DARPA Grand Challenge Safety Radio (DGCSR) User Manual
Contents
1. 16 4 1 2 5 Interface 17 4 2 DGCSR Design 19 9 0 System Integration Precautions and 5 20 6 0 DGCSR System Operation 21 6 1 Confirm Antennas are Installed 21 6 2 Set Safety Override 21 Oo POWE _ ____ _ __ 22 6 4 Monitor Status 22 6 5 Preset the DGCSR TX Mode Switches 22 6 6 Clear the Initial System DISABLE 23 6 7 Test the Operation Prior to Use 23 6 8 Run Pause 24 6 9 Emergency DISABLE Operation II 24 7 0 Error mh hara 26 8 0 Appendix A Shock Vibration Testing 20 9 0 Mounting Instructions 30 10 0 Technical 5 33 DGCSR User Manual Rev 1 1 amp 1 02. All contents subject to change Visit www omnitech com for updates OMNITECH DGCSR User Manual Rev 1 1 ROBOTICS ESC ET DIET M EK 1 CENTET AFET RAD10 25 Kc ux HEE LU pa SI16 18 LOCE NTLON RECEIVER SINGLE VEHICLE PRETS LIST EAMCMASTER 3588230030 FLAT 1 4 STL 7 ar ARE soci ar Fart Parens DF tele Tits TER 51 FELEN 13 is Ti DEANE ee Ee HOAT ISOLATION All contents subject to change Visit www omnitech com for updates 31 ROBOTICS E o MOI IVTI LN 3A ONY NOISK31Xx INDOM WOOHS 803 4 SIKL JAQAY 1208w4Y312 1 MOTIV 09 5 32 GILE SWI LANOM 3121H3A SIMON P J10H C30NJWBO238 s nis 81 91 5 801 N j3llVad JONVEWI TD F 11190 ii Fe 0 318 58 0 DGCSR User Manual Rev 1 1 32 All contents subject to change Visit www omnitech com for updates DGCSR User Manual Rev 1 1 OMNITECH ROBOTICS 10 0 Technical Support After reading this users manual if you have additional questions please check our web site for updates to this manual or other information If you still have questions or comments you can contact us using the fol lowing contact information Omnitech Robotics International LLC 2630 South Ra
3. 4 1 2 1 Connector Summary J1 Host This is a special purpose RS 232 port for use by trained maintenance personnel DGC Competition teams are not required to use this connector or functionality J2 RF This is a Radio Frequency RF input output connector using an SMA connector type It carries a 902 928 MHz RF signal from the DGCSR transceiver at up to 1 watt of power It is intended to cable to the supplied RF antenna using the supplied coaxial cable Users should take care to always have an antenna attached to J2 prior to applying power to the DGCSR TX or RX Users should also maintain at least a 23 cm distance between the attached antenna and any part of their body to limit their exposure to RF radiation J3 GPS This is a GPS antenna input It uses a normal thread SMA connector and is intended to connect to the supplied 3 3 volt active GPS antenna with preamplifier and filter J4 12V This is the power input connector It is intended to connect to the supplied power input cable with ter minal block connections Nominal power input is 12 volts 0 4A This power input can range from a minimum of 10 volts to a maximum of 20 volts 4 1 2 2 Switch Summary SW1 Power On up position or Power Off down position This is a pull to actuate toggle switch It is used to turn power on or off for the DGCSR STX power SW2 Run Passive Pause This is a three position sustaining pull to actuate toggle switch
4. OMNITECH ROBOTICS DGCSR User Manual Rev 1 1 DARPA Grand Challenge Safety Radio DGCSR User Manual Revision 1 1 November 4 2003 Omnitech Robotics International LLC 2630 South Raritan Circle Englewood CO 80110 303 922 7773 www omnitech com OMNITECH ROBOTICS DGCSR User Manual Rev 1 1 Table of Contents TU Important NOCES s 422433 dtd een dee RR RR ku 1 2 0 Assignment of Liabilily beeen 3 3 0 Package 4 4 0 6 4 1 Overview of the DGCSR 8 4 1 1DGCSR RX Safety 8 4 1 1 1 Connector 8 OMe SUMMA ao u u ss 9 4 1 1 3 Status Display LED Function Summary 9 4 1 1 4 Interface 11 4 1 2DGCSR STX Safety 14 4 1 2 1 Connector Summary 15 4 1 22 ___ ___ ____ a 15 4 1 2 3 Status Display LED Function Summary 15 4 1 2 4 Top Panel Mode LED
5. It is used to com mand the desired mode for the vehicle usually either RUN or PAUSE or in a special cases during the DGC event only while using Master Transmitters also a PASSIVE mode SW3 Enable Disable This is a two position sustaining toggle switch with cover It is used to command the ENABLE or DISABLE for the vehicle ENABLE is the normal mode for operation of the DGC competition vehicle and DISABLE is required to stop the engine or prime mover immediately Usually a DISABLE is only done after a PAUSE has been initiated to allow the PAUSE to initiate a controlled stop of the vehicle prior to disabling the vehicles prime mover engine or battery power and associated power assisted devices steering and brakes Once a DISABLE has been initiated it will be latched and the system will maintain this mode until the Clear Disable toggle switch is asserted located on the side panel of the DGCSR RX 4 1 2 3 Status Display LED Function Summary Master Warn Indicates a Master Warning Status Master Fault Indicates a Master Fault Status Lost Link Indicates that the communications link to the single transmitter has been lost Radio OK A green LED Indicates that the DGCSR transceiver radio has power and is operating normally GPS Fix Indicates that the GPS has found a position solution This may take up to 1 1 2 minutes to come on the first time Subsequently th
6. Notes 1 Pin 1 is nominally 12 V power in with respect to pin 2 GND Acceptable range is 10 V to 20V Typical Current draw for the DGCSR TX or RX without DGCTS is 0 4A Input is internally fused at 5A 2 Pin 4 is chassis GND It should be connected to the vehicles chassis ground or con trol electronic main chassis ground star point 3 For mobile chase vehicle operations the 12V and GND power connections can be adapted to a car cigarette lighter adapter plug like Digikey part APP 001 ND Figure 10 CA20 Detail All contents subject to change Visit www omnitech com for updates 18 DGCSR User Manual Rev 1 1 ROBOTICS 4 2 DGCSR Design Features Networked Time Division Multiple Access TDMA radios for all units to allow close range and long range operations of over 100 units License free Instrumentation Scientific and Medical ISM band 902 928 MHz Spread Spectrum Radios are multi path interference resistant Radio link interference problems are minimized using TDMA protocol spread spectrum RF techniques and custom frequency hopping patterns All Communications occur in a TDMA cycle epoch with 1 Hz period Latency time from the assertion of a PAUSE or DISABLE toggle switch on the DGCSR TX to the relay or opto coupler assertion on the DGCSR RX is typically between 1 to 2 seconds Programmable time out for the PAUSE to assert after a loss of RF data link 1 to 60 seconds Programmable time out for t
