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This allows for consistent and easier labeling of wires in the future (e.g., NWD = North West Drive motor). + +## Mounting Electronics + +See [Component Mounting](Component%20Mounting.md) and [Bolt to Tool Lookup](../Mechanical/Bolt%20to%20Tool%20Lookup.md) for tools to use. + +| Device | Bolt Size | Bolt Length | Notes | +| ------------ | ---------- | ----------- | --------------------------------------------------------------------------- | +| PDH | 10-32 Bolt | 3/4" | | +| RoboRIO 2.0 | 4-40 Bolt | 1/4" | RIO has a 3D printed cover that keeps all wires in place | +| CANivore | 4-40 Bolt | 3/4" | CANivore has a 3D printed cover that keeps the wire from unplugging. **THIS IS REQUIRED!!** | +| Pigeon 2.0 | 4-40 Bolt | 3/4" | | + +## Planning Wire Routes (String Method) + +Once electronics are mounted, use 3 different strings to plan wire routes **before** running any real wires. Route the string in this order: + +| String | Represents | +| ----------------------- | --------------------------------- | +| 🔴 Red thick string | 10 or 12 AWG power wires | +| 🟠 Orange thin string | 18 AWG power wires | +| ⬜ White thin string | CAN wire | + +!!! important + + Once all strings are laid, **get approval from a mentor** before proceeding to run real wires. + +![String method — wire routes planned with colored string](../.images/Electrical/DrivetrainWiring101/01-string-planning.png) + +## Wire Routing + +After mentor approval, run the real wires following the same order as the strings above (thickest wires first, then thinnest): + +1. 10 AWG power wires +2. 18 AWG power wires +3. CAN wires + +## Wire Labeling + +As you wire, label every wire with zip tie labels. + +!!! important + + Color of zip tie labels is important. Be sure to follow the **year-specific color coded wire guide**. The label color may change year to year — always check before starting! + +!!! note + + Use the label maker with **clear background labels** so the zip tie label color is still visible. + +### FROM/TO Labeling Convention + +Labels indicate which device the wire goes **FROM** and which device it goes **TO**. + +- **Both ends** of every wire must be labeled. +- Format: `FROM DEVICE` on top, `TO DEVICE` on bottom (separated by a dividing line). + +**Example:** A wire going from the PDH to the North West Drive motor: + +- PDH end label: `PDH/NWD` +- NWD end label: `NWD/PDH` + +![Real wires routed on the drivetrain with zip tie labels](../.images/Electrical/DrivetrainWiring101/02-real-wires.png) + +## PDH Breakers + +- **Top slots (10 or 12 AWG):** Use 40-amp breakers (🟠). +- **Smaller fuse slots (18 AWG):** Use small 10-amp fuses (🔴). + +## Main Power Wires + +Main power wires connect the battery to the robot's power system using 4 AWG red (positive) and black (negative) wire. + +### Making the Battery-Side End + +1. Source 4 AWG red and black wire. Choose either positive (red) or negative (black) to start. +2. Strip the wire to the **silver sharpie line** on the wire stripper. + + ![Wire stripper](../.images/Electrical/DrivetrainWiring101/03-wire-stripper.png) + +3. Place a **swaged SB50 Battery contact** on the stripped end and crimp. + +#### Swaging the SB50 Battery Contact + +1. Take the swage guide and place it in with the **curve facing down**. Make sure it is as straight as possible. +2. Once secured in the guide, take it to the **arbor press**. +3. Press starting from **small tool to big**, then end by pressing with the **concave end**. + +![Swage press tools (small, medium, and concave)](../.images/Electrical/DrivetrainWiring101/04-swage-tools.png) + +![Battery Swage Tool in the arbor press](../.images/Electrical/DrivetrainWiring101/05-arbor-press.png) + +#### Crimping the Swaged Contact + +- Use the **hydraulic crimper** with the **2 AWG crimp attachments** (even though