Electrical Workshop

Team 254 and 1868

What is Wiring?
The process of connecting electrical components together with electrical wires Used to transfer electricity between two components Raw Power Data/Signal

Electricity
Two forms: AC, DC Batteries provide DC, wall outlets provide AC Always two poles Measured in Volts, Amperes, and Watts Think of garden hose Volts = Pressure of water: Voltage Amperes (amps) = volume of water: Current Watts = Total amount of power Current - Amps; Voltage - Volts; Resistance - Ohms () Power - Watts

Electricity
Voltage = Resistance * Current (across a single component) V= I * R Power = Current * Voltage P = I * V Series vs. Parallel connections Resistance: Adds in series ( Rt = R1 + R2 + R3 + ...) In parallel: 1/Rt = 1/R1 + 1/R2 + 1/R3 + ... Current: Same through components in series Current through parallel adds: It = I1 + I2 + I3 + ... Voltage: Drops across components in a series (Vpower = V1 + V2 + V3 + ...) Same across components in parallel

Digital Multimeters
Used to measure resistance, voltage and current can also check continuity Make sure the multimeter dial is set to the correct position Do not move the dial through positions while the multimeter is connected to the circuit NEVER measure current in parallel Any of these could blow the fuse in the multimeter

Wire
Used to transfer electricity Measured in length and gauge Smaller gauge = larger diameter talk about awg (american standard + types of wires and their gauges) Most wire is insulated, conductor usually made of copper or aluminum Most common in black and red
Black = (-) Red = (+) Other colors: signal wires

Crimping
Usually involves some sort of terminal to crimp over wire Terminal is bent over wire to physically lock in place Terminal should always be insulated Heat shrink (preferred) Pre-insulated terminal Different types of terminals blade ring/spade pwm/servo, etc.

Crimping (cont.)
Advantages Strong Physical Connection Easy to perform Simple, requires 1 tool Disadvantages Not the best electrical connection Irreversible

Soldering
Melting a strand of metal between two contacts, in order to connect them physically, and electrically. Melt solder Typically thin wire of mixed lead, tin, and other metals Usually melts around 60-90 degrees C Toxic fumes in large quantities Usually Perminant Solution

Soldering (cont.)
Advantages Provides maximum contact between two connections Melted solder fills in any gaps Least electrical resistance Provides fairly good physical connection Disadvantages Takes skill and time Not always the strongest physical connection Requires power, specialized equipment Requires more care, safety, etc Excess heat can damage components, wire, etc Solder within wire can cause wire to be brittle vibrations can wear/break connection

Brief Process - Wiring

1. Acquire materials 2. Cut and strip wire to appropriate length 3. put on appropriate sized heat shrink 4. Crimp connection 5. Ensure secure, proper crimp 6. Solder connection 7. Double check solder joint is neat and not cold 8. Test continuity 9. Apply heat shrink

Wire Management
Keep wiring organized - label when necessary Organized wiring is easier to work on, troubleshoot, repair, etc Take pride in your wiring job - others also work on it Use zip ties when needed. They can always be cut, relocated, etc. Needs to be easy to see where each wire goes and comes from Wires should be secured so that they don't interfere with operation Use only as much wire as needed while providing adequate strain relief and service loop

Strain Relief/Service Loops

Strain relief Wire tension can damage connectors and terminals Ensure that terminal is not being pulled on excessively Allow wire to be moved or tugged on without too much strain being put on terminal Think of moving parts and how they will interact with the wire Service Loops What if you need to switch the which port something is plugged into? Terminal is getting bad connection, needs to be serviced Enough wire needs to be available for the terminal to be serviced and adjusted if needed

Layout Process
Power Distribution board - Central Battery - close to power distribution board heavy - need to check center of gravity Victors need easy access to power distribution board Spike relay with victors Digital side car - near cRIO Pneumatics near cRIO (if possible) Pneumatics components all together cRIO should be near digital components Digital components together Radio near cRIO Positioning is a compromise - all of this isn't possible

Components of the Electrical Board

cRIO Digital Sidecar Spike Relay Compressor Victor Speed Controller Solenoids Battery power switch Radio Power Distribution Board

Various Electrical Components