7. adjustments to time or judging of the DGC event Disable Time This LED Indicates that the six seven segment displays are showing hours minutes and sec onds of total cumulative time in the Disabled state This value is logged to non volatile memory also for use in making adjustments to time or judging of the DGC event Unit ID Indicates that the bottom 2 seven segment displays are showing the unit ID All contents subject to change Visit www omnitech com for updates 10 DGCSR User Manual Rev 1 1 amp 4 1 1 4 Interface Cables Figure 3 illustrates the overall cable connections diagram for the DGCSR RX GPS Antenna Radio CAO CA19 CA18 P4 P2 J4 12 VDC J3 GPS Antenna J2 Radio POWER IN Antenna User System J5 Safety Interlock CA21 TL E P6 DGCSR Safety Rx Box J6 Tracking Jt TS Track System I F CA22 ing Sys 1 P1 nose J1 Host I F a Host I F CA23 SW1 Power SW2 Safety SW3 Clear Note On Off Override Disable J is for Jack P is for Plug CA is for Cable Assembly TB is for Terminal Block Figure 3 The DGCSR RX Cable Connections Overview The two cables that require integration with the user system are CA20 and CA21 These are detailed in Figure 4 and Figure 5 respectively Figure 6 illustrates the suggested user connections to the Safety interlock SI cable terminal block TB2 All contents subject to change Vi
8. competition vehicles main power source motor or engine can not continue to operate In the case of a software failure this hardware circuit is intended to assure the vehicle does not continue to operate with the engine motor on Asserting the DIS ABLE should also result in the main service brakes being applied and held on While it is acceptable to use software in the loop to help implement a DISABLE a hardware disable of the main power source 15 also nec essary AND IT MUST TAKE EFFECT WITHIN 1 SECOND Also this hardware only engine disable circuit must function to disable in the power off state fail safe This will be an inspection criteria of the pre qualify ing inspection and test process The DISABLE signal interface is provided in two formats first as a signal level 100 mA max optically coupled digital output and second as a power level 3A relay type output All contents subject to change Visit www omnitech com for updates T OMNITECH ROBOTICS DGCSR User Manual Rev 1 1 4 1 Overview of the DGCSR Components 4 1 1 DGCSR RX Safety Receiver The DGCSR is shown in Figure 2 Subsequent sections detail the connector switch display and interface details for this component DGCSR RX Photograph DGCSR RX Status Display Detail DGCSR RX Connector Detail Figure 2 The DGCSR RX Side Panel Detail 4 1 1 1 Connector Summary J1 Host This is a special purpose RS 232 port for use by trained maintenan
9. displays are showing the unit ID DGCSR User Manual Rev 1 1 4 1 2 4 Top Panel Mode LED Summary RUN Status LED Lit Green if Radio Link is working System Mode is ENABLED and Operating Mode is RUN PAUSE Status LED Lit Yellow if Radio Link is working and PAUSE is asserted e g System mode is ENABLED and Operating Mode is PAUSED or if System Mode is DISABLED DISABLE Status LED Lit RED if Radio Link is working and System Mode is DISABLED Figure 8 The DGCSR STX Top Panel Detail All contents subject to change Visit www omnitech com for updates 16 DGCSR User Manual Rev 1 1 amp OMNITECH ROBOTICS 4 1 2 5 Interface Cables Figure 9 illustrates the overall cable connections diagram for the DGCSR STX GPS Antenna P1 MAE Host I F Host I F DGCSR STX Box Boundry CA23 Host iF pc L SW2 Run Pas SW3 Enable J2 Radio sive Pause Disable Anena p J is for Jack P is for Plug TB is for Terminal Block SW is for Switch Antenna Figure 9 The DGCSR STX Cable Connections Overview The only cable that requires user integration with their system is CA20 This is detailed in Figure 10 All contents subject to change Visit www omnitech com for updates 17 OMNITECH DGCSR User Manual Rev 1 1 ROBOTICS J4 Plug 16 GA white wire rc 2 Power GND 3 D 4 Chassis GND m
10. is asserted Lack of a green LED indicates a DISABLE mode 15 asserted or the user power supply on J6 TS is not present Radio OK A green LED Indicates that the DGCSR transceiver radio has power and is operating normally GPS Fix OK Indicates that the GPS has found a position solution This may take up to 1 1 2 minutes to come on the first time Subsequently the time to get the GPS Fix OK signal is reduced Temp OK Indicates that the internal temperature is within acceptable ranges lt 70C Log ON Indicates that the data logging feature has been activated F1 Function 1 Reserved for special use Elapsed Time This LED Indicates that the six seven segment displays are showing hours top 2 seven seg ment displays minutes middle 2 seven segment displays and seconds bottom 2 seven segment displays of total on time since the receiver was turned on Paused Time This LED Indicates that the six seven segment displays are showing hours minutes and sec onds of total time cumulative in the Paused state This value is logged to non volatile memory also for use in making adjustments to time or judging of the DGC event Lost Link Time This LED Indicates that the six seven segment displays are showing hours minutes and sec onds of total time that the receiver has not had a link with a transmitter This value is logged to non volatile memory also for use in making
