Beobot 2.0/Electrical System

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Revision as of 22:20, 3 Nov 2009 Siagian (Talk | contribs) ← Go to previous diff		Revision as of 00:00, 4 Nov 2009 Siagian (Talk | contribs) Go to next diff →
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	|[[Image:Baseboard Altium2D.JPG|200px]]		|[[Image:Baseboard Altium2D.JPG|200px]]
	|[[Image:BaseBoard Altium3D.JPG|200px]]		|[[Image:BaseBoard Altium3D.JPG|200px]]
-	|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 folder is "B2 PrototypeFinal".	+	|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: [[Beobot 2.0/Electrical System/Prototype_1|Prototype 1]],[[Beobot 2.0/Electrical System/Prototype_1_1|Prototype 1.1]], and [[Beobot 2.0/Electrical System/Prototype_Final|Final prototype]].		|This is by far the hardest board to implement and there are 3 prototypes: [[Beobot 2.0/Electrical System/Prototype_1|Prototype 1]],[[Beobot 2.0/Electrical System/Prototype_1_1|Prototype 1.1]], and [[Beobot 2.0/Electrical System/Prototype_Final|Final prototype]].
	|}		|}
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	|[[Image:KVMBoard Altium2D.JPG|200px]]		|[[Image:KVMBoard Altium2D.JPG|200px]]
	|[[Image:KVMBoard Altium3D.JPG|200px]]		|[[Image:KVMBoard Altium3D.JPG|200px]]
-	|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 folder is "KVM PrototypeFinal".	+	|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]], [[Beobot 2.0/Electrical System/Prototype_Final_KVM_Board|final KVM board]]. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint [[Beobot 2.0/Electrical System/PropStick | PropStick]]) to control the KVM USB and VGA.		|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]], [[Beobot 2.0/Electrical System/Prototype_Final_KVM_Board|final KVM board]]. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint [[Beobot 2.0/Electrical System/PropStick | PropStick]]) to control the KVM USB and VGA.
	|-		|-
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	|[[Image:BreakoutBoard Altium2D.JPG|200px]]		|[[Image:BreakoutBoard Altium2D.JPG|200px]]
	|[[Image:BreakoutBoard Altium3D.JPG|200px]]		|[[Image:BreakoutBoard Altium3D.JPG|200px]]
-	|The board would be hanging on top of the KVM board. '''SOLIDWORKS''': not modeled. '''ALTIUM''': The folder is "BreakoutBoard Prototype2".	+	|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: [[Beobot 2.0/Electrical System/Prototype_Final_BreakoutBoard|final Breakout board]]		|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: [[Beobot 2.0/Electrical System/Prototype_Final_BreakoutBoard|final Breakout board]]
	|-		|-
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	|[[Image:BackMainBoard Altium2D.JPG|200px]]		|[[Image:BackMainBoard Altium2D.JPG|200px]]
	|[[Image:BackMainBoard Altium3D.JPG|200px]]		|[[Image:BackMainBoard Altium3D.JPG|200px]]
-	|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 folder is "PanelMountBackBoard Prototype2".	+	|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: [[Beobot 2.0/Electrical System/Prototype_Final_BackMainBoard|final back main board]]		|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: [[Beobot 2.0/Electrical System/Prototype_Final_BackMainBoard|final back main board]]
	|-		|-
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	|[[Image:DisplayBoard Altium2D.JPG|200px]]		|[[Image:DisplayBoard Altium2D.JPG|200px]]
	|[[Image:DisplayBoard Altium3D.JPG|200px]]		|[[Image:DisplayBoard Altium3D.JPG|200px]]
-	|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 folder is "PanelMountDisplayBoard Prototype2".	+	|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.		|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: [[Beobot 2.0/Electrical System/Prototype_Final_DisplayBoard|final display board]]		There is 1 prototype: [[Beobot 2.0/Electrical System/Prototype_Final_DisplayBoard|final display board]]
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	|[[Image:USB8Board Altium2D.JPG|200px]]		|[[Image:USB8Board Altium2D.JPG|200px]]
