Electrical system to do list can be found here. Past overall deadlines can be found here.

The components in the electrical system can be divides into two types: devices that we bought (processors, sensors, LCD touch screen) and the boards to control/integrate these devices that we built from scratch:

• The design is done using Altium. We include a tutorial.
• The boards are manufactured by Advanced Circuits.
• Most electronics components are purchased from Digikey.
• We assemble and tested most of the boards ourselves. The only ones that we needed help on are the COM Express connectors on the Base board, which are done by an outside assembly house.

There are 10 different types of board (15 total) utilized in the robot. Note that because making these boards to work properly just from the design stage is not easy, some of them has to go through more than 1 iterations to iron out all the electrical problems.

The implementation and testing of these boards are described within its sub-systems below.

Below is the cost accrued in manufacturing, populating, and assembling the boards. Note there are “starting costs” that we did not include such as:

• Altium software: $5000. However, since we provide all the Altium and Gerber files, there is no need to have one unless you would like to modify them.
• Soldering irons
• heat shrinks for connectors
• Tools such as cutters, crimpers, etc.

Here is the BEOBOT2.0 ZIP FILE of all the Altium project, Gerber files and Bill of Materials (BOM).

We have different Altium projects for the different boards, most are in their own individual folder. In addition, some boards have multiple folders for past prototypes.

Here are the active folders:

• Baseboard: B2 PrototypeFinal; Project file: Beobot2_PrototypeFinal.PrjPcb
• Keyboard Video Mouse (KVM) board: KVM PrototypeFinal; Project file: Beobot2_KVM_PrototypeFinal.PrjPcb
• Breakout Board: BreakoutBoard Prototype2; Project file: Beobot2_Prototype2_BreakoutBoard.PrjPcb
• Back Main Board: PanelMountBackBoard Prototype2; Project file: Beobot2_Prototype2_PanelMountBackBoard.PrjPcb
• Display Board: PanelMountDisplayBoard Prototype2; Project file: Beobot2_Prototype2_PanelMountDisplayBoard.PrjPcb
• USB8 Adapter Board: PanelMountBackBoard Prototype2; Project file: Beobot2_Prototype2_USB8Adapter.PrjPcb
• USB4 Adapter Board: PanelMountBackBoard Prototype2; Project file: Beobot2_Prototype2_USB4Adapter.PrjPcb
• Sensor Board: SensorBoard Prototype2; Project file: Beobot2_Prototype2_SensorBoard.PrjPcb
• Motor Control Board: MotorBoard Prototype2; Project file: Beobot2_Prototype2_MotorBoard.PrjPcb
• Cooling Control Board: CoolingBoard Prototype2; Project file: Beobot2_Prototype2_CoolingBoard.PrjPcb
• PropStick: PropBoard Prototype2; Project file: PropBoard.PrjPcb

Total electronics cost: $8056.24 NOTE: prices may change and shipping cost not included.

The electrical sub-systems are listed below and the cost for each is itemized below. Note that the electronic board implementation cost is bundled together and not included in the individual sub-systems.

Total electrical system cost: $20276.6 NOTE: prices may change and shipping cost not included.

We use COM-EXPRESS for the basic processors.

There are 8 of them and they are placed on 1 of two baseboards that sandwiches a water-cooling block on the image below. These baseboards, which is manufactured by Advanced Circuits break out signals in and out of the processors to all peripheral connectors/sensors.

We use a Gigabit Ethernet switch to facilitate communication between the processors. We also connect a FIXXX WiFi bridge for wireless connection to the outside computers.

The following table itemize the components that are used in this sub-system:

Total sub-system cost: $7779.09 NOTE: prices may change and shipping cost not included.

We use 2 Carrier/base Boards with each board accommodating 4 COM Express modules. The PCB Files and the component Bill of Materials (BOM) are available at the Altium Files section above.

Board Name	Altium Layout	3D Model	Files	Notes
Base Board/Carrier Board			Both are at the center of the robot. SOLIDWORKS: The assembly name is: base_board2.SLDASM. Location: robot7 → robot_computer7 → computer_system7 → processors_block7 → base_board2. ALTIUM: The project file is “B2 PrototypeFinal/Beobot2_PrototypeFinal.PrjPcb”.	This is by far the hardest board to implement and there are 3 prototypes: Prototype 1,Prototype 1.1, and Final prototype.

