controller manual
Contents
1. Motor 3 is an optional device pins 10 11 and 12 are merely brought out to a pin header The location of these pin outs are shown in the Pin Header Breakout section Voltage Sensing Analog pin 6 A6 is used to sense the voltage on the last junction prior to ground of a 10K 10K 10K series resistor voltage divider connected from battery to battery also tied to Arduino ground A voltage divider is used because the recommended battery an E Flite EFLB8002SJ30 two cell Lipo has a charge voltage of about 8 4 volts The Arduino Nano analog pins can sense voltages up to a maximum of 5 volts By using the three resistor voltage divider a LiPo 2 cell or 3 cell battery can be monitored by simply multiplying the sensed voltage by three Here is an example calculation 3 ADC counts 5 1024 battery voltage AnalogReference must be set to DEFAULT and at least one analog sample taken prior to sampling the battery voltage Current Sensor The ACS715 current sensor uses the same circuit configuration as the Pololu part number 1186 however the Pololu part is a 30 amp chip and the part used for the AEV is a 20 amp model Analog pin A7 monitors the output voltage of the ACS715 which outputs a nominal 0 5 volts at O amps and increases in voltage by 0 185 volts per amp To increase the resolution of the 10 bit analog to digital converter while sampling the current sensor the external reference pin is pulled down to 2 46 volts2. 5 32K 32K 33K 2 46 volts instead of the default 5 volts by using a 33K resistor tied to ground The actual calculation is explained here The software collects the initial ADC count ADCi prior to the run which corresponds to the 0 5 volts at zero amps During the run the current calculation in amps is 2 46 ADC counts ADCi 1024 0 185 amps AnalogReference must be set to EXTERNAL and at least on analog sample must be taken prior to sampling the current sensor Wheel Count Sensors The system software has the ability to use digital pins 2 and 3 to monitor wheel rotation using a quadrature type encoder algorithim with reflectance type sensors as shown in the immediate picture using a wheel with alternating reflective and non reflective surfaces Wheel counting requires continuous background updating while the main program is running and the Arduino Nano has two pins digital 2 and digital 3 capable of handling interrupts Interrupts provide the necessary background processing triggers Pins 2 interrupt 0 and 3 interrupt 1 are brought out on separate motherboard pin headers and shown in the Motherboard Headers section Motherboard Pin Header Layout This section shows the location of the broken out pins Appendix B is a table showing Arduino Nano pins and their use with the AEV project and whether or not they are broken out to separate headers on the motherboard Some pins are not used at all while others can
3. 6 3 7 2 8 amp 8 1 9 1 10 1 11 4 12 Eagle Files single board SS22SDH4 ND ED1520 ND Description SW SLIDE DPDT SIDE ACT GOLD 28V TERMINAL BLOCK 3 5MM 8POS PCB IC EEPROM 256KBIT 400KHZ 24LC256T I SNDKR ND8SOIC 620 1230 6 ND P4 7KGDKR ND P1OKGDKR ND 311 1343 6 ND P33KGDKR ND 445 5659 6 ND P8081SCT ND S7041 ND SENSOR CURRENT 20A 5V UNI 8 SOIC RES 4 7K OHM 1 10W 5 0603 SMD RES 10K OHM 1 10W 5 0603 SMD CAP CER 0 1UF 50V Y5V 0603 RES 33K OHM 1 10W 5 0603 SMD CAP CER 1000PF 50V 10 X7R 0603 SWITCH TACTILE SPST NO 0 02A 15V CONN HEADER FEMALE 8POS 1 GOLD Other Pin Header As Shown Equiv To 11 Price 2 232 1 38076 0 72379 2 08287 0 00891 0 00721 0 00955 0 01605 0 02232 0 16402 0 4122
