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65 changes: 47 additions & 18 deletions book/robotarium/30_charging_setup/30_charging_module.md
@@ -1,4 +1,4 @@
# Charging module {#autocharging-charging-module status=draft}
# Charging module {#autocharging-charging-module status=beta}

For the construction of a charging module, you have many degrees of freedom. This includes the choice of material of the wooden structure (may be metal as well), the type of connection between the structure elements (screws, glue, nails), the length of the cables and many more.

Expand All @@ -12,8 +12,6 @@ However, the following requirements need to be satisfied:
In the following, you find the description on how we did it in Zurich.


TODO Thomas: from here

## Material for one charging module

In this list, $X$ will denote the number of charging rail tiles in a charging module. \emph{Reminder}: One charging rail tile can fit $3$ Duckiebots ($1.5$ per lane).
Expand All @@ -26,16 +24,25 @@ In this list, $X$ will denote the number of charging rail tiles in a charging mo
* $(8 \times (X + 1))$ $\times$ screw $M3 \times 30mm$ and $M3$ nuts
* $(2 \times (X + 1))$ $\times$ insulator - [self-print here](https://www.thingiverse.com/thing:2996297/files) or [order here](https://www.shapeways.com/product/QN3HP9EAH/megacity-insulator)
* Drill $Ø4mm$ and $Ø6mm$
* $\frac {1}{per charger} \times $ power supply which enables you to drive 5V and 30Amps
* $2 \times $ power supply which enables you to drive 5V and 30Amps
* $\frac{1}{per power supply} \times$ power cable
* $\frac{3}{per power supply} \times$ cable-end-sleeve
* $18 \times$ cable shoes $Ø4mm$
* $18 \times$ cable shoes $Ø4-6mm²$ M4
* $4 \times$ M4 screw 10mm and M4 Nut
* crimping tool
* $Ø4mm \times 6m$ red cable
* $Ø4mm \times 6m$ black cable
* $8 \times$ [laboratory plug CAT I Ø4mm](https://www.distrelec.ch/en/p/14048007)

## Extra tools
In order to put things together you may need the following extra tools:

* crimping tool
* wire stripper
* hot glue gun
* solder iron and solder
* drill
* screw driver


## Building a charging module

Expand Down Expand Up @@ -106,6 +113,8 @@ How the screw head is hidden.

Use double-sided tape to mount the high voltage poles to the tiles ([](#fig:glued_wooden_structure)). Make sure that the high voltage poles are aligned throughout the whole charging module.

\emph{Optional}: you could also use hot glue instead of double-sided tape.


### Bend brass rails and mount them

Expand All @@ -132,7 +141,26 @@ Soldered laboratory plugs to the cables.
</div>

### Attach cable shoes
Mount a cable shoe $Ø4-6mm$ with a crimping tool on the other side of these cables you have soldered. Then connect two red and two black cables respectively together with another cable shoe with a M4 screw and a M4 nut as seen in [](#fig:connected_cables). Then connect to the third cable shoe the corresponding red/black cable which will go towards the power supply. This third cable should be long enough to reach the power supply. Also attach to the end of the third cable a cable shoe.
In order to crimp a cable shoe onto a cable, you need the following things which you can see in [](#fig:crimping_tools).

<div figure-id="fig:crimping_tools">
<img src="images/crimping.jpg" style="width: 100%"/>
<figcaption>
Crimping tool with a cable and a cable shoe M4 $Ø4-6mm²$.
</figcaption>
</div>

First put the cable shoe onto the uninsulated cable such that it looks as in [](#fig:attached_crimped_cable). Then take the crimping tool, put the cable inside the yellow hole and press the cable shoe on it.

<div figure-id="fig:attached_crimped_cable">
<img src="images/crimped_cable.jpg" style="width: 100%"/>
<figcaption>
Crimped cable with a cable shoe.
</figcaption>
</div>

### Connect the cable to the power supply
Mount a cable shoe $Ø4-6mm²$ with a crimping tool on the other side of these cables you have soldered. Then connect two red and two black cables respectively together with another cable shoe with a M4 screw and a M4 nut as seen in [](#fig:connected_cables). Then connect to the third cable shoe the corresponding red/black cable which will go towards the power supply. This third cable should be long enough to reach the power supply. Also attach to the end of the third cable a cable shoe.