	|[[Image:USB8Board Altium3D.JPG|200px]]		|[[Image:USB8Board Altium3D.JPG|200px]]
-	|Would be at the side top of the robot. '''SOLIDWORKS''': Not modeled. '''ALTIUM''': The project is "PanelMountBackBoard Prototype2.prjpcb".	+	|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: [[Beobot 2.0/Electrical System/Prototype_Final_USB8_Board|final USB8 board]]		|This is a small USB adapter for 8 panel mount outlets. There is 1 prototype: [[Beobot 2.0/Electrical System/Prototype_Final_USB8_Board|final USB8 board]]
	|-		|-
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	|[[Image:USB4Board Altium2D.JPG|200px]]		|[[Image:USB4Board Altium2D.JPG|200px]]
	|[[Image:USB4Board Altium3D.JPG|200px]]		|[[Image:USB4Board Altium3D.JPG|200px]]
-	|Would be at the side top of the robot. '''SOLIDWORKS''': Not modeled. '''ALTIUM''': The project is "PanelMountBackBoard Prototype2".	+	|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: [[Beobot 2.0/Electrical System/Prototype_Final_USB4_Board|final USB4 board]]		|This is a small USB adapter for 4 panel mount outlet. There is 1 prototype: [[Beobot 2.0/Electrical System/Prototype_Final_USB4_Board|final USB4 board]]
	|}		|}
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	|[[Image:SensorBoard Altium2D.JPG|150px]]		|[[Image:SensorBoard Altium2D.JPG|150px]]
	|[[Image:SensorBoard Altium3D.JPG|150px]]		|[[Image:SensorBoard Altium3D.JPG|150px]]
-	|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 folder is "SensorBoard Prototype2".	+	|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: [[Beobot 2.0/Electrical System/Prototype_1_SB|P1 Sensor board]]. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint [[Beobot 2.0/Electrical System/PropStick | PropStick]]) to format some of the serial data from sensors.		|The Sensor Board manages sensors such as GPS, IMU, and Compass. It also has a few open pins for expansion. There is 1 prototype: [[Beobot 2.0/Electrical System/Prototype_1_SB|P1 Sensor board]]. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint [[Beobot 2.0/Electrical System/PropStick | PropStick]]) to format some of the serial data from sensors.
	|}		|}
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	|[[Image:MotorBoard Altium2D.JPG|150px]]		|[[Image:MotorBoard Altium2D.JPG|150px]]
	|[[Image:MotorBoard Altium3D.JPG|150px]]		|[[Image:MotorBoard Altium3D.JPG|150px]]
-	|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 folder is "MotorBoard Prototype2".	+	|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: [[Beobot 2.0/Electrical System/Prototype_1_MB|P1 motor board]]. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint [[Beobot 2.0/Electrical System/PropStick | PropStick]]) to control the motor inputs (either from the RC or the cluster).		|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: [[Beobot 2.0/Electrical System/Prototype_1_MB|P1 motor board]]. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint [[Beobot 2.0/Electrical System/PropStick | PropStick]]) to control the motor inputs (either from the RC or the cluster).
	|}		|}
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	|[[Image:CoolingBoard Altium2D.JPG|200px]]		|[[Image:CoolingBoard Altium2D.JPG|200px]]
	|[[Image:CoolingBoard Altium3D.JPG|200px]]		|[[Image:CoolingBoard Altium3D.JPG|200px]]
-	|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 folder is "CoolingBoard Prototype2".	+	|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: [[Beobot 2.0/Electrical System/Prototype_1_CB|P1 cooling board]]. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint [[Beobot 2.0/Electrical System/PropStick | PropStick]]) to process sonar as well as flowmeter data.		|There is 1 prototype: [[Beobot 2.0/Electrical System/Prototype_1_CB|P1 cooling board]]. Note that we use a Propeller microcontroller (that we package in a DIP40 footprint [[Beobot 2.0/Electrical System/PropStick | PropStick]]) to process sonar as well as flowmeter data.
	|}		|}

