Robot Wiring Methodology

Introduction

Every year during build season, we have to design the robot wiring from scratch. Depending on the competition task, the wiring may involve different number of I/O channels and configurations. Therefore, the wiring is customized differently every year. The problem with this approach is that the wiring process is error prone. The potential issues in the process include:

What improvements can we make to solve these issues?

Wiring Harness Standardization on the Robot Controller Side

On the robot controller, there are the following groups of signals.

Connector A: Sensor Inputs (D-Sub 50-pin Female)

Connector A: Sensor Inputs (D-Sub 50-pin Female)

Name

Function

Pin

Wiring ID

Analog-1

Ainput

18

FA1: White/Blue

5V

2

FA1: White/Brown

GND

34

FA1: Blue

Analog-2

Ainput

19

FA1: White/Orange

5V

3

FA1: Brown

GND

35

FA1: Orange

Analog-3

Ainput

20

FA1: White/Green

5V

4

FA2: White/Brown

GND

36

FA1: Green

Analog-4

Ainput

21

FA2: White/Blue

5V

5

FA2: Brown

GND

37

FA2: Blue

Analog-5

Ainput

22

FA2: White/Orange

5V

6

FA3: White/Green

GND

38

FA2: Orange

Analog-6

Ainput

23

FA2: White/Green

5V

7

FA3: Green

GND

39

FA2: Green

Analog-7

Ainput

24

FA3: White/Blue

5V

8

FA3: White/Brown

GND

40

FA3: Blue

Analog-8

Ainput

25

FA3: White/Orange

5V

9

FA3: Brown

GND

41

FA3: Orange

Digital-1

GPIO

26

FA4: White/Blue

5V

10

FA4: White/Brown

GND

42

FA4: Blue

Digital-2

GPIO

27

FA4: White/Orange

5V

11

FA4: Brown

GND

43

FA4: Orange

Digital-3

GPIO

28

FA4: White/Green

5V

12

FA5: White/Brown

GND

44

FA4: Green

Digital-4

GPIO

29

FA5: White/Blue

5V

13

FA5: Brown

GND

45

FA5: Blue

Digital-5

GPIO

30

FA5: White/Orange

5V

14

FA6: White/Green

GND

46

FA5: Orange

Digital-6

GPIO

31

FA5: White/Green

5V

15

FA6: Green

GND

47

FA5: Green

Digital-7

GPIO

32

FA6: White/Blue

5V

16

FA6: White/Brown

GND

48

FA6: Blue

Digital-8

GPIO

33

FA6: White/Orange

5V

17

FA6: Brown

GND

49

FA6: Orange

Unused

1

Unused

50

Connector B: Control Output-1 (D-Sub 25-pin Female)

Connector B: Outputs/Pneumatics (D-Sub 50-pin Female)

Name

Function

Pin

Wiring ID

Relay-1

FWD

18

FB1: White/Blue

REV

2

FB1: White/Brown

GND

34

FB1: Blue

Relay-2

FWD

19

FB1: White/Orange

REV

3

FB1: Brown

GND

35

FB1: Orange

Relay-3

FWD

20

FB1: White/Green

REV

4

FB2: White/Brown

GND

36

FB1: Green

Relay-4

FWD

21

FB2: White/Blue

REV

5

FB2: Brown

GND

37

FB2: Blue

Relay-5

FWD

22

FB2: White/Orange

REV

6

FB3: White/Green

GND

38

FB2: Orange

Relay-6

FWD

23

FB2: White/Green

REV

7

FB3: Green

GND

39

FB2: Green

Relay-7

FWD

24

FB3: White/Blue

REV

8

FB3: White/Brown

GND

40

FB3: Blue

Relay-8

FWD

25

FB3: White/Orange

REV

9

FB3: Brown

GND

41

FB3: Orange

DO-1

OUT

26

FB4: White/Blue

GND

42

FB4: Blue

DO-2

OUT

27

FB4: White/Orange

GND

43

FB4: Orange

DO-3

OUT

28

FB4: White/Green

GND

44

FB4: Green

DO-4

OUT

29

FB4: White/Brown

GND

45

FB4: Brown

DO-5

OUT

30

FB5: White/Blue

GND

46

FB5: Blue

DO-6

OUT

31

FB5: White/Orange

GND

47

FB5: Orange

DO-7

OUT

32

FB5: White/Green

GND

48

FB5: Green

DO-8

OUT

33

FB5: White/Brown

GND

49

FB5: Brown

Digital-9

GPIO

10

FB6: White/Blue

5V

11

FB6: White/Green

GND

12

FB6: Blue

Digital-10

GPIO

13

FB6: White/Orange

5V

14

FB6: Green

GND

15

FB6: Orange

Robot Status

Light +

16

FB6: White/Brown

Light -

17

FB6: Brown

Unused

1

Unused

50

Connector C: I2C/NXT (D-Sub 9-pin female)

Connector C: I2C/NXT (D-Sub 9-pin Female)

Function

Pin

Wiring ID

Unused

1

I2C-SDA

2

FC1: White/Green

I2C-SCL

3

FC1: White/Orange

I2C-5V

4

FC1: Orange

I2C-GND

5

FC1: Green

SpareOut-1

6

FC1: White/Blue

SpareOut-2

7

FC1: Blue

SpareOut-3

8

FC1: White/Brown

SpareOut-4

9

FC1: Brown

Connector D: Network Camera (RJ-45 Jack)

Connector D: Camera (RJ-45 Jack)

RJ-45 Plug (A)

Pin

RJ-45 Jack (B)

