"""The body's power and CAN wiring (milestone M5, P0 power skid): one wire list and the diagram drawn from it. .venv/bin/python cad/body_wiring.py # -> exports/body/wiring.json, exports/body/wiring.svg The wire list is the build sheet: every run with its two ends, gauge, colour, connector, the fuse that protects it and why that size. docs/body-electrical.md explains the system; this file is what the drawing and the table are made from, so they cannot disagree. The system (D65, D54-D56, D60, D66): two DeWalt DCB609 FLEXVOLT packs in 20 V mode on two rail adapters, in series: 10S3P, 36 V nominal, 41 V full, 30 V empty (the robot enforces 3.0 V a cell and the current limit: the packs talk to nothing); an XT90-S at the bay's lead; the 80 A MRBF main fuse then the 150 A / 50 mV shunt on the + lead (the INA228 reads it high side: in the - lead ahead of the low-side switch it would be destroyed when the switch opens, docs/ body-fuse-board.md 1); the anti-spark main switch on the - lead (low side, as Flipsky draws it: verify on its card); two C110 bus bars; Littelfuse MINI 58V fuses in inline holders to every branch (the fuse board in P3); one isolated TRACO TEP 150-4812WI for 12 V (the J501, the lidar box, the lights and eyes, the 5 V buck, the radio stop); the turret (D66) on its own fused branch of the bus through the stop relay. No charge port: the packs charge on DeWalt's chargers. The live-end rule (hazard 11, D58): every connector on the body's side of a lead that is live with the packs in is a SOCKET (female): the bay's XT90-S, every bus branch lead (XT60H-F; the turret's XT30U-F) and the 12 V branch leads (XT30U-F). The devices' leads carry the pins (males): the RS-04 pigtails (the leg's: 450 mm, XT60H-M), the VESCs' own leads, the J501's DC-IN, the lidar box's adapter lead and the turret's lead. `cad/test_body.py` checks it. """ from __future__ import annotations import json from pathlib import Path R = Path(__file__).resolve().parents[1] OUT = R / 'exports' / 'body' PACK = {'cells': 'two DeWalt DCB609 FLEXVOLT 9.0 Ah in 20 V mode (5S3P each), in series: 10S3P', 'v_nom': 36.0, 'v_full': 41.0, 'v_full_per_cell': 4.10, 'v_empty': 30.0, 'ah': 9.0, 'wh_rated': 360, 'peak_a': 80, 'cont_a': 30, 'protection': 'none in the packs the robot can use: the firmware sits at 32 V, cuts off at 30 V under load, limits the ' 'bus current to 30 A (1 s) and 80 A (0.5 s), clamps regeneration over 41.5 V and latches off over 44 V ' '(docs/body-firmware.md); the MRBF 80 A is the last line'} # (id, from, to, AWG, colour, connector/termination, fuse, why) WIRES = [ # ---- the packs, the bay's lead and the main path ('W1', 'front adapter + (its 10 AWG lead)', 'XT90-S female (the bay\'s lead) +', 10, 'red', 'XT90-S solder cup', '-', 'the adapter\'s own lead (Terrafirma, 10 AWG, 30 A stated): on the pack\'s side of the MRBF, unfused as every pack lead; keep it to its 300 mm'), ('W2', 'front adapter -', 'rear adapter + (the series link)', 10, 'black', 'XT90-S pair (in the bay\'s middle)', '-', 'the two packs in