2009 Control System 2009 Control System Workshop Workshop

January 10, 2009Farmingdale State College

SPBLI - FIRST

Mark McLeodMark McLeodAdvisorAdvisor

Hauppauge Team 358Hauppauge Team 358Northrop Grumman Corp.Northrop Grumman Corp.Mark.McLeod@ngc.comMark.McLeod@ngc.com

AgendaAgenda

FIRST Control System OverviewFIRST Control System Overview Team AssemblyTeam Assembly BenchtestBenchtest Firmware UpdatesFirmware Updates Wireless SetupWireless Setup Re-BenchtestRe-Benchtest Download Programs & TestDownload Programs & Test

FIRST Control SystemFIRST Control System

HardwareHardware

Gather around demo robotGather around demo robot Driver Driver

– Driver Station (DS)Driver Station (DS)– Router (for non-competition use only)Router (for non-competition use only)– Disable/Enable Competition Port switchDisable/Enable Competition Port switch– Joysticks (HID compatible only)Joysticks (HID compatible only)

RobotRobot– cRIOcRIO– Bumpers (Analog, Pneumatic)Bumpers (Analog, Pneumatic)– Digital SidecarDigital Sidecar– Power Distribution Panel (PD)Power Distribution Panel (PD)– Wireless BridgeWireless Bridge– Jaguar (or Victor) Speed ControllersJaguar (or Victor) Speed Controllers– Spike (primarily for compressor or other motors)Spike (primarily for compressor or other motors)

cRIOcRIO

400mHz, 400mHz, 64MB/128MB64MB/128MB

Fixed positions for:Fixed positions for:– (2) Analog modules(2) Analog modules– (2) Digital Modules(2) Digital Modules– (1) Pneumatic Module(1) Pneumatic Module

(2) Ethernet ports(2) Ethernet ports (1) serial port (1) serial port

(console)(console) 24v power24v power

Driver Station (DS)Driver Station (DS)

50Hz update rate50Hz 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 toggleAuto/Teleop toggle No hot-swapping No hot-swapping

joysticksjoysticks Joysticks must be Joysticks must be

centered at bootupcentered at bootup Will run off 9v batteriesWill run off 9v batteries

DongleDongle MUST be MUST be attached for DS to attached for DS to run run Connects pin 8 Connects pin 8 to 9to 9

Power Distribution Power Distribution Panel (PD)Panel (PD)

(8) 40A connectors(8) 40A connectors (12) 20/30A connectors(12) 20/30A connectors (2) Power-Safe (2) Power-Safe

ConnectionsConnections– 24V output for cRIO24V output for cRIO– 12V for WiFi12V for WiFi

5V for camera5V for camera Power input uses metric Power input uses metric

M6 nuts-don’t over M6 nuts-don’t over torquetorque

LEDs for 3 special LEDs for 3 special connectorsconnectors

Digital SidecarDigital Sidecar

12V via Wago connector12V via Wago connector DB-37 cable to cRIODB-37 cable to cRIO (10) PWM outputs(10) PWM outputs

– Jumper for servo useJumper for servo use (14) Digital IO (GPIO)(14) Digital IO (GPIO) (8) Relays(8) Relays I2C Interface (connector I2C Interface (connector

& pins)& pins) 2-pin status light output2-pin status light output Power status LEDs 5v, 6v, Power status LEDs 5v, 6v,

12v12v Need to add cable nutsNeed to add cable nuts

Analog Analog Bumper/BreakoutBumper/Breakout (7) Inputs(7) Inputs (1) Special Input(1) Special Input

Jumper controlledJumper controlled– Battery voltageBattery voltage– Standard InputStandard Input