11. occasions during the race and the competition vehicles should be able to perform a quick but controlled stop upon the assertion of this command PAUSE mode and to perform a controlled restart upon the removal of this command RUN mode It is anticipated that each DGC vehicles control computer s will be responsible for monitoring and responding to this command and that the vehicles should come to a complete stop within about 3 sec onds after this signal is asserted at the DGCSR RX from a typical operating speed of about 25 m p h While the PAUSE Is asserted the vehicle brakes should be held on even after the vehicle is stopped so that if the vehicle is stopped on a slope it will not roll The PAUSE signal interface is provided in two formats first as signal level 100 mA max optically coupled digital output and second as a power level 3A relay type output The DISABLE capability is intended to allow safety operator personnel to DISABLE the competition vehicle s during the course of the DGC event with the understanding that a DISABLE is intended to be per manent and not reversible Thus it will be used to assure the vehicle stops and stays stopped and disabled for the rest of the DGC event It is MANDATORY that all competition vehicles use the DISABLE interface to implement an immediate STOP of the vehicle using whatever means necessary for that specific vehicle Fur ther the DISABLE signal must use a hardware circuit to assure the
12. once the GPS has obtained a cor rect GPS position location fix and therefore has an accurate time reference Until this LED lights up the DGCSR system will not function Once both the DGCSR STX and RX are powered up and each unit s GPS FIX Ok LED is lit the RADIO OK LED should be lit green and the LOST LINK LED should be off The system is now ready to operate 6 5 Preset the DGCSR TX Mode Switches It is necessary to preset the DGCSR TX mode select switches to the state desired for initial operation Usually this will be system mode ENABLED and operational mode PAUSED This allows the vehicle engine to start but signals the user s control computer to maintain a Paused stopped status This is important so the vehicle does not start to move immediately after the next step before the operator can get away from the competition vehicle All contents subject to change Visit www omnitech com for updates 22 DGCSR User Manual Rev 1 1 amp 6 6 Clear the Initial System DISABLE Mode When the DGCSR system first powers up with the Safety Override in the SAFETY position not Over ride the system will default to the DISABLED system mode This is intended to assure that the vehicle engine will be off to begin with to allow a careful and controlled transition to the DGCSR system Safety Interlock operations and subsequently to the unmanned operations using each team s control system After the DGCSR is ready and the comp
13. ABLED system mode to allow continued testing Next it is recommended that the actual engine kill function be tested To do this make sure the system is in neutral gear PAUSE mode and ENABLED Be careful not to allow the engine to start when the vehicle Is in gear and a user is around the vehicle Start the engine then assert the DISABLE toggle switch Verify the engine or prime mover stops within one second Turn off the engine start signal if necessary in the user control system then press the Clear Disable toggle Switch on the DGCSR RX 6 8 Run Pause Operation Once the DGCSR system is operational and tested for functionality it can be used by a safety operator to aid in testing the DGC competition vehicles While testing if an unsafe condition is arising the operator should assert the PAUSE command with sufficient advance notice and planning to assure the vehicle will stop prior to a problematic event or accident If the situation warrants it the PAUSE can be removed and a normal RUN mode entered again Alternatively if the situation warrants it or if the PAUSE fails to stop the vehicle the DISABLE should be asserted to stop the engine prime mover on the vehicle 6 9 Emergency DISABLE Operation While testing if an unsafe condition is arising the operator should assert the PAUSE command with suf ficient advance notice and planning to assure the vehicle will stop prior to a problematic event or accident In an emergency if t
14. BLE OPTO Vin 1 1 DISABLE Out 12 DISABLE OPTO_GND 13 Chassis GND 14 All contents subject to change Visit www omnitech com for updates OMNITECH ROBOTICS DGCSR User Manual Rev 1 1 amp CA21 TB2 1 Run Pause Relay Vin rc 122 2 Run Pause Relay Out VEHICLE 12V _3 amp max ee Run Pause Relay Out OPT TO VEHICLE CONTROLS _ 3 Run Pause RELAY_GND VEHICLE GND COMPUTER 5V or 12V Run Pause OPTO Out 0 1A max TO COMPUTER IN COMPUTER GND VEHICLE 12V 3 amp max VEHICLE GND COMPUTER 5V or 12V DISABLE OPTO Out 0 1A max TO COMPUTER IN COMPUTER GND VEHICLE CHASSIS GND Ignition Disable or Fuel cut off solenoid or electrical disconnect contactor DISABLE OPTO Ou DISABLE Chassis GND VEHICLE GND Figure 6 Suggested User Connections to Safety Interlock SI Signals on Terminal Block TB2 All contents subject to change Visit www omnitech com for updates 13 OMNITECH ROBOTICS DGCSR User Manual Rev 1 1 4 1 2 DGCSR STX Safety Transmitter The DGCSR STX is shown in Figure 7 Subsequent sections detail the connector switch display and interface details for this component DGCSR STX Top Panel Switch and Mode LED Detail DGCSR STX Connector Detail Figure 7 The DGCSR STX Side Panel Detail All contents subject to change Visit www omnitech com for updates 14 DGCSR User Manual Rev 1 1 amp
15. Important Notices 1 The DGCSR STX and DGCSR RX contain expensive and sensitive electronics and must never be dropped They should be installed on their vibration isolation mounts in the vehicle as soon as possible to avoid inadvertent damage from dropping 2 The DGCSR STX and DGCSR RX contain expensive and sensitive electronics and must never be exposed to electro static discharge ESD on the exposed connector pins All personnel who handle the devices should keep the connector caps installed over the exposed connector pins to minimize the chance of an ESD event To minimize the probability of an ESD occurrence and potential damage the connector caps should only be removed in a controlled ESD safe environment once proper ESD precautions have been implemented Typical ESD prevention measures include the use of an earth ground contact strap or mat in contact with the body of the installer and the ESD sensitive components Handling the DGC SR com ponents in environments that generate ESD should be avoided like areas with carpet or anywhere that ESD sparks or shocks to metal objects occur 3 The DGCSR STX and RX use RF transceivers in the 902 928 MHz ISM band at power levels up to 1 watt Users should maintain at least a 23 cm distance separation between the attached RF antenna and any part of their body to limit their exposure to RF radiation per FCC guidelines 4 The DGCSR uses pull to actuate toggle switches For safety reasons these swi