series: the link unplugs so each half is 18 V when the bay is serviced'), ('W3', 'rear adapter -', 'XT90-S female (the bay\'s lead) -', 10, 'black', 'XT90-S solder cup', '-', 'the pair\'s negative'), ('W4', 'XT90-S male (robot) +', 'MRBF block, battery stud (M8)', 8, 'red', 'lug M8', '-', 'unfused until the MRBF: keep it short (<150 mm)'), ('W5', 'MRBF block, load stud (M8)', 'shunt, battery side (M8)', 8, 'red', 'lugs M8', 'MRBF 80 A', 'the shunt on the + side: the INA228 reads it high side (docs/body-fuse-board.md 1); its base insulates it from the plate'), ('W6', 'shunt, load side (M8)', '+ bus bar, tap 1 (M6)', 8, 'red', 'lugs M8 / M6', 'MRBF 80 A', 'the whole robot'), ('W7', 'XT90-S male (robot) -', 'main switch IN- (B-)', 8, 'black', 'ferrule / its lead', '-', 'Flipsky draws the switch on the negative: check its card'), ('W8', 'main switch OUT- (P-)', '- bus bar, tap 1 (M6)', 8, 'black', 'lug M6', '-', 'the switched negative: everything below is off with it'), # ---- the bus branches ('W10', '+ bus tap 2', 'RS-04 left front (XT60H)', 14, 'red', 'lug M6 / XT60H-F', 'MINI 58V 20 A', '~12 A at a jump, 25 A peaks: 14 AWG silicone; the motor\'s 450 mm pigtail carries the XT60H-M'), ('W11', '+ bus tap 2', 'RS-04 left rear (XT60H)', 14, 'red', 'lug M6 / XT60H-F', 'MINI 58V 20 A', 'as W10 (two lugs share the tap)'), ('W12', '+ bus tap 3', 'RS-04 right front (XT60H)', 14, 'red', 'lug M6 / XT60H-F', 'MINI 58V 20 A', 'as W10'), ('W13', '+ bus tap 3', 'RS-04 right rear (XT60H)', 14, 'red', 'lug M6 / XT60H-F', 'MINI 58V 20 A', 'as W10'), ('W14', '+ bus tap 4', 'VESC left (Flipsky 75100) +', 12, 'red', 'lug M6 / XT60H-F', 'MINI 58V 30 A', 'the wheel: its battery current limit 20 A in VESC Tool (the fuse board\'s FL1 holders carry 22 A); its own lead carries the XT60H-M'), ('W15', '+ bus tap 4', 'VESC right +', 12, 'red', 'lug M6 / XT60H-F', 'MINI 58V 30 A', 'as W14'), ('W16', '+ bus tap 5', 'TRACO TEP 150-4812WI Vin+', 18, 'red', 'lug M6 / ferrule', 'MINI 58V 10 A', '150 W out: 5.6 A in at 30 V'), ('W22', '+ bus tap 5', 'stop relay, pole B (in): the turret\'s branch', 16, 'red', 'lug M6 / screw terminal', 'MINI 58V 7.5 A', 'D66: the turret\'s own robot on the bus (its Orin NX ~40 W, flywheel bursts to ~140 W: 4.7 A at 30 V); 7.5 A keeps the G2RL-2\'s ' 'contact under its 8 A (about 6 A breaking at 41 V: docs/body-fuse-board.md); the stop relay cuts it'), ('W18', '- bus taps 2-3', 'RS-04 x 4 (XT60H)', 14, 'black', 'lug M6 / XT60H-F', '-', 'returns, one per motor (the - of W10-W13\'s plugs)'), ('W19', '- bus tap 4', 'VESC left, right -', 12, 'black', 'lug M6 / XT60H-F', '-', 'returns (the - of W14-W15\'s plugs)'), ('W20', '- bus tap 5', 'TRACO Vin-, the turret\'s XT30U-F -', 16, 'black', 'lug M6 / ferrule / XT30', '-', 'returns'), # ---- 12 V (isolated; its - tied to the - bus at the star point) ('W21', 'TRACO +V', 'J501 DC-IN (XT30)', 16, 'red', 'ferrule / XT30U-F', 'MINI 10 A (inline)', 'the J501 at 12 V (12-36 V in): 60 W peak, 5 A; its DC-IN adapter lead carries the XT30U-M'), ('W43', 'TRACO +V', '12 