The KVM system allows the user to access each of the 8 individual COM Express module. The KVM switch is 8 input : 2 output, with the output being either a regular monitor (and keyboard and mouse), or an 8” LCD Touch Screen Lilliput 8” Widescreen (16:9) VGA Touchscreen.

Related information:

• eGalax Touchscreen Driver
• eGalax Touchscreen Setup
• eGalax Touchscreen Setup

The following table itemize the components that are used in this sub-system:

Total sub-system cost: $327.95 NOTE: prices may change and shipping cost not included.

We have the following boards to connect from the computing cluster to the panel mount KVM (VGA and 2 USB) connectors. The PCB Files and the component Bill of Materials (BOM) are available at the Altium Files section above.

Board Name	Altium Layout	3D Model	Files	Notes
Keyboard Video Mouse (KVM) board			This board is behind the two baseboards. SOLIDWORKS: The assembly name is: side_board6.SLDPRT. Location: robot7 → robot_computer7 → computer_system7 → side_board7 → side_board6. ALTIUM: The project file is “KVM PrototypeFinal/Beobot2_KVM_PrototypeFinal.PrjPcb”.	This board to access individual COM Express modules. It is also the entry point for the 24V power from the battery. We have 48 (6 per computer) pins for them to flow to the base board. There are 2 prototypes: KVM, final KVM board. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint PropStick) to control the KVM USB and VGA.
Breakout Board			The board would be hanging on top of the KVM board. SOLIDWORKS: not modeled. ALTIUM: The project file is “BreakoutBoard Prototype2/Beobot2_Prototype2_BreakoutBoard.PrjPcb”.	This board allows us to use a high density board-to-board connector to connect the inside computing module to the peripheral panel mount connectors/devices. Here we use a 150-pin (3 rows x 50pins) tyco connector. There is 1 prototype: final Breakout board
Back Main Board			Ath the back top of the robot. SOLIDWORKS: The assembly name is: Robot_back_panel_mount_board.SLDPRT. Location: robot7 → robot_computer7 → robot_computer_case7 → Robot_back_panel_mount_board. ALTIUM: The project file is “PanelMountBackBoard Prototype2/Beobot2_Prototype2_PanelMountBackBoard.PrjPcb”.	This board houses the panel mount USB as well as the KVM connectors. It has a USB hub to split a single USB KVM signal for the Keyboard, Mouse, and USB touchscreen lanes. There is 1 prototype: final back main board
Display Board			At the back top of the robot. SOLIDWORKS: The assembly name is: panel_mount_display_board.SLDPRT. Location: robot7 → robot_computer7 → robot_computer_case7 → robot_topcenterback_connector_system → panel_mount_display_board. ALTIUM: The project file is “PanelMountDisplayBoard Prototype2/Beobot2_Prototype2_PanelMountDisplayBoard.PrjPcb”.	This board has VGA and KVM related module. It has a seven-segment display and a switch to toggle between computers. There is 1 prototype: final display board

The input and output connections to outside devices (sensors, for example) are done through various panel mount connectors. The traces goes through the same boards as the KVM system (Keyboard Video Mouse (KVM) board , Breakout Board, Back Main Board, and Display Board), plus a few extension cable some of which we have to create ourselves (check below). With these extra connectors we can add additional device such as speakers (through USB audio dongle), for example.

The following table itemize the components that are used in this sub-system:

Total sub-system cost: $46.8 NOTE: prices may change and shipping cost not included.

We have 2 types of USB extension panel mount cables that has an adapter board to utilize the connectors. The PCB Files and the component Bill of Materials (BOM) are available at the Altium Files section above.

Board Name	Altium Layout	3D Model	Files	Notes
USB8 Adapter Board			Would be at the side top of the robot. SOLIDWORKS: Not modeled. ALTIUM: The project file is “PanelMountBackBoard Prototype2/Beobot2_Prototype2_USB8Adapter.PrjPcb”.	This is a small USB adapter for 8 panel mount outlets. There is 1 prototype: final USB8 board
USB4 Adapter Board			Would be at the side top of the robot. SOLIDWORKS: Not modeled. ALTIUM: The project is “PanelMountBackBoard Prototype2/Beobot2_Prototype2_USB4Adapter.PrjPcb”.	This is a small USB adapter for 4 panel mount outlet. There is 1 prototype: final USB4 board

Power is regulated by 9 PICO-ATX modules. The power supply itself is provided by the two 12V 35Ah wheelchair' batteries, connected in series. We use 8 separate PICO-ATX module to provide power to each COM Express module. There is an extra PICO-ATX for powering all connected peripheral (sensors, Motor, cooling) boards.