White/Green

1

White/Orange

Green

2

Orange

White/Orange

3

White/Green

Blue

4

Blue

White/Blue

5

White/Blue

Orange

6

Green

White/Brown

7

White/Brown

Brown

8

Brown

Connector E: Wireless Bridge (RJ-45 Jack)

Connector E: Wireless Bridge (RJ-45 Jack)

RJ-45 Plug (A)

Pin

RJ-45 Jack (A)

White/Green

1

White/Green

Green

2

Green

White/Orange

3

White/Orange

Blue

4

Blue

White/Blue

5

White/Blue

Orange

6

Orange

White/Brown

7

White/Brown

Brown

8

Brown

Connector F: cRIO (RJ-45 Jack)

Connector E: Wireless Bridge (RJ-45 Jack)

RJ-45 Plug (A)

Pin

RJ-45 Jack (A)

White/Green

1

White/Green

Green

2

Green

White/Orange

3

White/Orange

Blue

4

Blue

White/Blue

5

White/Blue

Orange

6

Orange

White/Brown

7

White/Brown

Brown

8

Brown

Good Wiring Practices

Appendix A: Wiring Verification Tool

The Wiring Verification Tool is designed to verify the wiring correctness end-to-end. The tool consists of two components: a circuit board (shown in the schematic diagram in the attached VSD file) and a testing program running on the Robot Controller. To verify the correctness of the wiring, follow the instructions below.

Verifying Digital GPIO Channels

Verifying the Digital GPIO channels should be the first test. This is because testing other channels such as PWM involves using some Digital GPIO channels as input channels.

Verifying Analog Input Channels

Analog Input channels are used for sensors such as gyros and accelerometers. The Analog Input Tester on the verification circuit board tests it by connecting the channel to a potentiometer so that you can adjust the voltage to the Analog Input pin.

Verifying Relay Control Channels

Relay Control channels are similar to Digital Outputs except that they can have two states: Forward (FWD) and Reverse (REV) instead of just ON and OFF.

Verifying Pneumatic Control Channels

Pneumatic Control channels are similar to Digital Outputs except that they have higher voltage, usually 12V instead of 5V. Therefore, you cannot plug the Pneumatic Control channels to the Digital Output Tester or you may damage the LEDs on the tester.

Verifying PWM Channels

PWM channels are like Digital Outputs except that the signals on these outputs are not simple ON and OFF but square wave pulses with different widths according to the values programmed into the channels. Since the pulse widths are in the order of milliseconds, it is very hard to monitor those using LEDs. To simplify the tester circuit, it is decided to feed the PWM signals into the Digital Input Tester so that the Digital Input graphs on the test program will capture the wave forms of the signal.

Appendix B: Wiring Map for Running Base and Mechanical Attachment

The wiring map template is also available as an Excel spreadsheet RobotConnectors.xls.

Connector A: Sensor Inputs (D-Sub 50-pin Male)

Name

Function

Pin

Wiring ID

Robot Function

Analog-1

Ainput

18

MA

5V

2

MA

GND

34

MA

Analog-2

Ainput

19

MA

5V

3

MA

GND

35

MA

Analog-3

Ainput

20

MA

5V

4

MA

GND

36

MA

Analog-4

Ainput

21

MA

5V

5

MA

GND

37

MA

Analog-5

FWD

22

MA

REV

6

MA

GND

38

MA

Analog-6

FWD

23

MA

REV

7

MA

GND

39

MA

Analog-7

FWD

24

MA

REV

8

MA

GND

40

MA

Analog-8

FWD

25

MA

REV

9

MA

GND

41

MA

Digital-1

GPIO

26

MA

5V

10

MA

GND

42

MA

Digital-2

GPIO

27

MA

5V

11

MA

GND

43

MA

Digital-3

GPIO

28

MA

5V

12

MA

GND

44

MA

Digital-4

GPIO

29

MA

5V

13

MA

GND

45

MA

Digital-5

GPIO

30

MA

5V

14

MA

GND

46

MA

Digital-6

GPIO

31

MA

5V

15

MA

GND

47

MA

Digital-7

GPIO

32

MA

5V

16

MA

GND

48

MA

Digital-8

GPIO

33

MA

5V

17

MA

GND

49

MA

Unused

1

MA

Unused

50

MA

Connector B: Outputs/Pneumatics (D-Sub 50-pin Male)

Name

Function

Pin

Wiring ID

Robot Function

Relay-1

FWD

18

MB

REV

2

MB

GND

34

MB

Relay-2

FWD

19

MB

REV

3

MB

GND

35

MB

Relay-3

FWD

20

MB

REV

4

MB

GND

36

MB

Relay-4

FWD

21

MB

REV

5

MB

GND

37

MB

Relay-5

FWD

22

MB

REV

6

MB

GND

38

MB

Relay-6

FWD

23

MB

REV

7

MB

GND

39

MB

Relay-7

FWD

24

MB

REV

8

MB

GND

40

MB

Relay-8

FWD

25

MB

REV

9

MB

GND

41

MB

DO-1

GPIO

26

MB

5V

10

MB

DO-2

GND

42

MB

GPIO

27

MB

DO-3

5V

11

MB

GND

43

MB

DO-4

GPIO

28

MB

5V

12

MB

DO-5

GND

44

MB

GPIO

29

MB

DO-6

5V

13

MB

GND

45

MB

DO-7

GPIO

30

MB

5V

14

MB

DO-8

GND

46

MB

GPIO

31

MB

Digital-9

5V

15

MB

GND

47

MB

GPIO

32

MB

Digital-10

5V

16

MB

GND

48

MB

Reserved

33

MB

Robot Status

Light +

17

MB

Light -

49

MB

Unused

1

MB

Unused

50

MB

RobotWiring (last edited 2010-09-29 17:41:59 by MikeTsang)