---

Revision as of 00:00, 4 Nov 2009

The electrical system consists of the following components: computing cluster, KVM system, power boards, sensors, motor control, and cooling system. This section also going to discuss the design decisions, part manufacturing, assembly, as well as testing.

Note that the first 2 sections (Deadlines and To Do) is an ongoing internal message board. The public section starts at the Block Diagram section.

Table of contents

1 Deadlines 2 To Do 3 Block Diagram 4 Design And Implementation 4.1 Altium Files 4.2 Electronic Boards Related Cost 5 Electrical Sub-systems 5.1 Computing Clusters 5.1.1 Purchased Components 5.1.2 Boards 5.2 Keyboard Mouse Monitor (KVM) system Display Devices 5.2.1 Purchased Components 5.2.2 Boards 5.3 Input/Output Interface 5.3.1 Purchased Components 5.3.2 Boards 5.4 Power System 5.4.1 Purchased Components 5.4.2 Boards 5.5 Sensors 5.5.1 Purchased Components 5.5.2 Boards 5.6 Motor Control 5.6.1 Purchased Components 5.6.2 Boards 5.7 Cooling System 5.7.1 Purchased Components 5.7.2 Boards 6 Future Additions

Deadlines

Todo	Date
First Electrical prototype started	September 14, 2008
First Electrical prototype sent to AdvancedCircuits	October 31, 2009
Main Robot Order out	November 17, 2008
* Part List 1 (http://spreadsheets.google.com/pub?key=pI3A5bo5esPAACrmXN17MYQ)
First Electrical prototype tested	January 21, 2009
Electrical prototype 1.1 tested	February 26, 2009
Robot Order BOM2 Sent out	April 15, 2009
* Part List 2 (http://spreadsheets.google.com/pub?key=pD1mdbmFyQFSFLRtZWSVhBw)
Final Electrical prototype Sent to AdvancedCircuits	April 28, 2009
Final Electrical peripheral boards tested	May 31, 2009
Final Electrical base boards tested	June 22, 2009
Robot done	July 1, 2009

To Do

• Final Baseboard testing

  * Power and cooling for all 8 computers simultaneously from the battery

• ATX Power cable from:

  * KVM to Sensor board
  * Sensor board to motor board

• Touch Screen:

   VGA-touch_screen connector: VGA, USB, Power (12V) 
   Make Touch Screen to work on Linux

• Firewire setup

  * card secure mounting 
  * panel mount connector
  * cable to top

• wireless

 open wrt get it up and running in old version and then upgrade to new version.
 download new firmware.  

• Cooling Control Board & sonar (Propeller code)

• sensors:

  * Compass
  * edge sensors (figuring out that the robot is on the edge of a cliff)
  * Microphone
  * Bump Sensor
  * Smell Sensor : )

• Request more COM Express Connector

Block Diagram

Design And Implementation

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 (http://www.altium.com/). We include a tutorial.
• The boards are manufactured by Advanced Circuits (http://www.4pcb.com/).
• Most electronics components are purchased from Digikey (http://www.digikey.com/).
• 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.

Altium Files

Here is the BEOBOT2.0 ZIP FILE (http://ilab.usc.edu/siagian/Beobot2.0/Beobot2.0Altium.zip) of all the Altium project, Gerber files and Bill of Materials (BOM). FIXXX We will post a README file soon.

Electronic Boards Related Cost

Number	Item	Purpose	Cost	Count	Item Total	Supplier	Notes
1	Board Manufacturing	For all boards	$620.39	1	$620.39	Advanced Circuits (http://www.advancedcircuits.com/)	Student discounts, combine boards to reduce price
2	Electronic Components	Various (see FIXXX for BOM)	$7185.85	1	$7185.85	Digikey (http://www.digikey.com/)	minus the connectors itemized in subsections below
3	[Electronics component assembly	for the .5mm pitch COM Express connector	$250	1	$250	Assembly House Incorporated (http://www.4pcbassembly.com/contact.html)

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

Electrical Sub-systems

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.

Number	Sub-sytem	Cost	Notes
1	Electronics	$8056.24
2	Computing Cluster	$7779.09
3	KVM	$327.95
4	Input/Output	$46.8
5	Power	$777.20
5	Sensors	$2666.33
5	Motor Control	$605.99
5	Cooling	$17

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

Computing Clusters

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 (http://www.4pcb.com/) 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.