16. NABLE using the covered TX toggle switch however note the LEDs will not change right away It is necessary to go the DGCSR RX and lift assert the Clear Disable toggle switch first Then you can verify the RX Status Display LEDs show the ENABLED LED goes on Green LED on Also note the user powered DISABLED OPTO LED and DISABLE RELAY LED will go off Users may All contents subject to change Visit www omnitech com for updates 23 OMNITECH ROBOTICS also use these signals to implement their own unique indication prompting enunciation of these modes and DGCSR User Manual Rev 1 1 states using their own electrical or computer means Next it is recommended that the time out function be tested Move the DGCSR TX operating mode tog gle switch to the PASSIVE position This causes the DGCSR TX to stop sending RF messages to the DGCSR Rx After a period of time called the Pause time out period the DGCSR should assert the PAUSE operational mode then after an additional second period of time called the Disable time out period the DISABLE system mode should assert The actual Pause time out period and Disable time out period are programmable and will be set by DGC officials Users should confirm their units time out periods as received and confirm they are consistent over time within one second longer is possible if communications links are unreliable or noisy Again clear the DISABLED system mode and enter the EN
17. a PAUSE is asserted It should also stop the vehicle and apply the brakes and stop the engine when a DISABLE is asserted The engine should stop quickly within one second of a DIS ABLE command assertion The brakes should apply quickly within one second in either case to initiate a controlled stop as fast as possible The brakes actuator should also be designed to allow the brakes to be applied full force with a 100 duty cycle continuously for 1 hour and with sufficient holding force to hold the vehicle while on a 45 degree slope 100 grade Meeting these requirements will require care ful design and implementation These aspects of the DGCSR systems integration are critical to the safe and reliable operation of the DGCSR system and are under the control and responsibility of each com petition team All contents subject to change Visit www omnitech com for updates 20 DGCSR User Manual Rev 1 1 amp OMNITECH ROBOTICS 6 0 DGCSR System Operation The basic operating procedure for the DGCSR system is outlined here as initial guidance and for train ing purposes It is expected that normal operation of the DGCSR system will become routine after a few hours of successful operation However care must be taken to assure that all personnel are properly trained in the use of the DGCSR system and prepared to act quickly and reliably as necessary to implement an effective safety radio shut down procedure at any time To enhance the reliability o
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19. ce personnel DGC Competition teams are not required to use this connector or functionality 2 RF This is a Radio Frequency RF input output connector using an SMA connector type It carries a 902 928 MHz RF signal from the DGCSR transceiver at up to 1 watt of power It is intended to cable to the supplied RF antenna using the supplied coaxial cable Users should take care to always have an antenna attached to J2 All contents subject to change Visit www omnitech com for updates 8 OMNITECH DGCSR User Manual Rev 1 1 ROBOTICS M M prior to applying power to the DGCSR TX or RX Users should also maintain at least a 23 cm distance between the attached antenna and any part of their body to limit their exposure to RF radiation J3 GPS This is a GPS antenna input It uses a normal thread SMA connector and is intended to connect to the supplied 3 3 volt active GPS antenna with preamplifier and filter J4 12V This is the power input connector It is intended to connect to the supplied power input cable with ter minal block connections Nominal power input is 12 volts 0 4A This power input can range from a minimum of 10 volts to a maximum of 20 volts Jo SI This is the Safety Interlock interface connector It is intended to connect to the provided Safety Interlock cable with terminal block connectors for user signal terminations Users should review the detailed SI interface specification for
20. controlled Safety Interlock for the DGC competition vehicles to allow for a safety operator to remotely PAUSE and ENABLE DISABLE or more competition vehicles during the course of the DGC event The systems are being provided to DARPA Grand Challenge DGC teams in advance of the DGC event to allow each team to install these components in their competi tion vehicles They will be used during the DGC event and may also be used by the competition teams dur ing their development and testing The DGCSR system is only part of an overall safety program that all teams must implement and is not a single catch all safety system All competition teams are fully responsible for all operations of their competition vehicles and for monitoring and assuring the DGCSR components provided are fully functional at all times DGCSR consists of two major components first the DGCSR RX or Safety Receiver and secondly the DGCSR TX or Safety Transmitter These components are shown in Figure 1 The DGCSR RX is intended to be integrated with the DGC competition vehicle The DGCSR TX is intended to be operated by a human safety monitor supervisor from a remotely positioned chase vehicle or stationary position The main function of the DGCSR system is to provide a Safety Interlock for the competition vehicles to allow for a safety operator to PPAUSE or DISABLE one or more competition vehicles during the course of the DGC event Thi