the wire is 4 AWG). + + ![Hydraulic crimper with 2 AWG attachments on 4 AWG wire](../.images/Electrical/DrivetrainWiring101/06-hydraulic-crimper.png) + +- After crimping, fins will stick out the sides — **turn the crimp 90° and crimp again** to flatten the fins. + + ![Crimped wire with fins — rotate 90° and crimp again to flatten](../.images/Electrical/DrivetrainWiring101/07-crimped-wire.png) + +- Once all sides are flat, insert the contact into the **red SB50 AndyMark Battery Housing**. + + ![Flattened fins after second crimp](../.images/Electrical/DrivetrainWiring101/08-fins-flattening.png) + + - Make sure the curved hook side of the swage hooks over the metal prongs inside the Battery Housing. + + ![SB50 AndyMark Battery Housing with swaged contact inserted](../.images/Electrical/DrivetrainWiring101/09-battery-housing.png) + +4. Repeat for the other colored wire (red or black) and **get approval from a mentor**. + +### Cutting and Completing the PDH-Side End + +5. Once approved, have a mentor consult on the correct wire length to cut. (This can change year to year.) +6. Cut the wire to the desired length. +7. Slide a piece of **clear heat shrink** onto the end that does not already have the Battery Housing. +8. Strip this end **twice** to the gray line on the wire stripper. +9. Slide the heat shrink back to cover half of the exposed wire and heat shrink it. +10. The wire is now ready to connect to the PDH. + +!!! note + + For the red power wire, you will need to follow the [Main Breaker Wiring](#main-breaker-wiring) section below, since you essentially have two red wires. + +## Main Breaker Wiring + +The main power breaker has two ports for wire connection. **Only positive (red) 4 AWG wire** should be connected to both terminals. The breaker acts as an interruptor of the positive circuit: + +- **Closed (flipped shut):** power flows and the robot is on. +- **Red button pressed / switch flipped open:** circuit is interrupted and the robot shuts off. + +### Steps + +1. Strip the end of 4 AWG red wire once to the **gray line** on the wire stripper. +2. Slide a **4 AWG Breaker 1/4" Ring Terminal** onto the stripped end. +3. Use the **hydraulic crimper** with the **4 AWG attachments**. +4. Repeat this crimp for **two** 4 AWG red wire ends: + - One on the **opposite end of the red SB50 Battery Housing** wire. + - One on a **separate piece of 4 AWG red wire** that will go from the Main Breaker to the PDH. +5. The wire with the SB50 Housing is now ready to connect to the Main Breaker. Don't forget the **NordLock Washers** that sit on top of the ring terminals when tightening! +6. For the MB-PDH wire: once you know the wire length, cut it to length and complete the PDH-side end following steps 7–9 from [Main Power Wires](#main-power-wires) above. + +!!! important + + Once all wires are laid and connected, **ask a mentor for final approval** before powering on the robot. + +## Swerve Diagram + +![Swerve Drivetrain Wiring Guide](../.images/Electrical/29x29DrivetrainWiringGuide.svg) diff --git a/Electrical/Wiring Cheat Sheet.md b/Electrical/Wiring Cheat Sheet.md index ce76d441..444d3b20 100644 --- a/Electrical/Wiring Cheat Sheet.md +++ b/Electrical/Wiring Cheat Sheet.md @@ -74,10 +74,6 @@ | 18 AWG | [20A 🟡 Breaker](https://www.revrobotics.com/auto-resetting-breakers/) | | 22 AWG | 5A Breaker or [10A 🔴 Fuse](https://www.andymark.com/products/10-amp-mini-red-fuse?via=Z2lkOi8vYW5keW1hcmsvV29ya2FyZWE6Ok5hdmlnYXRpb246OlNlYXJjaFJlc3VsdHMvJTdCJTIyYnV0dG9uJTIyJTNBJTIyc2VhcmNoJTIyJTJDJTIycSUyMiUzQSUyMmZ1c2UlMjIlMkMlMjJ1dGY4JTIyJTNBJTIyJUUyJTlDJTkzJTIyJTdE) | -## Swerve Diagram - -![Swerve Drivetrain Wiring Guide](../.images/Electrical/29x29DrivetrainWiringGuide.svg) - ## Tips 1. When putting multiple wires into one connector (e.g. Kraken CAN Wire) the size becomes Original AWG - 3 (e.g. two 18 AWG - 3 = 15 AWG)