V loads: lidar box, buck, jack, lights, eyes', 16, 'red', 'ferrule / Wago 221', 'MINI 58V 7.5 A (inline)', 'about 40 W: the VLP-16 8 W (3 A at spin-up), the SSC1 pods, the eyes, the 5 V buck'), ('W23', 'TRACO -V', 'J501 return; star point', 16, 'black', 'ferrule / XT30U-F', '-', 'one tie from -V to the - bus (the CAN reference)'), ('W24', '12 V loads (W43)', 'lidar interface box (XT30)', 18, 'red', 'Wago 221 / XT30U-F', '(W43\'s 7.5 A)', 'the box\'s lead carries the XT30U-M'), ('W25', '12 V loads (W43)', '5 V buck VIN (Pololu D36V28F5)', 22, 'red', 'Wago 221 / solder', '(W43\'s 7.5 A)', '~0.6 A at 12 V'), ('W26', '12 V loads (W43)', 'radio-stop jack pin 3 (+12 V)', 22, 'red', 'Wago 221 / jack', '(W43\'s 7.5 A)', 'D37: the jack offers 12 V'), ('W27', 'TRACO -V', 'lidar box, buck, jack GND', 18, 'black', 'ferrule', '-', 'the 12 V loads\' returns'), # ---- 5 V ('W28', '5 V buck VOUT', 'Nucleo E5V, 3 CAN Pal, VN-100, radio receiver', 22, 'red', 'solder / GH', '(the buck\'s 3.2 A limit)', '~1 A in all'), ('W29', '5 V buck GND', 'the same, GND', 22, 'black', 'solder / GH', '-', ''), # ---- measurement and protection ('W30', 'shunt sense + (battery side screw)', 'INA228 IN+', 22, 'white', 'ring / screw terminal', '-', 'Kelvin pair, twisted, away from the 8 AWG; high side: 30-41 V above the INA228\'s ground, inside its 85 V'), ('W31', 'shunt sense - (load side screw)', 'INA228 IN-', 22, 'white', 'ring / screw terminal', '-', 'the INA228\'s own 15 mOhm shunt is removed'), ('W32', '+ bus tap 5', 'INA228 VBUS', 22, 'red', 'lug M6 / ring', 'MINI 58V 5 A (its own inline holder)', 'pack voltage, 85 V input; 22 AWG carries 7 A'), ('W33', 'frame (a tray PEM stud)', '- bus star point', 14, 'green', 'ring M5 / lug M6', '-', 'a + short to the frame blows a fuse, not leaves it live; 14 AWG: a + lead chafed ahead of its branch fuse puts the MRBF\'s let-through on it'), # ---- the turret (D66: its own robot; power on an XT30, Ethernet to the J501, the dry safety loop) ('W34', 'stop relay, pole B (out)', 'the turret\'s XT30U-F +', 16, 'red', 'screw terminal / XT30U-F', 'MINI 58V 7.5 A (W22)', 'dead whenever the stop relay is open; the turret\'s lead carries the XT30U-M'), ('W36', 'J501 Ethernet (its second port or a switch)', 'the turret\'s RJ45', None, 'blue', 'Cat 6, 0.5 m', '-', 'D66: the turret\'s link (it had can1)'), ('W37', 'stop relay, pole A (closed = run)', 'the turret\'s safety loop (SAFETY_A, SAFETY_B)', 22, 'white', 'twisted pair', '-', 'the turret\'s dry safety loop (12 V at 2 mA; D41 D7: it cuts the flywheels and the dial in hardware)'), ('W38', 'stop relay coil, + side', 'MCU STOP sense (divider 12 V to 3.3 V)', 22, 'white', 'GH', '-', '12 V on the coil = the radio says run: the MCU sits the robot down when it drops (D37)'), ('W39', '12 V loads (W43) via the RC switch\'s contact', 'stop relay coil, + side', 22, 'red', 'solder / screw terminal', '(W43\'s 7.5 A)', 'the coil (12 V, 33 mA) is fed only while the radio says run; its - side through the MCU\'s MOSFET (MCU_RUN), a diode across