO Signal (only one is necessary they just give opposite readings)

Allen-Bradley RightSight Catalog ( Adobe PDF

, 2.1 MB)
Allen-Bradley RightSight Specs ( Adobe PDF

, 108 KB)

Source: AndyMark

Kit Gyroscope

Analog Devices ADW22307 1-axis Analog Gyroscope

Wire to analog input:

rate connects to signal
next pin connects to 5v power
pin at corner of board connects to ground (-)

The gyro positive direct is shown on the board.
The second triplet of pins returns temperature (not commonly used).
FRC Gyroscope Specs

Kit Accelerometer

Analog Devices ADXL345 3-axis Digital Accelerometer.

Maximum of 250 degrees per second for the Analog Devices ADW22307. Nominal output is 2.5V at standstill, plus 7mV/¡/s.
This connects to the Digital Sidecar digital inputs.
SPI output (J4):
wire to Digital I/O pins on the Digital Sidecar

Connect CK, DI, DO, CS in order to four Digital I/O pins
Connect 0V to a ground (-) pin
Connect 5v to a power pin

The alternate I2C output (J2):
wire to the pins on the Digital Sidecar found directly behind the NXT connector. By default, the I2C address is 0x3A. The address can be changed to 0xA6 by shorting J1 with a blob of solder.

Connect 5V to 5V
SCL to SCL
SDA to SDA
(-) to 0V

FRC Accelerometer Specs

Rotary Magnetic Encoder

austriamicrosystems AS5030

Measures absolute angle (8 bits over 360 degrees) and angular rate (up to 30,000 RPM).
There are six ways possible to receive input from this device. See the FRC 2011_Sensor_Manual.pdf for the wiring of other input methods.

Here's one method that connects to the Analog Breakout (Filtered PWM):

Connect the Ana pin (JP2.3) to an input pin on the Analog Breakout
5v to power
GND to ground (-)

The voltage received is proportional to the angle.
NOTE: There is a 4.8 Hz filter on this output, so it is only useable for very low bandwidth (slowly moving) angular position measurements and is not appropriate in angular rate applications. This output can be sampled at 10Hz.
FRC Magnetic Rotary Encoder User Manual

Linear Encoder

This connects as a quadrature encoder to a Digital sidecar digital input:

5v -> power
GND -> ground (-)
A -> signal
B -> signal

FRC Magnetic Linear Encoder User Manual

Pneumatic Pressure Sensor

The pressure switch sensor is used as part of the pneumatic sub-system. It tells the controller when to turn the compressor on as the air pressure drops, and when to turn it off as pressure reaches maximum.
It connects to a Digital Sidecar digital input. The terminals are interchangable.

one terminal -> ground (-)
one terminal -> signal

Spec: Nason Pressure Switch

Potentometer

Potentiometers (or "pots") in robotics are most frequently coupled to a mechanism to measure the angle of rotation or a distance of mechanism travel. It is a simple analog device that's a little noisy, so doesn't return an exact value and has a certain amount of flicker in it's readings. Think of a volume control knob (avoid "audio tapers" for robotics use though) or a light dimmer.
Pots come in several useful varieties:

Rotary - several versions: 270 degree (most common), 3-turn/5-turn/10-turn (useful for great rotations), infinite rotation (usually with a 10 degree deadspot)
Linear - limited travel, typically used as faders on sound or lighting boards.
String - the most expensive type has a spring loaded wire reel that measures how far it is pulled out.

They have three terminals:

ground (-)
signal
power (+)

with two wiring options: 1) voltage divider, or 2) variable resistor
The voltage divider (used when connected as a cRIO Analog input) uses all three terminals.
The variable resistor only requires the ground and signal terminals.

Source: Radio Shack (search for "potentiometer")

Limit Switch

Limit switches are intended to be pressed by some mechanical mechanism to signal a stop or limit of movement.
The switch connects to a Digital Sidecar digital input and is marked on the side with a simple wiring diagram.