21. e time to get the GPS Fix OK signal is reduced Temp Indicates that the internal temperature is within acceptable ranges lt 70C Elapsed Time This LED Indicates that the six seven segment displays are showing hours top 2 seven seg ment displays minutes middle 2 seven segment displays and seconds bottom 2 seven segment displays of total on time since the unit was turned on Paused Time This LED Indicates that the six seven segment displays are showing hours minutes and sec onds of total time cumulative in the Paused state from RX This value is logged to non volatile memory also for use in making adjustments to time or judging of the DGC event All contents subject to change Visit www omnitech com for updates 15 OMNITECH ROBOTICS Lost Link Time This LED Indicates that the six seven segment displays are showing hours minutes and sec onds of total time that the receiver has not had a link with a transmitter from RX This value is logged to non volatile memory also for use in making adjustments to time or judging of the DGC event Disable Time This LED Indicates that the six seven segment displays are showing hours minutes and sec onds of total cumulative time in the Disabled state from RX This value is logged to non volatile memory also for use in making adjustments to time or judging of the DGC event Unit ID Indicates that the bottom 2 seven segment
22. etition vehicle s control system is ready users should clear the system disable by asserting the CLEAR DISABLE toggle switch on the DGCSR RX This switch should be asserted and held in the CLEAR DISABLE position for about a second The system will then enter the ENABLED system mode Confirmation that the DGCSR is in this mode and is ready for operation is possible by observing the mode status LEDs on the front panel of the DGCSR TX 6 Test the DGCSR Operation Prior to Use At this point the DGCSR is fully operational and the RX outputs Run Pause and Enable Disable should follow the command from the TX toggle switches Prior to use proper operation should be confirmed however First assert a PAUSE using the TX toggle switch and verify the RX Status Display LEDs show the PAUSED LED goes on Red LED on The user powered RUN OPTO LED and RUN RELAY LED should go off Return the operational Mode switch to the RUN position and verify the RX Status Display LEDs show the PAUSED LED goes off Red LED off and RUN OPTO LED and RUN RELAY LED should go on Users may also use these signals to implement their own unique indication prompting enunciation of these modes and states using their own electrical or computer means oecond assert a DISABLE using the covered TX toggle switch and verify the RX Status Display LEDs show the ENABLED LED goes off Green LED off The user powered DISABLED OPTO LED and DISABLE RELAY LED will go on Now assert an E
23. f operators using the DGCSR and to assure the DGCSR system is operating normally it is important to test the DGCSR system each time it is used prior to allowing the DGC competition vehicle to drive unmanned 6 1 Confirm Antennas are Installed The DGCSR should always have the RF antenna installed prior to powering up the DGCSR TX or RX An occasional brief failure to do this will not damage the DGCSR radios however it is not advised Operators should always keep at least a 23 cm separation between the antenna and their body parts to maintain com pliance with FCC limits on recommended RF radiation exposure from this antenna The DGCSR requires the GPS antenna to be installed and an initial GPS location fix to be acquired prior to operation of the DGCSR This is because the GPS provides a precise time reference that is an integral part of the DGCSR TDMA radio network design For this reason the GPS antenna needs to be installed as an initial check 6 2 Set Safety Override Switch The safety override toggle switch on the DGCSR RX has two settings up for OVERRIDE and down for SAFETY If the user wants to use the DGCSR system this switch must be in the down position selecting SAFETY If the user wants to operate the DGC competition vehicle without the DGCSR including to simply start the vehicle engine with the safety interlock in place the switch should be in the up or OVERRIDE posi tion Because this switch can potentially be placed in the w
24. g Status Master Fault Indicates a Master Fault Status Enabled Indicates that the receiver is in the Enabled State Paused Indicates that the receiver is in the Paused state Disabled Indicates that the receiver is in the Disabled state Lost Link Indicates that the communications link to the single transmitter has been lost Run Relay Indicates the state of the RUN Output at the Safety Interlock RELAY output pins A green LED light indicates the RUN mode is asserted Lack of a green LED indicates a PAUSE or DISABLE mode is asserted or the user power supply on J6 TS is not present Run Opto Indicates the state of the RUN Output at the Safety Interlock OPTO output pins A green LED light indicates the RUN mode is asserted Lack of a green LED indicates a PAUSE or DISABLE mode is asserted or the user power supply on J6 TS is not present Disable Opto Indicates the state of the DISABLE Output at the Safety Interlock RELAY output pins A green LED light indicates the ENABLE mode is asserted Lack of a green LED indicates a DISABLE mode is asserted or the user power supply on J6 TS is not present All contents subject to change Visit www omnitech com for updates 9 DGCSR User Manual Rev 1 1 OMNITECH ROBOTICS Disable Relay Indicates the state of the DISABLE Output at the Safety Interlock RELAY output pins A green LED light indicates the ENABLE mode
