 Robot: Dohn Joe
(Sub-section
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Robot: Dohn Joe
(Sub-section
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1) Power supply boards includes motor amplifiers etc
2) Bottom sensor boards. Has downward looking sensors to look for the edge of the table and also for line following etc.
3) CPU main board with AtoD etc.
4) Dedicated 2n'd FPGA w/video input processors
5) Display carrier/mounting board + switch inputs & Inverter..
6) Radio Board
7) Gyro_boards (2x)
8) Compass Module Board (purchased)
9) Tilt Module Board (purchased)
10) Backlight Inverter (1.5Kv) (purchased)
11) GPS interface board (purchased)
12) IR interface board (purchased)
13) Blue Tooth Datalink (purchased)
 Electrical Systems |
1) Power Supplies
2) Bottom Sensor Board (2x qty) -2 AtoD converters (8 Ch/ea) - FPGA (MAX1245) (4 lines, 3 out 1 in) -8~12 LEDs + MOSFETs (2n7002) + resistors (1206) (FPGA) (1 line) -8 Photo Diodes + resistors. -4 IR distance sensors (ground fall away)
3) Processor board  Click to Enlarge:  Click to Enlarge:  Click to Enlarge:  Click to Enlarge:  Click to Enlarge:
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-1 220MIPS 32 bit processor(5407)
-1 BDM
-1 Reset Chip (TPS3106K33)
-8 meg FLASH (AM29F641)
-8 meg SDRAM (MT48LC2M32B2TG-7)
-1 boot logic (ISPLSI2032VE)
-1 clock distribution (CY2309SI-1H) + osc (M216TCN50MHZ)
-1 FPGA (XC2S-300E)
-5 Encoders + Level Shifters (FPGA) (10 lines)
-5 SPI bus masters (4 ADC's + 1 DAC)
-3 I2C bus masters(3 video)
-5 PWM motor drivers + enables & Direction signals
-3 UARTS (Radio Module + tilt sensor + GPS)
-1 PWC Pulse Width Capture (Compass Module)
-3 74ALVC164245 3.3v to 5v level converters
-2 MAX3232 RS232 level converters
-1 expansion connector to daughter board.
-8 sonars + 3.3V => 5V converters - FPGA (SFR04's)
(16 lines 1 out + 1 in * 8)
-1 standard debug RS232 port (MAX3232CUE)
-1 AtoD 12bit (8 Ch/ea)-FPGA (MAX1245) (12 lines)
-8 ch IR sensors (AtoD3) (GPD12)
-1 Heartbeat LED + drivers
-2 buffered address & data bus drivers to drive busses offboard.
This board: 181 total components
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4) Display Board
 Click to Enlarge:  Click to Enlarge:  Click to Enlarge:  Click to Enlarge:  Click to Enlarge:
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-1 Display (FPGA) (19 lines 15data+4control) + Connector
-6 switch inputs + caps & pull-ups (FPGA) (8 lines)
-4 LED's + resistors & MOSFET's 2n7002 (FPGA)(1line)
-2 Sound Frequency Detector + Mic - (FPGA) (1 line)
-1 AtoD 12bit (8 Ch/ea) - FPGA (MAX1245) (12 lines, 3 out 1 in)
(requires SPI)
-2ch Microphone (MD6052ASZ-2) + OpAmp (AtoD1)
-2ch accelerometer XY(MMA3201D) (AtoD1-2ch)
-4ch Rate gyro board inputs.(Tokin CG-L43A0)(2EA)
-1 (DtoA) MAX5253 (1 SPI port from FPGA)
-2 Speaker + (LM386) + DtoA (extra channels from above MAX5253)
-1 Breakout SPI to parallel interface (MAX6597)
-1 Secure digital Interface + 512M-Byte Flash.
This board: 103 total components
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There is a slight need for a bit of rework here. The MAX6597 doesn't want to play in SPI parallel mode nicely along with the other IC's on this board. I'll have to lift the MISO pin and and forgoe the input funcitons from that device.
5) Video Daughter board  Click to Enlarge:  Click to Enlarge:  Click to Enlarge:  Click to Enlarge:  Click to Enlarge:
| -1 FPGA (XC2S-200E) -3 additional in dependant I2C ports. -3 Lasers + MOSFETs (VIP_INTF) w/field generator optics -3 Cameras + VIP (FPGA) (80 lines,16 data+2 control+2 I2C) -3 Phillips SAA7111A video input processors -1 xtal oscillator (24.576 MHz) & clock Dist circuitry -4 resistors, LED's & MOSFET's 2n7002 -2 High Speed Static RAM(2x) (512K) (FPGA) (38 lines) This board: 123 total components
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6) Radio Board  Radio Installed: 
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-33.6Kbaud radio transceiver module + antenna - RS232.
TR-900-SC-PA
(Requires FPGA UART + 3.3V => 5v Con (74ALVC164245))
- 1 adjustable signal strength indicator
This board: 6 total components
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7) Gyro Board  Click to Enlarge: 
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-2 rotational rate gyro (Tokin CG-L43A0) (AtoD1)
-1 6 conductor interface cable (2 power, 2 reference, 2 signal)
(Requires AtoD interface which uses QSPI through FPGA)
-1 Amplifier & twin coupled analog high pass filters
-1 LMH6642 LV, RtoR op-Amp.
This board: 14 total components
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8) Compass Module Board 
-1 4 wire interface to PWC IN FPGA + Power
(requires FPGA PWC (pulse width capture) & I2C interface)
9) Tilt Module Board
-1 6 wire interface to Power & UART function in FPGA.
(requires FPGA UART interface requires RS232C conversion)
10) GPS Module Board
-1 20 wire interface to Power & UART function in FPGA.
(requires FPGA UART interface for 3.3v signals)
11) Display Backlight Inverter
-12V DC to 1.5Kv-AC inverter
Includes on/off controls (Discrete FPGA-MOSFET)
Dimming control (control chain FPGA-SPI-DtoA)
So... Add about a gazillion power supply filter components decoupling caps, pull up/down resistors, bias & reference generators and you'll start to see the incredible battle I'm up against. :-)
Amongst all those connectors populating the different boards is one heck of a lot of wire & crimp connectors. The photo below is a pretty good example of that. Each individual wire is cut to length, marked for stripping length, stripped, trimmed for exposed length, crimped & inserted into the socket.
And the photo below shows some of these boards connected together during the debugging phase. In this photo, I'd just got the locked antiphase motor control up and running. In the foreground center (underneath) is the joystick (pot) used to test the AtoD system. Next to this, the large silver dongle connected to the 25 pin D-Sub cable is the P&E micro low voltage BDM driver cable. To the right of that the is the connection of the 9-pin serial port, and further to the right of that is the first DC motor to be hooked to the system. Next, the encoders.
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