NC stands for "Normally Closed" and means the switch will read as closed until it is activated
NO stands for "Normally Open" meaning the switch will read as open until it is activated

There are design reasons that you may want one over the other, but often it doesn't matter which is chosen. Normally Closed is desirable when you want to know if the switch is broken as a safety measure. This might be helpful if you have a mechanism that destroys itself if you cannot detect the limit. If the switch gets ripped off or otherwise becomes disconnected, then it will read as if the mechanical limit has been reached and your code can prevent the mechanism from moving in the direction of the limit switch.
Normally Open is how most people typically think of switches operating.
There are two wiring options. The switch only requires two connections:

COM1 -> ground (-)
NC2 -> signal (or NO3 -> signal)

As with most switches, there is no polarity to the connections and they are reversible.
FRC Limit Switch Spec

Source: Radio Shack (search for "SPDT switch")

Maxbotix - LV-MaxSonar-EZ1

42kHz Ultrasonic sensor measures distance to objects
Read from all 3 sensor outputs: Analog Voltage, Serial, Pulse Width
Virtually no sensor dead zone, objects closer than 6 inches range as 6 inches
Resolution of 1 inch
Maximum Range of 254 inches (645 cm)
Operates from 2.5-5.5V
Low 2.0mA average current requirement
20Hz reading rate
Small, light weight module

Connects to the Analog Breakout and returns an analog voltage output scaling (Volts/512=inches)
A 5v power supply yields ~9.8mV/inch
LV-MaxSonar-EZ1 Datasheet

Source: Maxbotix

Outdated But Still of Use at Home

Wireless

2009 & 2010 Versions

The 2009 & 2010 robot bridge used for Wi-Fi depended on the KOP supplied Linksys WGA600N, however that product is no longer made. An authorized replacement was the WET610N, but that was slow to link up and caused field delays.
FIRST 2009-2010 Robot Radio Linksys WGA600N

<i>FIRST</i> 2009-2010 Robot Radio Linksys WGA600N

Linksys WGA600N wireless bridge manual (2009-2010)
Linksys WET610N wireless bridge manual (2010 substitute)

Driver Station (DS) (2009 only)

Mounting is possible by velcro, double-sided tape, or brackets to three of the cover screws (not the fourth screw protected by warranty tape).

~0.3 lb, 6 1/8" x 4 5/8" x 1 3/16" The .1" header pins and the competition port stick out another 1/8" each and screw heads on the top/bottom sides add 1/16" each
(4) Four USB ports supporting HID standard joysticks/controllers
(8) Eight digital inputs 0.100" header pins
(8) Eight digital outputs (3+ amps total at most of 5v power shared with USB ports, .3amps each)
(4) Four analog inputs
(2) Two ethernet port connections: one to dashboard laptop, one for cRIO/wireless router.
Toggle switch for manually choosing autonomous or tele-operated mode (repeat autonomous requires cycling robot power)
(3) Three buttons for LCD output mode selection
128 x 64 backlit graphic LCD display (user addressable-bottom line of 1st screen & full 2nd selectable screen)
Powered by external 9V power supply or field Competition Port
Updates arrive from robot at 50Hz
Reboot by pulling the power plug
800+ bytes of user data can be sent to the dashboard
Firmware updates are via USB memory stick

Some button sequences:

Hold all three white buttons for 4 seconds to reset robot
Hold up + down for 10 seconds to load firmware update
Hold down arrow for 4 seconds to set team number
- Up (left) button increases the selected digit (and wraps around)
- Down (center) button moves to select the next digit
- Select (right) button sets the team number to the number currently displayed

<i>FIRST</i> 2009 Driver Station Disable Switch

The 2009 Driver Station came with a ready-made disable/enable switch to plug into the Competition port. By default the DS is Disabled if this switch is not connected. You can make your own by connecting pins 8 & 9 to a switch. The competition port enable/disable switch included sticks out 2 1/8" in all from the case.

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