4. be used for multiple items buses Usable pins have been broken out on the motherboard usually in pin header groups of three consisting of a signal pin a 5 volt pin and a ground pin Cables There are three JST cables battery uses male JST attached to the board with room for an optional cable that would supply power to a separate motor control chip used for a third motor Battery to motor 3 leads Optional Battery Plus Red Battery Neg Blk Motor 2 Leads The motor cables are not polarity sensitive just determines initial motor rotation direction The battery cable is polarity sensitive and can easily destroy the entire board if wired backwards Sensor Pin Headers As previously mentioned digital pin 2 and digital pin 3 are interrupts used for background processing of the quadrature type wheel counter implemented in the AEV6 software The provided sensors are attached to a three wire extension with wire colors of white red and black For consistency please make sure the black wire attaches to the labeled ground GND pin of the sensor The sensors attach to the following locations black wire to ground white to digital pin D3 pin 5v in GND 5 D2 pin l a N Shown below are the reflectance sensors attached to the wheel mounting strut When using quadrature encoding you will need to determine the proper sensor orientation by trail and error If when moving forward on the track the track
5. counts decrease or go negative just swap the sensor locations digital 2 plug and digital 3 plug Button Extender The pushbutton mounted on the motherboard is held down for a second or so as a signal to the software to begin the run This button may not be in a convenient location when the vehicle model is complete The two pin female header located next to the button allows an extension to be run to a remote button The button has no pull up resistor associated with it To use the button the parallel implementation of D4 to GND on the button extension make sure you use the proper pinMode setup command pinMode 4 INPUT_PULLUP GND Button Extension Servo Header Digital 9 is often used for servo operation D9 is brought out on a three pin female header consisting of GND 5v and D9 Please note that microcontrollers have several clocks but multiple process calls to a Clock may cause conflicts On boards other than the Mega use of the servo library disables analogWrite PWM functionality on pins 9 and 10 whether or not there is a Servo on those pins from Arduino Reference Thus the normal servo library could not be used if the optional third motor is employed There are several alternate servo libraries that can be tried if a conflict is suspected http playground arduino cc ComponentLib Servo http arduiniana org libraries pwmservo GND 5v D9 The mini servo has brown red and orange wires Brown
6. AEV 6 Integrating an Off the Shelf Microcontroller amp Motor Control For the Advanced Energy Vehicle Project User Manual Rev 0 Table of Contents AEV Controller Design Goals Re is 3 Motherboard Active Surface Mount Pai A A AR ta ias 4 External Pat tS ali SS A a cae naan eades 5 PINOS At is dad 7 Us A E AE AAE EE E AEE EAEE Ei 7 Noag Ce INS NE a E a E maps ie eee eee 7 Current Sens Ok ri Aia 8 Wheel Count Senso a A alo 8 Motherboard Pin Header Layo tcsrserrie n o a A AAA 9 Cape S E A A E E A T Ne EER ANY 9 DCIS OF PIN H Ead Cl a EA 10 Button Eden COD aetna terete se dere O E E aciced 11 Servo Header duos lod 12 Wireless Header tl E TE 13 Unused Analog PIE A ts 14 Lira WEOTOR Oro PLA Cade ere e ais 15 IG Bus Extension Hed ed fat alas Ses 16 Appendix A The Unofficial Arduino Nano Pinout cccccccccccceccccccceeeeeesssseeeeeececcccceeeeeeeeaaeaesees 17 Appendix Bz PI SAC Casas aa ASA viestuiuie salaumntese aerate 18 Appendix C Bill Ob Materia St 19 AEV Controller Design Goals Results Light Weight 23 grams bare motherboard 43 grams w cables Arduino motor controllers mm 4103 613 IC KAALI 8 a Small Size f 1 2 inches wide x 3 7 inches long x 0 625 inches high Mounting hole spacing is 1 by 3 5 inches Simple Microcontroller with Easy to Use Software Arduino Nano microcrontroller http www gravitech us arna30wiatp html Uses the open source Arduino Integrated Devel