12V Wago power12V Wago power Green power LEDGreen power LED CANNOT survive CANNOT survive

reversed polarityreversed polarity

Pneumatic Pneumatic Bumper/BreakoutBumper/Breakout (8) Outputs(8) Outputs 12V Wago power12V Wago power Green power LEDGreen power LED ONLY board with ONLY board with

reverse power reverse power polarity protectionpolarity protection– Test white Wago Test white Wago

connectors for other connectors for other devices/boards heredevices/boards here

Axis Ethernet CameraAxis Ethernet Camera

Ethernet Web-ready Ethernet Web-ready cameracamera

Connects to cRIO port 2Connects to cRIO port 2 Requires special Requires special

crossover cable (orange)crossover cable (orange) Black lens turns to focusBlack lens turns to focus Reset button on backReset button on back Use “Setup Axis Camera” Use “Setup Axis Camera”

on PC to configure it for on PC to configure it for FRC competition useFRC competition use

Wireless Wireless Bridge/Wireless RouterBridge/Wireless Router

BridgeBridge– On robotOn robot– 12V power from PD12V power from PD– Ethernet to cRIO port 1Ethernet to cRIO port 1– Disconnect to tether in Disconnect to tether in

pitspits RouterRouter

– For DS and PCFor DS and PC– NOT for competitionNOT for competition– AC powerAC power– Ethernet to DS ETH1 portEthernet to DS ETH1 port

Jaguar Speed Jaguar Speed ControllerController

20kHz PWM frequency & 20kHz PWM frequency & 5ms update rate (Victors 5ms update rate (Victors are 17ms)are 17ms)

Limit switch inputs Limit switch inputs (forward/reverse)(forward/reverse)

Coast/Brake (jumper or Coast/Brake (jumper or DIO)DIO)

PWM cable retention clipsPWM cable retention clips Slow flashing Yellow LED Slow flashing Yellow LED

indicates no valid pwm indicates no valid pwm signalsignal

Slow flashing Red LED Slow flashing Red LED indicates limit switch, over indicates limit switch, over temp/current, or under temp/current, or under voltage <6Vvoltage <6V

Over-current protection can Over-current protection can cause motors to cut out in cause motors to cut out in pushing matchespushing matches

Fan runs only when neededFan runs only when needed

What We’ll Do TodayWhat We’ll Do Today

Follow step-by-step directions in the 2009 Follow step-by-step directions in the 2009 Control System manual at: Control System manual at: usfirst.org/frccontrolsystemusfirst.org/frccontrolsystem

Connect everythingConnect everything Bench testBench test Update the firmware (DS & cRIO)Update the firmware (DS & cRIO) Bench testBench test Setup wireless networkingSetup wireless networking Bench testBench test Download LabVIEW & Wind River programsDownload LabVIEW & Wind River programs

Wiring-PowerWiring-Power

Wiring-DataWiring-Data

Assembly StepsAssembly Steps

WiringWiring– Battery w/ Anderson Connector (6 awg)Battery w/ Anderson Connector (6 awg)– 120amp breaker w/ Anderson Connector w/ Power 120amp breaker w/ Anderson Connector w/ Power

Distribution (PD) Board (6 awg)Distribution (PD) Board (6 awg)– cRIO to PD (18 awg)cRIO to PD (18 awg)– Digital Sidecar 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 Attach test servo to Digital Sidecar & add power

jumperjumper– Analog & Solenoid Bumpers Analog & Solenoid Bumpers

Directly attach to cRIODirectly 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)Wireless Bridge (requires cutting the cord off the adaptor)– Camera power (requires cutting the cord off the extra Camera power (requires cutting the cord off the extra

adaptor)adaptor)– Wire Jaguars/Victors to PDWire Jaguars/Victors to PD

Assembly StepsAssembly Steps

Triple check wiring polarityTriple check wiring polarity– Unplug Analog Bumpers to Unplug Analog Bumpers to test in Solenoid Bumper firsttest in Solenoid Bumper first– Add circuit breakersAdd circuit breakers– Add jumpers to Analog Bumpers (battery feedback vs Add jumpers to Analog Bumpers (battery feedback vs

normal)normal) Power it upPower it up

– One at a time plug the wago connectors into the Solenoid One at a time plug the wago connectors into the Solenoid Bumper (a green light means is wired correctly)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 & bumpersConnect 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 jumpersConnect Servos to Digital Sidecar – add jumpers