Purchased Components

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

Number	Item	Purpose	Cost	Count	Item Total	Supplier	Notes
1	Kontron ETXexpress-MC (http://www.wdlsystems.com/modperl/view_services.cgi?r=detail&prod_num=1JXMC22&aisle_id=970)	COM Express Module	$708	8	$5664	WDL systems (http://www.wdlsystems.com/)	Only Kontron Supplier in US
2	Heatspreader for ETXexpress-MC (http://www.wdlsystems.com/modperl/view_services.cgi?r=list_aisle.plate&aisle_id=970)	threaded hole heat spreader	$24	8	$192	WDL systems (http://www.wdlsystems.com/)
3	Memory (http://www.newegg.com/Product/Product.aspx?Item=N82E16820145172&Tpk=N82E16820145172)	two 2GB SO-DIMM Memory per computer	$27.99	16	$447.84	Newegg (http://www.newegg.com/)
4	Solid State Hard Drive (http://www.newegg.com/Product/Product.aspx?Item=N82E16820609393)	64GB SATA SSD HD	$138	8	$1104	Newegg (http://www.newegg.com/)
5	Gigabit Ethernet Switch  (http://www.newegg.com/Product/Product.aspx?Item=N82E16833122139&Tpk=N82E16833122139)	NETGEAR GS116	$162.99	1	$162.99	Newegg (http://www.newegg.com)
6	Gigabit Ethernet Cables (http://www.newegg.com/Product/Product.aspx?Item=N82E16812119157)	Cat 6 for Gigabit Ethernet	$.69	12	$8.28	Newegg (http://www.newegg.com/)
7	WiFi Access Point (http://www.newegg.com/Product/Product.aspx?Item=N82E16833156178)	TRENDnet TEW 453APB	$99.99	2	$199.98	Newegg (http://www.newegg.com/)

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

Boards

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.

Keyboard Mouse Monitor (KVM) system Display Devices

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.

 (http://store.mp3car.com/v/vspfiles/photos/MON-029-2T.jpg)

Related information:

• eGalax Touchscreen Driver (http://home.eeti.com.tw/web20/eg/drivers.htm)
• eGalax Touchscreen Setup (http://tzilla.is-a-geek.com/articles/egalax/)
• eGalax Touchscreen Setup (http://wiki.linuxquestions.org/wiki/EGalax_Touchscreen)

Purchased Components

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

Number	Item	Purpose	Cost	Count	Item Total	Supplier	Notes
1	LCD touchscreen (http://store.mp3car.com/ProductDetails.asp?ProductCode=MON-029)	889GL-80NP/C/T	$268	1	$268	Mp3Car (http://store.mp3car.com/)
2	camera post (http://www.bhphotovideo.com/c/product/272449-REG/Manfrotto_by_Bogen_Imaging_486RC2_486RC2_Compact_Ballhead_w_Rapid.html)	Compact Ballhead with Rapid Connect System	$59.95	1	$59.95	B&H Photo Video (http://www.bhphotovideo.com/)

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

Boards

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

Input/Output Interface

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.

Purchased Components

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

Number	Item	Purpose	Cost	Count	Item Total	Supplier	Notes
1	6" FireWire panel mount connector cable (http://www.usbfirewire.com/Parts/rr-gcfrextp-66r01-14.html)	connection from firewire card to panel mount connector	$23.1	1	$23.1	USBfirewire.com (http://www.usbfirewire.com/)
2	24" FireWire cable (http://www.usbfirewire.com/Parts/rr-gcfs-66r03-12.html)	panel mount connector to camera	$23.7	1	$23.7	USBfirewire.com (http://www.usbfirewire.com/)

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

Boards

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 System

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.