7. EB PE Croma HAD on version 2 Analog Pins are reversed e g A0 A7 A7 AD OCOA PCINT22 H P AINI PCINT23 Heo H anm gt TOO hu oO J OC1A PCINTL 31 13 23 PCC PCINTS OC1A PCINT4 16 12 PCINTS L JACK GROSA 07 FEB 2013 Appendix B Pin Usage AEV 6 Pin Usage To Header Comment DO Serial Input Reserved Yes Serial Input or Wireless Use Only D1 Serial Input Reserved Yes Serial Input or Wireless Use Only D2 Interrupt O Yes Used for wheel count sensor D3 Interrupt 1 Yes Used for wheel count sensor D4 Button Yes Allows for remote D5 PWM Motor 1 No D6 PWM Motor 2 No D7 H bridge logic 1 for Motor 1 No D8 H bridge logic 2 for Motor 1 No D9 Available Yes Possible servo usage D10 H bridge logic 1 for Motor 3 Yes Available SPI CS D11 PWM Motor 3 Yes Available SPI MOSI D12 H bridge logic 2 for Motor 3 Yes Available SPI MISO D13 Built in LED Yes SPI SCK A0 14 Available Yes A1 15 Available Yes A2 16 H bridge logic 1 for Motor 2 No A3 17 H bridge logic 2 for Motor 2 No A4 18 12C SDA for ext eeprom Yes eeprom uses addr 80 A5 19 12C SCL for ext eeprom Yes eeprom uses addr 80 A6 20 battery voltage sensor No A7 21 current sensor No REF tied to 33K resistor to 5 No EXTERNAL gives 2 46 volts Appendix C Bill of Materials Item Qty Digikey Stk 1 1 2 4 3 1 4 1 5 2
8. is GND red is 5v and orange is signal D9 Use male pin extender to join the two connectors Wireless Header The wireless header will have limited use but it does allow for a wireless connection using the serial bus DO labeled as TX and D1 labeled as RX Connecting to these pins will interfere with normal USB communications and should be avoided in most cases The remainder of the this five pin female header includes a 5V pin GND pin and a hardware reset pin In some cases it may be desirable to do a hardware reset Connecting the reset pin temporarily to the GND pin will restart the microcontroller and then restart the program that has been flashed to the microcontroller Unlike a software watchdog reset all caches are flushed as well which is usually an advantage NX E BAT A y de A n2b r2a 11 s Mia Y gt SS a A po A A V d Unused Analog Pin Headers Two analog pins AO and Al are available for use These pins can also be called as digital pin 14 and 15 respectively Never place more than 5 volts on these pins Battery voltage of a two cell LiPo used for this project is approximately 8 volts Placing battery voltage directly on one of the Arduino pins will destroy that pin which is why a voltage divider is used to measure battery voltage during the run Third Motor or SPI Header The control section of the optional third motor can be connected as shown below a GND V PID D11 i cts GND 5y N1 PWM N2 NIA
9. nd PWMB PWM input signal e A01 and B01 motor lead output e A02 and B02 motor lead output The Arduino Nano and the two motor control chips mount to the mother board as shown below Arduino Nano NIN_ONS LS JF patible Fs L E PUR wy as Arduino Com A ud A T amp f TXL OXY ISVONO ZO Ey O SOO 2 12C EEPROM e gt gt G a zuar osepe Nano ONA SD Poy ws y Arduino Compatible ho PO ex AN a AN Y II a e O 0y 0 SO 90 ZO 80 SO ye MITO ZTO ry 9 EO m OK A 2 E r E aes dose A 7 Heat sinks were added to the motor control chips to help control over temperatures during extended high speed runs The heat sinks are modified Digikey parts Pinouts Motors The Arduino Nano has 12 usable digital pins D2 D13 and 8 usable analog pins A0 A7 Analog pins AO to A5 can be used as either an analog inputs called as AO A5 or as a digital pins called as 14 19 Each motor requires a specialized digital pin capable of sending a PWM signal for speed control and two digital outputs to control the H bridge for reversing and braking The Toshiba TB6612FNG h bridge logic is shown in the following table taken from the device data sheet H SW Control Function To conserve pins the STBY pin is wired HIGH 5 volts so the Standby state is not available The pins used are Motor IN1 IN2 PWM 1 8 9 2 16 1 6 3 10 12 11