25. he DISABLE to assert following a PAUSE time out 1 to 60 seconds GPS based time reference accurate to 1 microseconds with a hold up circuit in case of temporary GPS drop outs typically sufficient for more than 10 minutes of GPS loss without loss of radio functionality Integrated GPS based vehicle tracking capable Integrated data logging with 1000 hours of data logging of critical Built In test BIT data and vehicle tracking log Power up and background Built in Test BIT of power supply voltages enclosure ambient and internal power supply temperatures and other operational performance parameters Interface to the DGC TS tracking system and satellite transceiver communications relay system Normal Operating Temperature range 0 to 60 C Units tested to 70C and safety critical circuits built with 85 C temperature range specified components Designed and tested for high shock and vibration environments Power and Interface connections designed for automotive voltage range 12V nominal minimum 10V maximum 20V All contents subject to change Visit www omnitech com for updates 19 OMNITECH ROBOTICS 5 0 System Integration Precautions and Warnings DGCSR User Manual Rev 1 1 DGC SR system should always be tested for proper operation prior to use as a Safety interlock for the DGC competition vehicle tis recommended that users implement a control system for the competition vehicle that does not allow the engine to s
26. he situation warrants it or if the PAUSE fails to stop the vehicle the DISABLE should be asserted to stop the engine prime mover on the vehicle This should prevent a run away vehicle condition All contents subject to change Visit www omnitech com for updates 24 DGCSR User Manual Rev 1 1 Operational Notes system will only work is GPS lock can be acquired i e not indoors OMNITECH ROBOTICS All contents subject to change Visit www omnitech com for updates 20 DGCSR User Manual Rev 1 1 7 0 Error Codes e OMNITECH ROBOTICS The DGCSR STX and RX will display error codes on the Status Display if an error condition is detected To aid in diagnosing system faults the following error codes are provided Error Error Likely Error Source No Com pactFlash Found GPS Not Respond ing Remote BIT Error 5VA Error 51 Trans ceiver Not Respond ing il 12 V Error Table 1 Error Codes Compact Flash Not Installed or error The GPS uses a battery backup to maintain nonvolatile memory and real time clock settings This battery backup is actually designed using an 0 47 F ultra capacitor that requires charging occasionally if it is fully dis charged Until it has sufficient charge this error may occur at power up Radio Failure Built In Test error Internal 5V power supply failure or fuse blown Internal 5V Analog power sup ply failure or fuse blown Inte
27. hicle may resume it s progress immediately and may move immediately in any direction It is impera tive that users ensure that the area around the vehicle is clear and safe before returning the vehicle to an ENABLED state All contents subject to change Visit www omnitech com for updates 2 DGCSR User Manual Rev 1 1 amp 2 0 Assignment of Liability By using the DGCSR components provided each DGC competition team thereby agrees to accept full responsibility and all legal liability for their DGC competition vehicle and its operation and consequences and to indemnify and hold harmless Omnitech Robotics International LLC from all responsibility and legal lia bility and recourse Omnitech Robotics International LLC does not take any responsibility for the safe operation of any DGC competition vehicle or any related equipment or conduct at any time It is entirely up to each team to imple ment a comprehensive and conservative safety program to assure safe operation and testing of their com petition vehicles at all times The DGCSR components provided have been tested for proper functionality and reliable operations when installed used and maintained properly However since most critical aspects of the DGCSR system are under the control of the competition teams each team is exclusively responsible for the overall safety of their entry at all times If any team does not agree to accept total and complete responsibility and legal
28. liability for their DGC competition vehicle at all times and to unconditionally hold Omnitech Robotics International LLC harmless against any incidents that might occur then the DGCSR systems are not authorized for use and should be returned immediately All contents subject to change Visit www omnitech com for updates 3 DGCSR User Manual Rev 1 1 OMNITECH ROBOTICS 3 0 Package Contents Upon receiving the DGCSR materials you should carefully unpack the contents of all boxes and verify the receipt of all contents using the following checklist each of a DGCSR RX 1eachofa DGCSR STX 2 each of a CA19 GPS antenna with 5 meter long cable and SMA connector 2 each of a CA18 ASC0102SN 10 RF antenna cable EB8965C 5 dB gain antenna MBC800 antenna base and mounting bracket 2 each of a CA20 Power Cable 1 each of a CA21 Safety Interlock Cable 1 of a bag of 8 Vibration Isolation Mounts DGCSR User Manual this document All contents subject to change Visit www omnitech com for updates 4 OMNITECH DGCSR User Manual Rev 1 1 ROBOTICS DGCSR RX DGCSR STX 19 GPS CA20 Power Cable CA21 Safety Interlock Cable 18 10 RF cable antenna and mount Figure 1 The DGCSR Components All contents subject to change Visit www omnitech com for updates 5 DGCSR User Manual Rev 1 1 amp 4 0 Introduction The DGCSR system provides a remotely
29. more details on this set of signals J6 TS This is the Tracking System interface connector It is intended to connect to the separate Tracking Sys tem box using a cable provided with that system 4 1 1 2 Switch Summary SW1 Power On up position or Power Off down position This is a pull to actuate toggle switch It is used to turn power on or off for the DGCSR RX power SW2 Override up position or Safety down position This is a pull to actuate toggle switch It is used to over ride the safety radio function altogether In some cases a DGC team may want to drive their vehicle normally some of the time without the need to use the DGCSR In that case they can place the toggle switch in the up position selecting the Safety Override option and the vehicle pause and disable outputs are forced to their operating state This may be useful when it is necessary to operate the vehicle in a manned mode to move it in or out of a building for instance Alternatively if this switch is in the down position selecting the Safety option then the DGCSR will operate as defined in this manual and a continual safety radio enable is necessary SW3 Clear Disable This is a momentary acting pull to actuate toggle switch It is used to clear the DISABLE state first at power up and subsequently after any DISABLE of the system 4 1 1 3 Status Display LED Function Summary Master Warn Indicates a Master Warnin
