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hardware's Introduction

hardware

Schematics and layout work

Getting started with git

Tutorial: https://www.youtube.com/watch?v=1xfp2Cx9FUk

the main workflow is usually like this:

  1. install git on your machine https://git-scm.com/download/
  2. use the git bash terminal window to work with the repositories:
  3. clone the repository of choice: in your terminal window, navigate to the folder you want to store the repository in, and send the command git clone https://github.com/sfuphantom/hardware.git' for the hardware repository for example
  4. the hardware repo has folders that contain a submodule - which is essentially just a version of a different repo, nested inside the hardware folder. this nested repo is the altium-libraries repository! to enable it, use git submodule init while in the hardware directory, and then git submodule update
  5. now if you navigate to that folder in your normal file browser, you should see the repository folder with all the files in it
  6. you can now edit the files and add new files into the repository folder like normal, as you would any folder system
  7. to register new added files you have placed in the repository folder in your file browser, use the command git add -A in your terminal window while in the directory of your repository (cd /documents/phantom will change your active directory to /documents/phantom, and cd .. will change your active directory up one level)
  8. Make sure you create a new branch before editing any files! Branching instructions down below
  9. Once in your new branch, git add -A will add all new files repo folder to be tracked by git
  10. to save the changes you have made and the files you have added, use the command git commit -m "fill in your update here" to commit your changes and save them with a useful message
  11. when you are ready to update the centralized repository on github with your changed localized cloned repository, use the command git push and you should see your changes show up on github

http://rogerdudler.github.io/git-guide/

https://learngitbranching.js.org/

http://www.ndpsoftware.com/git-cheatsheet.html#loc=workspace

Branching

If you wish to work on a version of the repo without affecting or potentially causing conflicts, use branches. They are very useful for developing a new feature of a program/board without affecting the master branch. They can later be merged into the master branch by using a pull request.

  1. Navigate to your hardware directory in the git bash terminal window.
  2. Use the following command git branch MyBranchName to create a new branch
  3. Use the following command git checkout MyBranchName to switch your active branch to MyBranchName instead of Master
  4. If you want to perform both commands in one line, here's a shortcut: git checkout -b MyBranchName
  5. Now you can develop and make changes as you wish on MyBranchName, adding files, making commits, and pushing up to the repository held in Github.
  6. When you have decided you are ready to combine your changes/additions to the master branch of the repository, use Github's web interface (https://github.com/sfuphantom/hardware) to create a new pull request.
  7. A pull request will alert other people that you are ready to combine your branch (MyBranchName) with the Master branch, and will allow them to review your work and approve it for merging.

hardware's People

Contributors

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hardware's Issues

5V, 3V3, & 1V2 rails down

Fix the broken power rails on the VCU. Something looks like it is wrong with the 5V OR-ing controller as it is burning hot when on. Board now draws 140mA from power supply with 5V, 3V3, and 1V2 rails down. Previously drew 60-80mA under normal operation.

Prototype Latching Circuit

Order components and prototype JK flip flop latching circuit - this will be used on the output fault signals of the AMS, IMD, and BSPD
1517718636686-1951242273

Fix 24V->5V DCDC footprint

Current one has 24V and 5V mixed up.. leading to the DCDC having 24V put to its output... This is fixed on the board by placing the DCDC upside down on the PCB

Question: How effective is the TSAL?

Hey friends,
I'm working on my own comparator-based TSAL, but your solution is attractive owing to it's simplicity. If you have the time spare, I have a couple of questions:

  • Does it trigger at a repeatable and accurate voltage? (both the turn-on and turn-off)
  • Does the circuit need tuning? I imagine that for the small currents at the optocoupler LED, small manufacturing differences between optocouplers of the same type could change the trigger levels substantially. What have you experienced?
  • How's the power dissipation in the input voltage-divider?
  • What voltage accumulator are you running?

I appreciate any time you take to answer these questions - I know well how short time is when building a race car.
If you prefer to answer outside of the public domain you can reach me at:
[email protected]

Thanks, and best of luck.

Create XDS110 adapter

Need adapters for 20-pin TI JTAG interface to 10-pin ARM connection for JTAG that is on the VCU. Can be a good starter PCB project for new members.

Increase VCU 5V rail trace widths

On VCU 5V rail is currently dropping ~0.2-0.3 volts from USB/DCDC to 5V loads. This is likely due to the long thin traces that 5V runs through up and down the board. Increase these widths to decrease the resistance and hopefully minimize the voltage drop

Add info to PCB doc

Create better fab layer, show stackup, copper thickness, trace min width, impedance, min hole size. Add keepins and keepouts, and use only one mechanical layer for components instead of two

Add RX TX LEDs

Add RX and TX LEDs to FTDI chip to see UART communication

JTAG Power

Look into providing power through JTAG instead of needing a separate usb connector.

Clean up schematic

Clean up VCU schematic, separate features into more pages instead of having them crammed onto one page.

Higher Current DCDC

Should we replace the 2A 24->5V DCDC with a higher current one? Additional current draw from new components plus inrush on the AIRs will likely exceed the rating of our current DCDC, which would result in the voltage rail dropping

Prototype Shutdown Circuit

Prototype first version of shutdown circuit. Wire inline buttons to simulate the inertia switch, brake over travel switch, HVD, and other master switches.

Use mosfets as shown in attached picture, you might need to be careful about the Vgs of each fet.
img_20180202_102608 2

Schematic Design

Design schematic on paper for TSAL, red LED blinking for HV and green solid LED for LV.

Find Fast Blow Fuses

Current fuses on 5V, 3V3, and 1V2 rails on VCU do not blow at their rated currents. Check in datasheet to find trip curve, and find fuses that are fast blow and will trip when needed.

Higher Current DCDCs

Find higher current DCDCs for 3V3 and 5V rails, current ones blow really easily (5V one at 2A and 3V3 one at 300mA). Also find ones that have a much smaller footprint to save board space

Increase low side driver trace width

Increase trace width through drain-source path of low side drivers for contactor switching. Want a low resistance/inductance path for contactor relay coil current pass through, without getting hot. The increased thickness will also help heatsink the FETs. Consider making them small planes.

MCU Debugger Power

Look into providing power through the JTAG debugger. Currently the target (VCU) needs to be separately powered to be able to debug it and flash.

Find new MCU

Stay within tms570 family, find one with smaller packaging since we don't use all the pins anyway, and one that can be sampled from TI

Switch to cheaper FETs

Use lower rated FETs on VCU, current ones are overkill and can handle way too much (i.e. 110 amps). They are expensive, too big, and also hard to solder

Add voltage sensing on all the rails

Using op amps to compare voltage rails to ensure they are operating nominally. Currently even if a rail is half up (i.e. 24V rail is running at 12V for some reason), our power good LED will still turn on

Decrease board size to 10cmx10cm

Decrease VCU board size from 15cmx11cm down to 10cmx10cm. If we can get it down to that size, then the board will only cost $5 with a lead finish, and $6.90 with a lead-free. Super worth

Add EEPROM for parameter saving

Add EEPROM IC to VCU, is useful to dump parameters and values periodically in case of an unexpected loss of power. Upon reset of MCU, data can be loaded back with a timestamp of the last data dump

BSPD

Notes November 22, 2018
Faraz and Raaj

Last time we tested the comparator and the inverter. The Inverter worked as expected, the comparator had open drain output (active low), not the same problem on PCB, and required a pull-up resistor on the outputs.

Debugging LEDs

Need to add nERROR red LED as well as 1V2 regulator power good LED

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