Purchased Components

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

Number	Item	Purpose	Cost	Count	Item Total	Supplier	Notes
1	PICO ATX PSU (http://www.mini-box.com/PicoPSU-80-WI-32V;jsessionid=0a010c441f4301a7c5985f50440d8c689b39b28c162d.e3eTa3aSaxmTe34Pa38Ta38Mch50?sc=8&category=13)	12-32V input DC-DC ATX power supply unit (PSU)	$55.5	10	$555	miniBox (http://www.mini-box.com/)	Almost 10% discount when buying 10 to 49 ($15 for the 10th module)
2	Fuses (http://www.crutchfield.com/p_211FAFS40/StreetWires-AFS-Fuses-40-amp.html?search=211FAFS40+&ssi=0&tp=1806)	40-amp AFS Fuses	$9.99	1	$9.99	Crutchfield (http://www.crutchfiled.com/)
3	Fuse Holder (http://www.crutchfield.com/p_211FHXS8/StreetWires-FHXS8-AFS-Fuse-Holder.html?search=211FHXS8+&ssi=0&tp=2188)	AFS Fuse Holder 8-ga.	$24.99	1	$24.99	Crutchfield (http://www.crutchfiled.com/)
4	Ground Cable (http://www.crutchfield.com/p_211UFX8B/StreetWires-Ultra-Flow-8-gauge-Power-Cable-Blue.html?search=211UFX8B&ssi=0&tp=2472)	per ft 8 ga. Blue Power Cable	$1.25	10	$12.5	Crutchfield (http://www.crutchfiled.com/)
5	Power Cable (http://www.crutchfield.com/p_211UFX8R/StreetWires-Ultra-Flow-8-gauge-Power-Cable-Red.html?search=211UFX8R&ssi=0&tp=2472)	per ft 8 ga. Red Power Cable	$1.25	10	$12.5	Crutchfield (http://www.crutchfiled.com/)
6	Battery Power Connector (recpt) (http://search.digikey.com/scripts/DkSearch/dksus.dll?lang=en&site=US&WT.z_homepage_link=hp_go_button&KeyWords=ACC02E22-22P%28025%29-ND&x=21&y=21)	CONN RECEPT PNL MT 4POS SIZE 8	$34.59	1	$34.59	Digikey (http://www.digikey.com/)
7	Battery Power Connector (plug) (http://search.digikey.com/scripts/DkSearch/dksus.dll?lang=en&site=US&WT.z_homepage_link=hp_go_button&KeyWords=ACC06E22-22R%28025%29-ND&x=4&y=20)	CONN PLUG FREE/HANG 4POS SIZE 8	$56.67	1	$56.67	Digikey (http://www.digikey.com/)
8	KVM Power Connector (recpt) (http://search.digikey.com/scripts/DkSearch/dksus.dll?lang=en&site=US&WT.z_homepage_link=hp_go_button&KeyWords=C10-638974-000-ND)	CONN PLUG RADSOK 2POS	$15.4	2	$30.8	Digikey (http://www.digikey.com/)
9	KVM Power Connector (plug) (http://search.digikey.com/scripts/DkSearch/dksus.dll?vendor=0&keywords=C10-638977-000-ND)	CONN RECEPT PIN RADSOK 2POS PCB	$14.1	2	$28.2	Digikey (http://www.digikey.com/)
14	Killswitch (http://us.100y.com.tw/ChanPin.asp?MNo=39181)	Emergency E-Stop Switch w/ LED	$2.99	4	$11.96	Cebtenary (http://us.100y.com.tw)	Import from Taiwan

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

Boards

The Power traces goes through the KVM and base boards.

Sensors

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

 (http://www.sparkfun.com/commerce/images/products/EM408-01-L.jpg)  (http://www.sparkfun.com/commerce/images/products/PNI-Eval-Board-Loaded.jpg)

 (http://www.microstrain.com/images/product/3dm-gx2.jpg)