10. o foundation http arduino cc en Main ArduinoBoardNano Sg A ede ae mea 150 o A rei A T ds r ray ell TTT NS a a i E T m o T E a as Bu TF The Nano differs from the Arduino UNO in that it still uses the FTDI USB to serial converter and breaks out an additional two analog pins from the Atmel 328 microprocessor chip Itis a 5 volt device with 12 usable digital pins 2 13 and 8 10bit analog pins A0 A7 the first six of which can also be used as digital pins by addressing them as 14 19 The pin out of the Nano is provided in Appendix A The Arduino Nano controls the current provided to the recommended E Flite EFLH1322 direct drive motors by using the built in Pulse Width Modulation PWM of the Nano that is decoded by the Toshiba motor control chip The chip also provides an integrated H bridge providing for current reversal motor reverse These surface mounted motor control chips TB6612FNG are placed on a breakout board by Sparkfun https www sparkfun com products 9457 The motherboard design allows the surface mounted moor control chips to be easily replace if damaged The Toshiba motor control chips can handle two motors at 1 2 amps each but the AEV mother board ties these two circuits together in parallel to give 2 4 amps for a single motor i e the following inputs are tied together e Ain1 and Ain2 H bridge input control logic e Bini and Bin2 H bridge input control logic e PWMA a
11. opment Editor IDE Software available from http arduino cc High Motor Output Currents Ability to supply 2 amps 3 amp peak per motor Uses parallel operation of the TB6612FNG motor driver https www sparkfun com products 9457 Current and Voltage Sensing Allow constant current and voltage sensing throughout a run Hall effect current sensor ACS715LLCTR 20A T Simple 10K 10K 10K voltage divider allows for monitoring of batteries up to 15 volts Extra memory to record voltage and current for a two minute run at 50 ms intervals Additional 32k bytes of eeprom memory 24LC256 uses i2c bus Low Cost 75 not including development cost Motherboard Active Surface Mount Parts The current sensor voltage divider and external eeprom memory are located directly on the motherboard Hall effect current sensor ACS715 is located just under motor control chip 2 sensed by pin A6 Three resistor voltage divider 10K 10K 10K sensed by pin A7 External eeprom 241 C256T 1 SN using the i2c bus pins A4 and A5 Sea NAO y External Parts and Assembly The AEV motherboard pulls together three commercially available electronic daughter boards thus leveraging the design work and production level discounts of these devices The heart of the AEV controller is the Arduino Nano 3 0 board manufactured by Gravitech http store gravitech us arna30wiatp html The Arduino Nano uses and open source design accepted by the Arduin
12. when used for third motor GND ES ss MOSI MISO SCK if using the SPI bus WM IN1 _ STBY a tOV GND STBY is shorted to 5v To battery terminal pair next to battery connector on motherboard This same header can be used to access the SPI bus The AEV software uses digital 13 as an indicator conflicting with SPI use but this could easily be overcome by using the D14 or D15 headers as indicators using an LED with a 330 ohm resistor current limiting resistor to ground I2C Bus Extension Header The Arduino communicates with the external eeprom using the i2c bus address 80 The i2c bus is addressable and can handle multiple items such as i2c displays other addressable sensors and sensor interfaces Maximum wiring distance is about three feet N 1993 i ISU ONG AGe ajay o ee a aw o a e uy y uy ay ar a pa De oe me TA 2 e III OE eh ee oe GND 5V A4 SDA A5 SCL Appendix A The Unofficial Arduino Nano Pinout From http www pighixxx com downloads arduino nano THE LEGEND UNOFFICIAL ARDUINO PHYSICAL PIN ATMEGA328 PIN FUNC PINOUT DIAGRAM DIGITAL PIN nr is Absolute max 200mA for entire package General Information Pay Attention NoR Connected to the AT Mega PAY ATTENTION and used for USB program and communicating with it O PCINTIT H 31 o PCINTI6 H PDO HBO PCINT15 H F 29 LED PCINT15 f cco E Cocos rama ME E
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