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OpenServo Lynx - Redux
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Cliff



Joined: 23 Jan 2007
Posts: 150
Location: Saratoga, CA

PostPosted: Fri Jun 01, 2007 3:25 pm    Post subject: Reply with quote

Jay,

Thanks, Mike sent me that sketch, but didn't include dimensions. The problem is that even though Jim did that sketch, I don't think he put much effort into thinking about it - if he had, he would have a better plan than shrink-wrap and wire ties. I'm pushing Jim and everybody else who might use that new servo motor, to think about what will work best, because I would like to see a good design done.

A good design accounts for the system it lives in and if a design doesn't, more often than not, it just ends up being a hack. I have nothing against hacks, its just that they don't make good products, because they generally cost more and don't work as well. The difference between a creating a hack and creating a good product is often just a little more thought.

BTW, it is never safe to assume. Smile

Cliff
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ginge
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Joined: 14 Jan 2006
Posts: 1029
Location: Manchester, UK

PostPosted: Fri Jun 01, 2007 3:26 pm    Post subject: Reply with quote

Cliff,

Cliff wrote:
Barry,
From DigiKey 100 unit prices:

ADP3339 $2.45 ea.
LM3480 $0.60 ea.
NDS351 $0.25 ea.

I'm not insisting on my solution, only suggesting it. I'll be happy to see a better solution.

Cliff


I see what you are saying, but I was pulling part numbers out of my arse with that last one. I was trying to convey the idea that maybe we could source a cheap(ish) part with the right characteristics instead of using several components in it's place. There is no point arguing in circles when we are talking <$1 prices. I will add the NDS351 protection in.

BTW I get the ADP3389 for £0.64 or about $1.18. LM3480 £1.06 or $2.12. I must remember to look at US supplier costs too. Sometimes the UK prices are misleading.

Barry
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robotjay
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Joined: 01 Aug 2006
Posts: 225
Location: Nebraska, USA

PostPosted: Fri Jun 01, 2007 4:18 pm    Post subject: Reply with quote

Cliff wrote:
A good design accounts for the system it lives in and if a design doesn't, more often than not, it just ends up being a hack.


Gotcha. I guess Jim is really the only one who can make a decision regarding the final mounting then.

Cliff wrote:
BTW, it is never safe to assume.


Smile Again you are correct. I'm notorious for making false assumptions. I really need to get that under control. Embarassed Have you e-mailed Jim about this directly? Or are we all trying to funnel information through Mike?
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ginge
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PostPosted: Fri Jun 01, 2007 4:26 pm    Post subject: Reply with quote

Jay, Cliff,

Jim sent me a PM asking what is going on over here. I suggested we feed back as much as possible through Mike, who can liaise with Jim directly regarding general status etc. Anything more technical, like Cliff's questions over mounting brackets/placement etc are fine ok to ask over on the lynxMotion forums (like Cliff is doing).

Barry
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ginge
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PostPosted: Fri Jun 01, 2007 6:21 pm    Post subject: Reply with quote

I have done a quick mock up of the mounting options.

I like the idea of using a daughterboard. If we went with that we could use the ISP header as a connector.

Ignore nearly all part placements at this time. I have not started the real work of laying it out properly. This is a rough idea based on the sketches from Jim Fry. I have added a few mount points, one on each corner of the board, 5 for the heatsink, and 6 for the daughterboard mount.

Top part placement. The caps are near the power connector.


Bottom part placement. Plenty of space for the FETs


Daughterboards could be a couple of sizes. We could also go for both mount options to allow for small and large daughterboards


An idea of the heatsink placement. There is plenty of space for copper pour heatsinking.


As I said, very rough jotting down of ideas.

Barry
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mpthompson



Joined: 02 Jan 2006
Posts: 650
Location: San Carlos, CA

PostPosted: Fri Jun 01, 2007 7:12 pm    Post subject: Reply with quote

Cliff wrote:
The Lynx design requires operation from a 7.2V battery and that does not provide enough over head voltage to use a LM78xx regulator for the +5V supply - just as in OSv2, low dropout is needed.