The following table itemize the components that are used in this sub-system:

Total sub-system cost: $777.20 NOTE: prices may change and shipping cost not included.

The Power traces goes through the KVM and base boards.

We have the following sensors, some of which (GPS, Compass, IMU) are integrated through the sensor board :

• Cameras: we use Firewire (over PCI Express), but we may also use Internet Protocol (IP) cameras using the Gigabit ethernet.
• Laser Range Finder
• Sonar Array
• Global Positioning System (GPS)
• Compass
• Inertial Measurement Unit (IMU)
• Encoders

The following table itemize the components that are used in this sub-system:

Total sub-system cost: $2666.33 NOTE: prices may change and shipping cost not included.

Also note that our Laser Range Finder is donated by Hokuyo AUT and thus not part of the total. We categorize this device as optional because we include the cost of the sonar suite. The Hokuyo Laser range finder can be found here and the cost ranges from $1300 to $5600.

The PCB Files and the component Bill of Materials (BOM) are available at the Altium Files section above.

Board Name	Altium Layout	3D Model	Files	Notes
Sensor Board			The board is at the back of the robot. SOLIDWORKS: The assembly name is: sensor_system7.SLDASM. Location: robot7 → robot_computer7 → robot_computer_case7 → sensor_system7. ALTIUM: The project file is “SensorBoard Prototype2/Beobot2_Prototype2_SensorBoard.PrjPcb”.	The Sensor Board manages sensors such as GPS, IMU, and Compass. It also has a few open pins for expansion. There is 1 prototype: P1 Sensor board. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint PropStick) to format some of the serial data from sensors.

This system pertains to the robot control movement. There are a few control sources: computing cluster (autonomous mode), various direct uninterrupted devices (sonar, killswitches, cliff sensors), and RC remote controller (for manual mode).

In order to have a more robust system, we use the latest 2.4Ghz RC control system from Futaba, which have more bandwidth and much less interference compare with the 33Mhz RC system. Also, killswitches are placed all over the robot for last resort safety mechanisms.

To provide the motors with power we used Dimension Engineering Sabertooth dual 25A motor drivers.

We also modified the motors to add encoders. We splice a USB cable to connect the encoder to the Motor Connector on the robot body. Note that the encoder model is not integrated with the rest of the robot (robot7.SLDASM).

The following table itemize the components that are used in this sub-system:

Total sub-system cost: $605.99 NOTE: prices may change and shipping cost not included.

The PCB Files and the component Bill of Materials (BOM) are available at the Altium Files section above.

Board Name	Altium Layout	3D Model	Files	Notes
Motor Control Board			At the back of the robot. SOLIDWORKS: The assembly name is: motor_system7.SLDASM. Location: robot7 → robot_computer7 → robot_computer_case7 → motor_system7. ALTIUM: The project file is “MotorBoard Prototype2/Beobot2_Prototype2_MotorBoard.PrjPcb”.	The Motor Control board house the motor driver and RF remote control receiver. It also has a few open pins for sensor expansion. There is 1 prototype: P1 motor board. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint PropStick) to control the motor inputs (either from the RC or the cluster).

We have a board to control the water-cooling system. It provides power to:

• water pump
• two fans cooling the radiator.

It takes monitoring data from:

• flow Meter
• liquid temperature sensor.

We also have a propeller chip to process sonar array data because of its close proximity to the array (to minimize cables). In addition, we have a few extra open pins for sensor expansion.

Most items are listed in the mechanical portion of the Water Cooling system except for a USB cable to connect the cooling control board to the cluster:

Total sub-system cost: $17 NOTE: prices may change and shipping cost not included.

The PCB Files and the component Bill of Materials (BOM) are available at the Altium Files section above.

Board Name	Altium Layout	3D Model	Files	Notes
Cooling Control Board			At the front top of the robot. SOLIDWORKS: The assembly name is: cooling_control.SLDASM. Location: robot7 → robot_computer7 → computer_system7 → cooling_system7 → cooing_control. ALTIUM: The project file is “CoolingBoard Prototype2/Beobot2_Prototype2_CoolingBoard.PrjPcb”.	There is 1 prototype: P1 cooling board. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint PropStick) to process sonar as well as flowmeter data.

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