30. ons Contact ORI Note recent operational and storage conditions Contact ORI All contents subject to change Visit www omnitech com for updates 2 DGCSR User Manual Rev 1 1 OMNITECH ROBOTICS 8 0 Appendix A Shock Vibration Testing Reference Laboratory Test Report Date 22 Sep 03 Test Report No 0733 2 of B 2 0 3 0 4 0 TEST ARTICLE One 1 OmniTech Robotics DGC Safety Radio with associated antenna and Test SPECIFICATIONS Vibration per MIL STD 810F Method 514 4 Category 20 Figure 514 5C 3 Vertical Axis Profile all three test axes except modified to 0 02 G2 Hz from 5 to 20 Hz three 3 hours in each of three mutually perpendicular axes Shock per MIL STD 810F Method 516 5 Procedure Figure 516 5 10 20G amplitude 11 msec duration three 3 shocks in both directions along three mutually perpendicular axes Temperature soak at 70 C 160 F for a minimum of eight 8 hours TEST EQUIPMENT The equipment used to complete the testing was 1 PCB Model J353B34 Accelerometer SN 14922 Cal Due 19 Feb 04 1 Unhaltz Dickie Model SA30 R24 Shaker SN 523 Cal N A 1 Spectral Dynamics Model 2552 Control System Cal Due 22 Oct 03 1 Tenny T20RC 4 Temp Humidity Chamber SN 24521 07 Cal Due Date13 Feb 04 RESULTS OmniTech Robotics personnel monitored the electronic functionality and operation of the radio before during and after each axis of testing and afte
31. r temperature soak No failures of the radio or the antenna were observed Vibration test profiles are shown in vibration test plots Figures 1 through 3 Shock test profiles are shown in shock test plots Figures 1 through 6 Figure Appendix 10 1 Testing Overview All contents subject to change Visit www omnitech com for updates 28 DGCSR User Manual Rev 1 1 edi Bee OMNITECH ROBOTICS Test Lek D B IH HAS 1585 Tag Harga 5 00 HE Tesi Time CO 0 3C DT 25 Conte _ j 11 _______ j d 01 E E Pri they ghz DOF S F 5 Uy RT s s 1 585 0 Th it J LET x l i i ito um Hei Figure 1 Fri e Fins DOC 17 Bap Test Hara T1732 Dmnlioch 005 Figure Appendix 10 2 Typical Vibration Profile di e ler Lovet Fun a Hamen Page DY Ful Cri WcrsmEbrO 8 LI Fic 25 ni 2 c Liriagi Timo moo d Tiree Fr Sop 162508 Chena Bock Teed Mme DIDA Figure Appendix 10 3 Typical Shock Profile lorna Pas All contents subject to change Visit www omnitech com for upd
32. ritan Circle Englewood Co 80110 Phone 303 922 7773 Fax 303 922 7775 web site www omnitech com email info omnitech com All contents subject to change Visit www omnitech com for updates 33
33. rnal 12V power supply fail ure or fuse blown Recommended Procedure Note recent operational and storage conditions Contact ORI Keep the power on for several minutes then cycle the power off and on again The error should go away Note recent operational and storage conditions Contact ORI Note recent operational and storage conditions Contact ORI Note recent operational and storage conditions Contact ORI Note recent operational and storage conditions Contact ORI Note recent operational and storage conditions Contact ORI All contents subject to change Visit www omnitech com for updates 26 DGCSR User Manual Rev 1 1 Error Error Likely Error Source 71 3 3 V Error J15 temp sensor Error J16 temp sensor Error Main Board ambient temp sen sor Error Power Board Temp Sen sor Error Table 1 Error Codes Internal 12V power supply fail ure or fuse blown J15 temp sensor not used Provi sional Over temp Sensor J16 temp sensor not used Provi sional Over temp Sensor Main board ambient temp greater than 70 C Power Supply board temperature greater than 70 C ROBOTICS Recommended Procedure Note recent operational and storage conditions Contact ORI Note recent operational and storage conditions Contact ORI Note recent operational and storage conditions Contact ORI Note recent operational and storage conditi
34. rong position inadvertently it is important to always test the DGCSR for proper operation prior to use All contents subject to change Visit www omnitech com for updates 21 DGCSR User Manual Rev 1 1 amp 6 3 Power Up Powering up the DGCSR TX and RX can occur in either order To power the units the Power On Off toggle switch SW1 should be placed in the up ON position Visual confirmation of the power up sequence of the units is possible by observing the Status Display window and watching the LED light test where all DGCSR controlled LEDs are turned on briefly at power up 6 4 Monitor Status Displays The initial power up progress can be monitored by observing the status display LEDs Normal operation will be indicated by the presence of the Elapsed Time LED coming on and the time displays beginning to increment there are six 7 segment displays that show hours top 2 characters minutes middle 2 charac ters and seconds bottom 2 characters If the display shows an EE and number code this is an error code display indicating an abnormal situa tion The error code number should be recorded for later reference If this occurs users should verify proper installation and use of the system then call Omnitech Robotics for consultation if necessary Once the elapsed time counter begins to increment the user can observe the GPS FIX OK LED in the upper right corner of the status display window This LED will turn green
35. s is done by flipping toggle switches on the DGCSR TX In addition if the radio link between the DGCSR TX and RX is lost for any reason the PAUSE and DISABLE outputs will automatically assert after a programmable delay time During the DGC event more than one safety operator will be supervising each vehicle and more than one DGCSR Transmitter will be used Teams are being supplied with only a single DGCSR TX but during the competition officials will also use another component called a DGCSR Master Transmitter capable of sending a PAUSE or DISABLE to all teams DGCSR RX units individually or as a whole The DGCSR is designed to allow more than 100 safety radio components Receivers Transmitters or Master Transmitters to operate in one area at one time The operating range of the DGCSR system has been tested in specific parts of the DGC competition route with line of sight range in excess of 11 miles Non line of sight range has also been tested in specific critical areas of the route with range in excess of 1 mile All contents subject to change Visit www omnitech com for updates 6 DGCSR User Manual Rev 1 1 OMNITECH ROBOTICS _ lt _ The PAUSE capability is intended to allow safety operator personnel to pause the competition vehicles during the course of the race with the understanding that the pause will be subsequently removed and a RUN status resumed It is emphasized that a PAUSE mode will occur on numerous