it'), # ---- D69: the hub wheels' leads, each through the cheek's gland at the hip (IP54) to its VESC. The body's ends are # sockets (DT06 / DTP06 plugs, as the live-end rule asks: the VESC side is live with the packs in); the wheel's lead # carries the pins (DT04 / DTP04 receptacles), so a wheel pushed by hand (its back-EMF, ~7 V at a walking pace) shows # pins only on the unplugged wheel. Contacts: DTP size 12 for 12-14 AWG (25 A), DT size 16 for 16-20 AWG (13 A) ('W50', 'VESC left phases A/B/C', 'left wheel phases (its lead\'s DTP04-4P)', 14, 'yellow/green/blue', 'DTP06-4S plug + WM-4S wedge, 3 x 0462-203-12141 sockets (4th cavity plugged, 114017)', '-', 'D69: 30 A motor peak for 0.5 s, 10 A continuous; 14 AWG silicone, 400 mm to the cheek\'s gland; no fuse (the VESC limits it)'), ('W51', 'VESC left halls (5 V, GND, H1-H3) + motor NTC', 'left wheel sensors (its lead\'s DT04-6P)', 20, 'per VESC', 'DT06-6S plug + W6S wedge, 6 x 0462-201-20141 sockets', '-', 'D69: halls and the stator NTC; a shielded 6-core, shield to the VESC\'s GND only'), ('W52', 'VESC right phases A/B/C', 'right wheel phases (its lead\'s DTP04-4P)', 14, 'yellow/green/blue', 'DTP06-4S plug + WM-4S wedge, 3 x 0462-203-12141 sockets (4th cavity plugged, 114017)', '-', 'as W50'), ('W53', 'VESC right halls (5 V, GND, H1-H3) + motor NTC', 'right wheel sensors (its lead\'s DT04-6P)', 20, 'per VESC', 'DT06-6S plug + W6S wedge, 6 x 0462-201-20141 sockets', '-', 'as W51'), ] CAN = [ ('A', 'MCU FDCAN1 (CAN Pal 1, 120 Ohm on)', ['RS-04 left front', 'RS-04 left rear (120 Ohm at its plug)'], '1 Mbit/s, the left leg'), ('B', 'MCU FDCAN2 (CAN Pal 2, 120 Ohm on)', ['RS-04 right front', 'RS-04 right rear (120 Ohm at its plug)'], '1 Mbit/s, the right leg'), ('C', 'MCU FDCAN3 (CAN Pal 3, 120 Ohm on)', ['VESC left', 'VESC right', 'J501 can0 (its own 120 Ohm on)'], '1 Mbit/s: wheels, the computer'), ] STOP = ('The radio stop (D37, D55): the ER3C-i receiver (failsafe: no pulses) drives one Pololu RC relay switch; its contact feeds ' 'the coil of the stop relay (Omron G2RL-2, DPDT, 12 V), whose other end goes to ground through the MCU\'s MOSFET. The relay ' 'holds only while the radio says run AND the MCU says run. Pole A is the turret\'s dry safety loop (TM pins 7, 8: the turret ' 'cuts its flywheels and dial in 20 ms), pole B is in the turret\'s bus branch (W22, W34: the independent cut); the MCU senses the coil ' 'voltage and sits the robot down when the radio drops, and opens the relay itself when the robot sits. The main switch is the ' 'hard off.') def svg() -> str: """The diagram (1300 x 900): the pack and the main path left, the bus bars and fuses in the middle, the loads right, the low-voltage rails and CAN below. Every wire carries its W-number from WIRES.""" W, H = 1400, 960 o = [f'', '', '', 'Gyropup body P0: power and CAN wiring', f'Two DCB609 in series (10S, D65): {PACK["v_nom"]} V nominal, {PACK["v_full"]} V full, {PACK["v_empty"]} V empty. ' 'W-numbers are the rows of docs/body-electrical.md (cad/body_wiring.py). Red +, black -, white