<div figure-id="fig:connected_cables">
<img src="images/cable_shoe_connection.jpg" style="width: 100%"/>
Expand Down Expand Up @@ -161,11 +189,18 @@ The polarities of the brass rods.
</div>

### Prepare the power cable for the power supply
Take the power cable and strip the isolation off. Then attach a cable-end-sleeve with the crimping tool as seen in [](#fig:power_cable). Then connect the prepared cable to the power supply exactly as it is shown in [](#fig:attached_power_cable).
Take the power cable [](#fig:pow_kabel) and strip the isolation off. Then attach a cable-end-sleeve with the crimping tool as seen in [](#fig:power_cable). Then connect the prepared cable to the power supply exactly as it is shown in [](#fig:attached_power_cable).

Note:
**It is important that ground, phase and neutral phase is connected the right way, so the colors need to match**.
<div figure-id="fig:pow_kabel">
<img src="images/powercable.jpg" style="width: 100%"/>
<figcaption>
A power cable.
</figcaption>
</div>

<p float="left">
<div figure-id="fig:power_cable">
<img src="images/power_cable.jpg" style="width: 100%"/>
<figcaption>
Expand All @@ -179,27 +214,21 @@ One end of the power cable before and after.
Attached power cable to the power supply.
</figcaption>
</div>
</p>

### Attach to power source
Connect the power supply to the rails. Red cable to V+ and black cable to V- as shown in [](#fig:powersupply). Make also a connection between the two power supplies ground, in order to have a common ground.

<div figure-id="fig:powersupply">
<img src="images/powersupply.jpg" style="width: 80%"/>
<img src="images/powersupply_attach.jpg" style="width: 80%"/>
<figcaption>
The connected power supply.
</figcaption>
</div>

### Adjust the output voltage of the power source
Turn on the power supply by plugging in the power cable. There is a voltage regulator next to the V+ connection - there you can adjust the voltage. Take a screw driver and a multimeter and measure the Voltage across V+ and V-. The Voltage should be adjusted to 5.5V.

<div figure-id="fig:powersupply_cc">
<img src="images/powersupply_cc.jpg" style="width: 80%"/>
<figcaption>
Voltage regulator seen as the plastic screw.
</figcaption>
</div>
Turn on the power supply by plugging in the power cable. There is a voltage regulator - the plastic screw - (see [](#fig:powersupply)) next to the V+ connection - there you can adjust the voltage. Take a screw driver and a multimeter and measure the Voltage across V+ and V-. The Voltage should be adjusted to 5.5V.

### Test your setup

Place an assemblied Duckiebot which is capable of charging underneath the charging rails and see if the battery is going to charge.
Place an assemblied Duckiebot [](#fig:result_cc) which is capable of charging underneath the charging rails, turn on the power supplies and see if the battery is going to charge.
10 changes: 4 additions & 6 deletions book/robotarium/30_charging_setup/40_current_collector.md
Expand Up @@ -89,10 +89,8 @@ Neccessary parts for the assembly.

Assemble the april tag plate by using the acrylic glass, screws and distance keepers as seen in [](#fig:assembled_at_plate)

TODO Thomas: replace this pic

<div figure-id="fig:assembled_at_plate">
<img src="images/assembled_duckietop.jpg" style="width: 80%"/>
<img src="images/topplate.jpg" style="width: 80%"/>
<figcaption>
The assembled april tag plate
</figcaption>
Expand All @@ -103,7 +101,7 @@ The assembled april tag plate
Mount the current collector by using three screws and nuts as seen in [](#fig:screwed_current_collector)

<div figure-id="fig:screwed_current_collector">
<img src="images/screwed_current_collector.jpg" style="width: 80%"/>
<img src="images/curr_collector_attach.jpg" style="width: 80%"/>
<figcaption>
The current collector mounted to the april tag plate.
</figcaption>
Expand All @@ -125,14 +123,14 @@ The robotarium add-on board.
Mount the april tag board with the current collector assembled to a Duckiebot as in [](#fig:result_cc) and [](#fig:mounted_at_plate). Plug in the USB cable to the battery of the Duckiebot.

<div figure-id="fig:mounted_at_plate">
<img src="images/mounted_duckietop.jpg" style="width: 80%"/>
<img src="images/att_topplate.jpg" style="width: 80%"/>
<figcaption>
The april tag plate mounted to a Duckiebot.
</figcaption>
</div>

<div figure-id="fig:result_cc">
<img src="images/result_current_collector.jpg" style="width: 80%"/>
<img src="images/assemblied_dbot.jpg" style="width: 80%"/>
<figcaption>
The resulting charging-capable Duckiebot.
</figcaption>
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