36. sit www omnitech com for updates 11 DGCSR User Manual Rev 1 1 J4 Plug In 4 nm TU nanam 2 Power GND 2 3PowerGND gt 1 9 AM 18 GA drain 4 Chassis GND Notes 16 GA white wire LABEL 1 12V PWR IN 2 GND 3 4 Chassis GND 1 Pin 1 is nominally 12 V power in with respect to pin 2 GND Acceptable range is 10 V to 20V Typical Current draw for the DGCSR TX or RX without DGCTS is Input is internally fused at 5A 2 Pin 4 is chassis GND It should be connected to the vehicles chassis ground or control electronic main chassis ground star point Figure 4 CA20 Detail P5 Socket In 1 Run Pause Relay Vin t 2 Run Pause Relay Out 3 Run Pause RELAY 4 Run Pause Vin 5 Run Pause Out 6 Run Pause 7 DISABLE Relay Vin 8 DISABLE Relay Out 9 DISABLE RELAY 10 DISABLE Vin 11 DISABLE Out rm 12 DISABLE OPTO_GND x 13 Chassis GND Figure 5 CA21 Detail 6 bue L MILLS Tediblack OOO Ts greenback ____ _ 70 orangea ELT Bae T anoe TB2 1 Run Pause Relay Vin 2 Run Pause Relay Out 3 Run Pause RELAY GND 4 Run Pause OPTO Vin 5 Run Pause OPTO Out 6 Run Pause OPTO GND 7 DISABLE Relay Vin 8 DISABLE Relay Out 9 DISABLE RELAY_GND 10 DISA
37. tart when the vehicle is in gear Many commercial automotive systems have this feature already This increases safety when using the DGCSR by assuring that when the engine is first started the vehicle will not move right away This is important in case users are near the vehicle to operate as is often the case The radio frequency RF Antenna emits RF radiation in the 902 928 MHz frequency range at power levels up to 1 watt The FCC authorizes these radios to operate at this power level license free however all personnel should maintain a minimum separation from all parts of their body to the radio antennas of at least 23 cm at all times to reduce their exposure to RF radiation particular competition vehicle uses power steering power brakes or other power assist devices to maintain control of their vehicle then consideration must be given to assure the compatibility of the DGC SR system Specifically the PAUSE signal does not necessarily stop the prime mover motor or engine of the competition vehicle but the DISABLE command does It is intended that the PAUSE is used to ini tiate an immediate controlled stop using all such power assist equipment and the DISABLE will engage after the vehicle has come to a controlled stop to turn off the engine and assure a faulty vehicle does not drive off indefinitely with power DGC competition vehicle control system should be designed to stop the vehicle and apply the brakes quickly when
38. tches are intended to avoid inadvertent actuation by requiring the user to pull the toggle switch lever out away from the switch base prior to trying to move the switch to a different position Failure to pull the toggle lever out prior to actu ation may cause the switch to break and necessitate replacement 5 The DGCSR system is primarily designed to provide a remote controlled safety radio RUN PAUSE and ENABLE DISABLE function for the DGC competition vehicles during the DGC event It relies on each DGC competition team to install it as a part of an overall safety program and maintain it in an operational state DGCSR operators should normally command a PAUSE prior to commanding a DISABLE to allow the competition vehicle control system to stop in an orderly way using the power brakes and power steering and other power assisted devices of their vehicle This is because one of the DGCSR systems intended functions is to DISABLE the power plant of a rogue vehicle to avoid a run away condition in case of cata strophic control system failures However disabling the engine of some automotive vehicles reduces or eliminates power assisted control devices like steering and brakes It is the responsibility of each DGC team All contents subject to change Visit www omnitech com for updates 1 DGCSR User Manual Rev 1 1 OMNITECH ROBOTICS L s to analyze and design a safe conservative and effective means of using
39. the RUN PAUSE and ENABLE DISABLE to assure safe and reliable operations occur as required 6 This manual and the DGCSR system specifications are subject to changes updates modifications or clarifications as determined by Omnitech Robotics International LLC Users should periodically check for the latest revisions of all manuals and product information posted at www omnitech com under the DGCSR heading and links 7 All DGCSR components were designed with Electromagnetic Compatibility and Interference in mind special design precautions have been taken to minimize the noise generated from the DGCSR components and the sensitivity of these component to noise from other sources like the user s DGC competition vehicle ignition or control system Users should exercise good design practice to minimize the amount of noise electrical RF magnetic their system produces to assure the best DGCSR radio link range and perfor mance It is specifically suggested that high noise sources like PWM motor amplifiers DC DC converters and all switching power supplies use LC filters ferrite suppressors and proper power ground and chas sis ground design practices to limit the noise generated by these components 8 The DGC SR system should always be tested for proper operation prior to use as a safety interlock for the DGC competition vehicle 9 Please note that upon returning a vehicle to an ENABLED state from a PAUSED or DISABLED state the ve
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