sense, green frame bond.'] def box(x, y, w, h, title, lines=(), fill='#f4f6f8', stroke='#333'): o.append(f'') o.append(f'{title}') for i, t in enumerate(lines): o.append(f'{t}') def wire(pts, colour, label=None, at=0, dx=4, dy=-4, width=3.0): c = {'red': '#d62728', 'black': '#222', 'white': '#888', 'green': '#2ca02c', 'blue': '#1f5fbf', 'orange': '#e08a00'}[colour] p = ' '.join(f'{x},{y}' for x, y in pts) o.append(f'') if label: x, y = pts[at] o.append(f'{label}') def fuse(x, y, label): o.append(f'') o.append(f'{label}') # the battery drawer box(20, 70, 210, 210, 'Battery bay (belly)', ['two DeWalt DCB609, 20 V mode', 'on two Terrafirma rail adapters', 'in series (W2: an XT90 link)', '10S3P, 30-41 V, 360 Wh rated', 'no BMS the robot can read:', 'the firmware cuts off at 30 V', '', 'XT90-S female on the bay\'s lead'], fill='#fff7e6') box(20, 300, 210, 80, 'Charging', ['the packs come out and charge', 'on DeWalt\'s own chargers', '(no charge port, D65)'], fill='#fff7e6') # main path parts box(290, 70, 170, 60, 'MRBF main fuse', ['Blue Sea 5191 + 5181 80 A', '58 V DC, 2 kA'], fill='#ffe08a') box(290, 160, 170, 60, 'Shunt 150 A / 50 mV', ['Blue Sea, in the + lead (W5, W6)', 'INA228 high side (W30-31)']) box(290, 290, 170, 70, 'Main switch', ['Flipsky Smart Enhanced V2.0', 'low side, momentary', '(16 mm button, rear face)'], fill='#e8f0ff') # bus bars box(520, 70, 60, 330, '+ bus', ['C110', '5 x M6'], fill='#fde3e3') box(520, 420, 60, 120, '- bus', ['C110', 'star', 'point'], fill='#e6e6e6') # wires of the main path wire([(230, 100), (290, 100)], 'red', 'W1 W4 10/8', 0, 4, -8) wire([(375, 130), (375, 160)], 'red', 'W5 8', 0, 6, 18) wire([(460, 190), (490, 190), (490, 100), (520, 100)], 'red', 'W6 8', 1, 4, -6) wire([(230, 250), (260, 250), (260, 320), (290, 320)], 'black', 'W3 W7 10/8', 0, 4, 16) wire([(460, 330), (500, 330), (500, 480), (520, 480)], 'black', 'W8 8', 1, 4, -4) # branches loads = [('RS-04 L front', 'XT60H', 20, 14, 'W10'), ('RS-04 L rear', 'XT60H', 20, 14, 'W11'), ('RS-04 R front', 'XT60H', 20, 14, 'W12'), ('RS-04 R rear', 'XT60H', 20, 14, 'W13'), ('VESC left (75100)', 'XT60H', 30, 12, 'W14'), ('VESC right (75100)', 'XT60H', 30, 12, 'W15'), ('TRACO TEP 150-4812WI in', 'ferrules', 10, 18, 'W16'), ('Turret (stop relay B, XT30)', 'XT30', 7.5, 16, 'W22')] for i, (name, conn, amps, awg, wid) in enumerate(loads): y = 95 + 38 * i wire([(580, y), (700, y)], 'red', f'{wid} {awg} AWG', 0, 30, -5, width=2.2) fuse(640, y, f'{amps} A') box(700, y - 15, 170, 30, name, [], fill='#eef7ee') wire([(580, 500), (680, 500), (680, 95)], 'black', '', 0, width=2.2) o.append('W18-W20: each load\'s - back to the - bus') # 12 V box(930, 340, 170, 60, 'TRACO 12 V out', ['12 V 12.5 A, isolated', '-V tied to the star (W23)'], fill='#eef7ee') box(1180, 300, 130, 30, 'J501 DC-IN', [], fill='#e8f0ff') wire([(1100, 355), (1125, 355), (1125, 315), (1180, 315)], 'red', 'W21 16', 2, 18, -5, width=2) fuse(1125, 335, '10 A') box(1180, 380, 150, 30, 'Lidar box (VLP-16)', [], fill='#e8f0ff') box(1180, 420, 150, 30, '5 