Cliff, just so I can get this right, looking at the spec sheet for a LM78M05 device, it appears that Vin (input voltage required to maintain line regulation) is 7.2 volts. Is the issue that a 7.2 volt battery will actually deliver less than 7.2 volt as the battery drains?

I notice that the Lynxmotion SSC-32 servo controller board uses the LM2937 regulator (I assume the 5v version). The LM2937-5 is a 5V regulator that can supply 500mA and differs from the common 7805 by having a much lower dropout voltage, 0.5V vs. 2.0V. It also appears to have nice features such as reverse battery protection, internal short circuit and thermal overload protection. I'm not sure about output protection though.

-Mike
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mpthompson



Joined: 02 Jan 2006
Posts: 650
Location: San Carlos, CA

PostPosted: Fri Jun 01, 2007 7:41 pm    Post subject: Reply with quote

ginge wrote:
Gotcha. I guess Jim is really the only one who can make a decision regarding the final mounting then.


When I was working with Jay on the first version of the board we were basically sending Jim schematics and PCB layouts as Eagle and PDF files every few days with each update. Other than some issues regarding holes for the heatsink, we didn't receive a lot of feedback regarding the layout. In general, we did try to keep it somewhat in line with Jim's original sketch with didn't include dimensions.

Cliff wrote:
A good design accounts for the system it lives in and if a design doesn't, more often than not, it just ends up being a hack. I have nothing against hacks, its just that they don't make good products, because they generally cost more and don't work as well. The difference between a creating a hack and creating a good product is often just a little more thought.


I fully understand what you are saying here. I think the situation is that we have a fair amount of flexability here to come up with a good design and can likely influence the end product to those ends. I would suggest giving Jim regular updates on the design as it evolves and see where the feedback takes us.

Since Jim doesn't have time to follow this thread and read/comment on each posting in detail, my ideal situation would be to post a regular update to this thread (at least every few days) specifically meant for feedback from Jim. Such a posting could include links to the latest schematic and PCB layout. I or someone else can manually send Jim a link to the message and request feedback that he may have. Hopefully such an approach would keep everything open and keep things reasonably streamlined from a communication standpoint. Thoughts?

-Mike
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robotjay
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Joined: 01 Aug 2006
Posts: 225
Location: Nebraska, USA

PostPosted: Fri Jun 01, 2007 7:50 pm    Post subject: Reply with quote

I agree with this approach. It'll allow Jim to know our progress via forum, without having to wade through all the technical details of how we arrived at that revision level. Is it possible to hyperlink to just a specific post within a thread? Or will he still have to search through the posts for a specific heading or something?
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mpthompson



Joined: 02 Jan 2006
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Location: San Carlos, CA

PostPosted: Fri Jun 01, 2007 8:05 pm    Post subject: Reply with quote

If you get the message id, it is possible to hyperlink to a specific message as shown below:

http://www.openservo.com/Forums/viewtopic.php?p=2949#2949

This link above goes to Barry's message regarding mounting options.

-Mike
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ginge
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Joined: 14 Jan 2006
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Location: Manchester, UK

PostPosted: Fri Jun 01, 2007 9:45 pm    Post subject: Reply with quote

Here is revision 0.7.

This adds back the PWM connector (as you probably already noticed above) and also incorporates the NDS351 regulator protection.



Other than possibly changing the connector scheme, I would say we are very nearly there. I am sure Cliff has some more to add Wink

Barry
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mpthompson



Joined: 02 Jan 2006
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Location: San Carlos, CA

PostPosted: Fri Jun 01, 2007 10:22 pm    Post subject: Reply with quote

Barry, how about the PWM input being a two pin connector rather than a three pin connector. Most servos have a +5/6v input on the third wire and in this case we have a +5v output. I think it would be better to leave it off (or unconnected) than risk having someone accidently connect it to voltage.

Also, the signal from an RC controller isn't technically PWM. I would suggest changing the name from "PWM" to "RC Pulse" as that name is a bit more accurate and seems to be in use for such an input signal.