• 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

Purchased Components

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

Number	Item	Purpose	Cost	Count	Item Total	Supplier	Notes
1	Firewire camera (http://www.unibrain.com/Products/VisionImg/Fire_i_DC.htm)	UniBrain FireI Camera	$109	1	$109	UniBrain (http://www.unibrain.com)
2	FireWire Card (http://)	PCI Express - Firewire card	$49	1	$49	UniBrain (http://www.unibrain.com/)
3	IMU (http://www.microstrain.com/3dm-gx2.aspx)	3DM-GX2 Inertial Measurement Unit	$1695	1	$1695	MicroStrain (http://www.microstrain.com.com/)
4	Compass (http://www.sparkfun.com/commerce/product_info.php?products_id=418)	MicroMag 3-Axis Magnetometer	$239.9	1	$239.9	SparkFun (http://www.sparkfun.com/)
5	GPS (http://www.sparkfun.com/commerce/product_info.php?products_id=8234)	20 Channel EM-408 SiRF III Receiver with Antenna/MMCX	$64.95	1	$64.95	SparkFun (http://www.sparkfun.com)
6	Sonar (http://www.senscomp.com/minis.htm)	SensComp Mini S sonar	$68.50	7	$68.50	SensComp (http://www.newegg.com/)
7	USB Hub (http://www.newegg.com/Product/Product.aspx?Item=N82E16817366017)	In case there is a need to add more USB connection	$7.99	2	$15.98	Newegg (http://www.newegg.com/)
8	24" USB cable (http://www.usbfirewire.com/Parts/rr-abr03-24.html)	24" right angle USB (connect sensor board with cluster)	$13	1	$13	USBfirewire.com (http://www.usbfirewire.com/)

Total sub-system cost: $2666.33 NOTE: prices may change and shipping cost not included. FIXXX: LASER RANGE FINDER IS DONATED

Boards

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.

Motor Control

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 (http://2.4gigahertz.com/systems/futk7000.html), 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.

 (http://2.4gigahertz.com/systems/futk7000-2.jpg)  (http://2.4gigahertz.com/receivers/futl7627b.jpg)

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).

Purchased Components

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

Number	Item	Purpose	Cost	Count	Item Total	Supplier	Notes
1	Radio Controller (http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXTTM1&P=7)	Futaba-7C 7-Channel 2.4GHz System	$279.99	1	$279.99	Futaba RC (http://www.futaba-rc.com/)
2	Motor Driver (http://www.dimensionengineering.com/Sabertooth2X25.htm)	SaberTooth 2x25 Motor Driver	$124.99	1	$124.99	Dimension Engineering (http://www.unibrain.com/)
3	24" USB cable (http://www.usbfirewire.com/Parts/rr-asbl01-24.html)	24" left angle USB (connect motor board with cluster)	$12.5	1	$12.5	USBfirewire.com (http://www.usbfirewire.com/)
4	Motor connector (recept) (http://search.digikey.com/scripts/DkSearch/dksus.dll?vendor=0&keywords=PT02E-14-12S-ND)	CONN RECEPT 12POS W/SOCKT SOLDER	$25.91	1	$25.91	Digikey (http://www.digikey.com/)
5	Motor connector (plug) (http://search.digikey.com/scripts/DkSearch/dksus.dll?vendor=0&keywords=PT06A-14-12P%28SR%29-ND)	CONN PLUG 12POS W/PINS SOLDER	$24.27	1	$24.27	Digikey (http://www.digikey.com/)
6	Motor power cable (http://www.parts-express.com/pe/showdetl.cfm?Partnumber=100-656%20%20%20%20%20%20%20%20&FTR=%20%20%09%20100-656&CFID=2301949&CFTOKEN=18682435)	Monster 14 AWG 4C Speaker Cable 1 ft. CL3	$1.45	25	$36.25	PartsExpress (http://www.partsexpress.com/)
7	Encoders (http://search.digikey.com/scripts/DkSearch/dksus.dll?lang=en&site=US&WT.z_homepage_link=hp_go_button&KeyWords=516-2018-nd&x=0&y=0)	OPT 2CH QUICK ASSM	$51.04	2	$102.08	Digikey (http://www.digikey.com/)

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

Boards

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).

Cooling System

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.

Purchased Components

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:

Number	Item	Purpose	Cost	Count	Item Total	Supplier	Notes
1	USB cable (http://www.usbfirewire.com/Parts/rr-ar4br1-36g.html)	16" double angle USB (connect cooling board with cluster)	$17	1	$17	USBfirewire.com (http://www.usbfirewire.com/)

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

Boards

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.

Future Additions

• Relay controller for head/tail lights
• Robotic arm FIXXXScorBot bought from ebay
• We also thought about using RGB LED Matrix with Serial Interface from Sparkfun (http://www.sparkfun.com) $59.95 each

   (http://www.sparkfun.com/commerce/images/products/00760-04-L_i_ma.jpg) for display.

Back to Beobot 2.0