V buck D36V28F5', [], fill='#e8f0ff') box(1180, 460, 150, 30, 'Radio-stop jack, lights', [], fill='#e8f0ff') wire([(1100, 385), (1140, 385), (1140, 395), (1180, 395)], 'red', 'W43 W24 16', 0, 4, -5, width=2) fuse(1140, 410, '7.5 A') wire([(1140, 420), (1140, 435), (1180, 435)], 'red', 'W25 22', 1, 8, 14, width=1.6) wire([(1140, 435), (1140, 475), (1180, 475)], 'red', 'W26 22', 1, 8, 14, width=1.6) wire([(870, 323), (900, 323), (900, 370), (930, 370)], 'orange', '', 0, width=2) wire([(580, 525), (1015, 525), (1015, 400)], 'black', 'W23: the converter\'s -V to the star point', 0, 160, 16, width=2) wire([(550, 540), (550, 590)], 'green', 'W33 frame bond 14 AWG', 1, 8, 0, width=2) # 5 V and control box(20, 600, 330, 140, 'MCU board (on the power plate)', ['Nucleo-G474RE: FDCAN1/2/3 = buses A/B/C', 'CAN Pal x 3 (120 Ohm on: the bus ends)', 'INA228 on I2C: pack V and I, high side (W30-32)', 'the cut-off, current limit, regen clamp (D65)', 'STOP loop in (radio relay, closed = run)', '5 V from the buck (W28-29)'], fill='#e8f0ff') yy = 600 for k, (bus, master, nodes, note) in enumerate(CAN): y = yy + 36 * k o.append(f'CAN {bus}') o.append(f'') txt = f'{master} → ' + ' → '.join(nodes) + f' ({note})' o.append(f'{txt[:150]}') if len(txt) > 150: o.append(f'{txt[150:]}') words, line, ys = STOP.split(), '', 800 for w_ in words: if len(line) + len(w_) > 190: o.append(f'{line}') line, ys = '', ys + 15 line += w_ + ' ' o.append(f'{line}') o.append('Fuses: Littelfuse MINI 58V (0997) in inline holders rated 32 V: the fuse interrupts (1 kA at 58 V); label every holder ' '"58 V fuses only" and pull a fuse only with the pack unplugged.') o.append('Twist every CAN pair (22 AWG); keep the shunt\'s sense pair away from the 10 AWG runs; ' 'crimp, never solder-tin, a wire that goes into a screw terminal (ferrules).') o.append('') return '\n'.join(o) DOC = R / 'docs' / 'body-electrical.md' TABLE_HEAD = '| Wire | From | To | AWG | Colour | Ends | Fuse | Why |' def write_doc_table(rows, doc=DOC): """docs/body-electrical.md section 3.1's table, rewritten from WIRES (the rows between its header and the next blank line), so the page and this list cannot disagree.""" lines = doc.read_text().split('\n') i = lines.index(TABLE_HEAD) j = i + 2 while j < len(lines) and lines[j].startswith('|'): j += 1 body = [f"| {r['id']} | {r['from']} | {r['to']} | {r['awg']} | {r['colour']} | {r['termination']} | {r['fuse']} | {r['why']} |" for r in rows] doc.write_text('\n'.join(lines[:i + 2] + body + lines[j:])) def main(): OUT.mkdir(parents=True, exist_ok=True) rows = [dict(zip(('id', 'from', 'to', 'awg', 'colour', 'termination', 'fuse', 'why'), w)) for w in WIRES] (OUT / 'wiring.json').write_text(json.dumps({'pack': PACK, 'wires': rows, 'can': [dict(zip(('bus', 'master', 'nodes', 'note'), c)) for c in CAN], 'stop': STOP}, indent=1) + '\n') (OUT / 'wiring.svg').write_text(svg()) write_doc_table(rows) print(f'exports/body/wiring.json ({len(rows)} wires), exports/body/wiring.svg, docs/body-electrical.md 3.1') if __name__ == '__main__': main()