-Mike
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Cliff



Joined: 23 Jan 2007
Posts: 150
Location: Saratoga, CA

PostPosted: Sat Jun 02, 2007 9:54 am    Post subject: Reply with quote

Mike,

Mike wrote:
Cliff, just so I can get this right, looking at the spec sheet for a LM78M05 device, it appears that Vin (input voltage required to maintain line regulation) is 7.2 volts. Is the issue that a 7.2 volt battery will actually deliver less than 7.2 volt as the battery drains?


NiMH battery voltage per cell can be as high as 1.4V fully charged and as low as 1.0V at the end of useful charge. The 7.2V R/C NiMH battery packs have 6 cells with a nominal voltage of 1.2V per cell, so the full charged voltage can be as high as 8.4V and the fully discharged voltage as low as 6V. Under light load (.2x the pack rating), the pack voltage will be between 7.8V and 7.2V, declining rapidly below 7.2V. Under heavy load (3x the pack rating), the pack voltage will be between 7.2V and 6.6V, when the pack voltage gets below 6.6V the voltage will very quickly drop to the 6V level.

On the Lynxmotion board, the stated requirement is to run with 7.2V to 12V, but I think we need to account for running with a 14.4V NiMH battery pack or a 14.8 Li-Poly battery pack, which would make the real voltage range 6.6V to 16.8V. Any capacitors used on the battery supply will need a minimum 25V rating.

Mike wrote:
The LM2937-5 is a 5V regulator that can supply 500mA

The LM2937-5 would work fine, the only downside is the extra cost. I can find nothing in the datasheet that would lead me to believe that the output is protected for reverse current, it may be there, but it is not specified - so I would still use the protection circuit. The part cost is about $0.40 more than the LM3480 and the required 10uF output capacitor will add another $0.30. The only advantage I can see is that it would deliver 400mA extra current for your daughter board - the extra current is not needed for the core design.

The LM2937-5 reverse battery protection is nice, but if we are going to use that feature, we will need to look into protecting the FET drivers as well. Adding that protection to the high-side driver is straight forward, but the low-side driver will take some work.

Cliff
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ginge
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Joined: 14 Jan 2006
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PostPosted: Mon Jun 04, 2007 8:19 pm    Post subject: Reply with quote

All,

It has just come to my attention that the original schematic fished from my design archive (post 1 on this thread) is seemingly a copy of a from a product by Andras Tantos of Modular Circuits. More specifically this:- http://www.modularcircuits.com/h-bridge.htm

It is only fair that I attribute the correct sources to bridge portion of the derived design to the rightful owner; Andras Tantos.
Also note that the uModule is covered under a commercial license, and subsequently the first schematic (pg1) is not suitable for use without the the significant changes detailed above. The changes that Cliff has outlined will mitigate us from any potential trouble inferred by the original license.

Because of this oversight, and what this could have meant for OpenServo I feel it prudent to hand the torch over to Cliff, who has what it takes to make this all a reality.

Apologies if anyone feels cheated by me, I am genuinely sorry if that is how you feel. I will in future pay due care and attention to source listings in any designs in my archive that may be based on another.

Barry
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mpthompson



Joined: 02 Jan 2006
Posts: 650
Location: San Carlos, CA

PostPosted: Tue Jun 05, 2007 12:14 am    Post subject: Reply with quote

Folks, I'm very sorry for this bump in the road. However, the good thing about open development is that such issues can be spotted and corrected as they occur. It's important that we all remember that nobody here is in it for the money and glory and none of us is immune to mistakes. We are all contributing in various ways because we feel we can lend a helping hand to a project we think is worthwhile. Let's please remember this as we move forward.

-Mike
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poor-robot



Joined: 09 Mar 2007
Posts: 45
Location: Portland, OR

PostPosted: Fri Jun 08, 2007 1:16 am    Post subject: Reply with quote

Not to throw another stick in the spokes, but doesn't the TPS76150 provide what we're looking for? The combination of the current limiting and the reverse diode should protect it, no?
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