Driver Station (DS) Driver Station (DS) ConnectionsConnections Connect joysticks to USB1 & 2Connect joysticks to USB1 & 2 Connect ETH1 port to cRIO port 1Connect ETH1 port to cRIO port 1 Attach Disable/Enable switchAttach Disable/Enable switch Plug in powerPlug in power

Bench Test IBench Test I

Verify green power status LEDs Verify green power status LEDs on PD, Bumpers and Digital on PD, Bumpers and Digital SidecarSidecar

Basic objective is to move a Basic objective is to move a joystick at the DS end and have a joystick at the DS end and have a motor respond at the cRIO endmotor respond at the cRIO end

Default is Arcade (1 joystick) Default is Arcade (1 joystick) while a top button is pushedwhile a top button is pushed

DS Firmware UpdateDS Firmware Update

Both DS & cRIO must be updated togetherBoth 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)USB memory stick (some do not work)– Firmware update & detailed directions at Firmware update & detailed directions at

http://www.usfirst.org/frccontrolsystemhttp://www.usfirst.org/frccontrolsystem– Rename update file to: “dsud_pkg.bin” (make sure file Rename update file to: “dsud_pkg.bin” (make sure file

extensions are not hidden on your PC)extensions are not hidden on your PC)– Copy to top level of USB memory stickCopy to top level of USB memory stick– Plug USB stick into DSPlug USB stick into DS– Hold both up & down arrow buttons for ~8secHold both up & down arrow buttons for ~8sec– Follow further directions on DS LCD screen quickly – if Follow further directions on DS LCD screen quickly – if

the DS screen goes back to normal then you’ve either the DS screen goes back to normal then you’ve either been too slow or your memory stick/update file was been too slow or your memory stick/update file was rejected.rejected.

– Do NOT interrupt the loading process once it puts up Do NOT interrupt the loading process once it puts up the big warningthe big warning

Set team number (Manual 5.3.2)Set team number (Manual 5.3.2)

cRIO Firmware UpdatecRIO Firmware Update

Confirm PC LabVIEW updateConfirm PC LabVIEW update Manual 5.1.2Manual 5.1.2 Watch for laptop issuesWatch for laptop issues Power up the cRIO and connect your PC through Power up the cRIO and connect your PC through

the DS ETH2 portthe DS ETH2 port Firmware update at Firmware update at

http://www.usfirst.org/frccontrolsystemhttp://www.usfirst.org/frccontrolsystem as part of as part of the LabVIEW FRC software updatethe LabVIEW FRC software update

Start the “FRC cRIO Imaging Tool”Start the “FRC cRIO Imaging Tool”– Choose Development EnvironmentChoose Development Environment– Click “Format Controller”Click “Format Controller”– Select Image: FRC_2009_v7.zipSelect Image: FRC_2009_v7.zip– Device Name: FRC-cRIO-Device Name: FRC-cRIO-team#team#– Team ID: Team ID: team#team#

Bench Test IIBench Test II

With new firmware behavior will With new firmware behavior will differdiffer

USB1 joystick throttle selects USB1 joystick throttle selects arcade or tank drivearcade or tank drive

Wireless SetupWireless Setup

Bridge (Manual 5.6.1)Bridge (Manual 5.6.1)– Connect PC to Bridge via EthernetConnect PC to Bridge via Ethernet– Set laptop IP to DHCPSet laptop IP to DHCP– Browse to 192.168.1.250 (admin/admin)Browse to 192.168.1.250 (admin/admin)– Basic -> WirelessBasic -> Wireless– Basic -> Network SettingsBasic -> Network Settings– Connect to cRIO port 1 (disconnect DS Ethernet cable)Connect to cRIO port 1 (disconnect DS Ethernet cable)

Router (Manual 5.6.2)Router (Manual 5.6.2)– Set laptop IP to DHCPSet laptop IP to DHCP– Connect PC to Router via EthernetConnect PC to Router via Ethernet– Browse to 192.168.1.1 (blank/admin)Browse to 192.168.1.1 (blank/admin)– Wireless -> ManualWireless -> Manual– Setup -> Basic SetupSetup -> Basic Setup– Set laptop IP to 10.XX.YY.6, Mask: 255.0.0.0, Gateway: Set laptop IP to 10.XX.YY.6, Mask: 255.0.0.0, Gateway:

10.XX.YY.410.XX.YY.4– Connect to DS ETH1 portConnect to DS ETH1 port– Connect PC to DS ETH2 portConnect PC to DS ETH2 port

Bench Test IIIBench Test III

Same behavior as Bench test IISame behavior as Bench test II Start LabVIEW Dashboard projectStart LabVIEW Dashboard project

CautionsCautions The cRIO and camera cases must be electrically isolated. The cRIO and camera cases must be electrically isolated.

Don’t mount on metal.Don’t mount on metal. The DS must NOT lose power or be interrupted while the The DS must NOT lose power or be interrupted while the

firmware is being updatedfirmware 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) requirementsDon’t mixup the voltage (24v,12v,5v) requirements Test all 12v white Wago power cables on the pneumatic Test all 12v white Wago power cables on the pneumatic

bumper first. It alone has reverse power protection and a bumper first. It alone has reverse power protection and a green light means your cable is good.green light means your cable is good.

Don’t over-torque the Power Distribution M6 nuts (10mm Don’t over-torque the Power Distribution M6 nuts (10mm wrench)wrench)

Don’t confuse the (2) Analog bumpers with the (1) Solenoid Don’t confuse the (2) Analog bumpers with the (1) Solenoid BumperBumper

The robot WiFi MUST be powered by the special connector The robot WiFi MUST be powered by the special connector on the PD. That connector is protected against sudden on the PD. That connector is protected against sudden power drops while the regular 12v connections will be power drops while the regular 12v connections will be shutdown momentarily to conserve power.shutdown momentarily to conserve power.

The cRIO modules and bumper power connectors can be The cRIO modules and bumper power connectors can be shaken looseshaken loose

NotesNotes

The DS inputs have a value if nothing is attachedThe DS inputs have a value if nothing is attached The orange Ethernet cable is a special crossover The orange Ethernet cable is a special crossover

cable for use with the camera.cable for use with the camera. Servos require a jumper on the Digital SidecarServos 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 The cRIO and WiFi will operate at 4.5V and

survive transients down to ~3.5Vsurvive transients down to ~3.5V The Digital Sidecar will shutdown the PWMs when The Digital Sidecar will shutdown the PWMs when

battery voltage hits ~5V, so they’d start battery voltage hits ~5V, so they’d start dropping out as the voltage dips below 5Vdropping out as the voltage dips below 5V

Joysticks must be centered when the DS is Joysticks must be centered when the DS is powered up. Similar to N64 or Gamecube.powered up. Similar to N64 or Gamecube.

OdditiesOddities

The DS LCD can blank out from a static The DS LCD can blank out from a static discharge, but the DS keeps working discharge, but the DS keeps working fine.fine.

Some Power Distribution 5v LEDs don’t Some Power Distribution 5v LEDs don’t work, but the power is fine.work, but the power is fine.

The PD will squeal at times from the 12 The PD will squeal at times from the 12 & 24V boost supplies cycling& 24V boost supplies cycling

Some redundant loose parts found in Some redundant loose parts found in PD and Digital Sidecar should be PD and Digital Sidecar should be removed.removed.

Links to Further Links to Further InformationInformation Firmware Updates & Control Firmware Updates & Control

System Manuals: System Manuals: http://www.usfirst.org/frccontrolsysthttp://www.usfirst.org/frccontrolsystemem

Jaguar Getting Started: Jaguar Getting Started: http://www.luminarymicro.com/indehttp://www.luminarymicro.com/index.php?option=com_remository&funx.php?option=com_remository&func=download&id=1127&chk=ed03cc=download&id=1127&chk=ed03ce56ed47704071431b33a1fe7e20&Ie56ed47704071431b33a1fe7e20&Itemid=591temid=591

Presentation slides at: Presentation slides at:

Team358.orgTeam358.org

Questions/Help please email Questions/Help please email

Mark.McLeod@ngc.comMark.McLeod@ngc.com