r""" Electronics diagrams for the motorized 6-component sting balance. Writes SVG (text converted to paths: no font dependency, white card background so it reads on light and dark pages) and a PNG copy of each diagram into this folder: block system block diagram (station, rig box, moving rig, balance + model) power_safety power distribution, E-stop / safety chain, star ground steppers Arduino Uno + CNC shield v3 (grbl 1.1) pins, drivers, motors, limit switches bridge one strain-gauge bridge in detail + the 6-bridge harness to the ADCs pinmap Raspberry Pi 4 header assignments, I2C address map, Pico sensor-node pins harness_route balance cable route through balance, sting and spindle, with bore fill Run: ..\..\.venv\Scripts\python make_electronics_diagrams.py """ import math from pathlib import Path import matplotlib matplotlib.use("Agg") import matplotlib.pyplot as plt from matplotlib.patches import FancyBboxPatch, Rectangle, Circle, Polygon, Arc plt.rcParams.update({"font.family": "DejaVu Sans", "svg.fonttype": "path", "svg.hashsalt": "wt-electronics"}) OUT = Path(__file__).resolve().parent C = dict(power="#c0392b", motor="#d35400", analog="#1f5fbf", digital="#1e8449", safety="#8e44ad", shield="#7f8c8d", gnd="#2c3e50", ac="#5d4037", ink="#1d2430", sub="#4a5566", fill="#f5f7fb", hi="#e9f1fd", zone="#fcfcfe", warn="#b9770e", grey="#9aa3ae") class D: def __init__(self, W, H, title, subtitle=""): self.W, self.H = W, H self.fig = plt.figure(figsize=(W, H), facecolor="white") ax = self.fig.add_axes([0, 0, 1, 1]) ax.set_xlim(0, W); ax.set_ylim(0, H); ax.axis("off"); ax.set_facecolor("white") self.ax = ax ax.text(0.35, H - 0.32, title, fontsize=17, weight="bold", color=C["ink"], va="center") if subtitle: ax.text(0.35, H - 0.68, subtitle, fontsize=10.5, color=C["sub"], va="center") # ---------------------------------------------------------------- primitives def text(self, x, y, s, size=9, color=None, ha="left", va="center", weight="normal", rot=0, bg=None, z=6): kw = {} if bg: kw["bbox"] = dict(boxstyle="round,pad=0.18", fc=bg, ec="none") return self.ax.text(x, y, s, fontsize=size, color=color or C["ink"], ha=ha, va=va, weight=weight, rotation=rot, zorder=z, linespacing=1.3, **kw) def box(self, x, y, w, h, title, lines=(), fc=None, ec=None, ts=11, ls=8.6, tc=None, lw=1.3, dy=0.27): self.ax.add_patch(FancyBboxPatch((x, y), w, h, boxstyle="round,pad=0,rounding_size=0.08", fc=fc or C["fill"], ec=ec or C["ink"], lw=lw, zorder=2)) ty = y + h - 0.24 if title: self.text(x + 0.12, ty, title, size=ts, weight="bold", color=tc, va="center", z=4) for i, t in enumerate(lines): self.text(x + 0.12, ty - 0.30 - i * dy, t, size=ls, color=C["sub"], z=4) def zone(self, x, y, w, h, label, color=None): self.ax.add_patch(FancyBboxPatch((x, y), w, h, boxstyle="round,pad=0,rounding_size=0.12", fc=C["zone"], ec=color or C["grey"], lw=1.3, ls=(0, (5, 3)), zorder=1)) self.text(x + 0.15, y + h - 0.2, label, size=9.5, weight="bold", color=color or C["sub"], z=3) def wire(self, pts, color, lw=1.8, ls="-", arrow=False, label=None, at=0.5, lsize=8.2, loff=(0, 0.13), lha="center", z=3, both=False): xs, ys = zip(*pts) self.ax.plot(xs, ys, color=color, lw=lw, ls=ls, zorder=z, solid_capstyle="round") if arrow or both: self._head(pts[-2], pts[-1], color) if both: self._head(pts[1], pts[0], color) if label: # label on the segment holding the 'at' fraction of the length seg = [math.dist(pts[i], pts[i + 1]) for i in range(len(pts) - 1)] tgt, acc = at * sum(seg), 0 for i, L in enumerate(seg): if acc + L >= tgt: f = (tgt - acc) / L if L else 0 x = pts[i][0] + f * (pts[i + 1][0] - pts[i][0]) y = pts[i][1] + f * (pts[i + 1][1] - pts[i][1]) break acc += L self.text(x + loff[0], y + loff[1], label, size=lsize, color=color, ha=lha, bg="white", z=5) def _head(self, p0, p1, color, L=0.16, Wd=0.07): dx, dy = p1[0] - p0[0], p1[1] - p0[1] n = math.hypot(dx, dy) or 1 ux, uy = dx / n, dy / n bx, by = p1[0] - ux * L, p1[1] - uy * L self.ax.add_patch(Polygon([p1, (bx - uy * Wd, by + ux * Wd), (bx + uy * Wd, by - ux * Wd)], closed=True, fc=color, ec=color, zorder=4)) def dot(self, x, y, color, r=0.045): self.ax.add_patch(Circle((x, y), r, fc=color, ec=color, zorder=5)) def term(self, x, y, color=None): self.ax.add_patch(Circle((x, y), 0.05, fc="white", ec=color or C["ink"], lw=1.1, zorder=5)) def resistor(self, p0, p1, label="", color=None, lpos=(0, 0.2), lsize=8.5, n=6, amp=0.07, lead=0.25): """Zig-zag resistor between p0 and p1 (straight leads of length `lead` at both ends).""" color = color or C["ink"] dx, dy = p1[0] - p0[0], p1[1] - p0[1] L = math.hypot(dx, dy) ux, uy = dx / L, dy / L nx, ny = -uy, ux a = (p0[0] + ux * lead, p0[1] + uy * lead) b = (p1[0] - ux * lead, p1[1] - uy * lead) seg = (L - 2 * lead) / n pts = [p0, a] for i in range(n): s = (i + 0.5) * seg sgn = 1 if i % 2 == 0 else -1 pts.append((a[0] + ux * s + nx * amp * sgn, a[1] + uy * s + ny * amp * sgn)) pts += [b, p1] xs, ys = zip(*pts) self.ax.plot(xs, ys, color=color, lw=1.6, zorder=4) if label: mx, my = (p0[0] + p1[0]) / 2, (p0[1] + p1[1]) / 2 self.text(mx + lpos[0], my + lpos[1], label, size=lsize, ha="center", color=color, bg="white") def nc_switch(self, x, y, label="", color=None, vertical=False, size=0.42, lsize=8): """Normally-closed contact drawn horizontally (or vertically) starting at (x, y), length `size`.""" color = color or C["ink"] if not vertical: x1 = x + size self.ax.plot([x, x + 0.12], [y, y], color=color, lw=1.6, zorder=4) self.ax.plot([x1 - 0.12, x1], [y, y], color=color, lw=1.6, zorder=4) self.ax.plot([x + 0.12, x1 - 0.05], [y + 0.0, y - 0.06], color=color, lw=1.6, zorder=4) # closed blade self.ax.plot([x1 - 0.12, x1 - 0.12], [y, y - 0.1], color=color, lw=1.6, zorder=4) # NC stop if label: self.text(x + size / 2, y + 0.17, label, size=lsize, ha="center", color=color) return (x1, y) y1 = y - size self.ax.plot([x, x], [y, y - 0.12], color=color, lw=1.6, zorder=4) self.ax.plot([x, x], [y1 + 0.12, y1], color=color, lw=1.6, zorder=4) self.ax.plot([x, x + 0.06], [y - 0.12, y1 + 0.05], color=color, lw=1.6, zorder=4) self.ax.plot([x, x + 0.1], [y1 + 0.12, y1 + 0.12], color=color, lw=1.6, zorder=4) if label: self.text(x + 0.17, y - size / 2, label, size=lsize, color=color) return (x, y1) def no_button(self, x, y, label="", color=None, size=0.42): color = color or C["ink"] x1 = x + size self.ax.plot([x, x + 0.12], [y, y], color=color, lw=1.6, zorder=4) self.ax.plot([x1 - 0.12, x1], [y, y], color=color, lw=1.6, zorder=4) self.ax.plot([x + 0.1, x1 - 0.1], [y + 0.1, y + 0.1], color=color, lw=1.6, zorder=4) self.ax.plot([x + size / 2, x + size / 2], [y + 0.1, y + 0.2], color=color, lw=1.6, zorder=4) if label: self.text(x + size / 2, y + 0.33, label, size=8, ha="center", color=color) def gnd(self, x, y, color=None): color = color or C["gnd"] self.ax.plot([x, x], [y, y - 0.12], color=color, lw=1.5, zorder=4) for i, w in enumerate((0.16, 0.10, 0.04)): self.ax.plot([x - w, x + w], [y - 0.12 - i * 0.05] * 2, color=color, lw=1.5, zorder=4) def fuse(self, x, y, label="", color=None, w=0.36): color = color or C["power"] self.ax.add_patch(Rectangle((x - w / 2, y - 0.07), w, 0.14, fc="white", ec=color, lw=1.3, zorder=5)) self.ax.plot([x - w / 2, x + w / 2], [y, y], color=color, lw=1.0, zorder=6) if label: self.text(x, y + 0.2, label, size=7.8, ha="center", color=color, bg="white") def legend(self, x, y, items, w=2.7): h = 0.32 + 0.27 * len(items) self.ax.add_patch(FancyBboxPatch((x, y - h), w, h, boxstyle="round,pad=0,rounding_size=0.06", fc="white", ec=C["grey"], lw=1.0, zorder=2)) self.text(x + 0.12, y - 0.18, "Legend", size=9, weight="bold", z=4) for i, (lab, col, ls) in enumerate(items): yy = y - 0.45 - i * 0.27 self.ax.plot([x + 0.15, x + 0.65], [yy, yy], color=col, lw=2.2, ls=ls, zorder=4) self.text(x + 0.78, yy, lab, size=8.3, z=4) def note(self, x, y, s, size=8.4, color=None, w=None): self.text(x, y, s, size=size, color=color or C["sub"], va="top") def save(self, name): self.fig.savefig(OUT / f"{name}.svg", facecolor="white") self.fig.savefig(OUT / f"{name}.png", dpi=110, facecolor="white") plt.close(self.fig) print("wrote", name) LEG = [("mains AC", C["ac"], "-"), ("DC power", C["power"], "-"), ("motor phases", C["motor"], "-"), ("bridge / analog", C["analog"], "-"), ("digital: USB, I2C, SPI, step/dir", C["digital"], "-"), ("safety chain", C["safety"], "-"), ("shield / ground", C["shield"], "--")] # ====================================================================== (a) block diagram def block(): d = D(16, 11.0, "System block diagram", "Station Pi -> rig Pi -> grbl motion controller + bridge DAQ; motors and sensors on the moving rig; " "gauges and pod sensors inside the model") # zones d.zone(0.3, 5.5, 2.75, 3.75, "CONTROL STATION") d.zone(3.35, 0.35, 6.75, 8.9, "RIG BOX (beside the tunnel, DIN rail, steel enclosure)") d.zone(10.4, 3.85, 5.35, 5.4, "MOVING RIG (yaw carriage > pitch sector > roll spindle)") d.zone(10.4, 0.35, 5.35, 3.0, "BALANCE + MODEL (inside the pod)") # station d.box(0.5, 7.0, 2.35, 1.75, "Station Pi 4", ["GUI: attitude, sweeps,", "live plots, data reduction,", "reports"], fc=C["hi"]) d.box(0.5, 5.75, 2.35, 0.95, "Station E-stop S2", ["2 NC channels, J7"], ec=C["safety"], tc=C["safety"]) d.box(0.5, 0.5, 2.35, 1.95, "Tunnel", ["pitot-static probe", "fan drive run contact", "air temperature probe", "(DS18B20)"]) d.legend(0.45, 5.15, LEG, w=2.55) # rig box - left column d.box(3.65, 7.0, 2.85, 1.85, "Rig Pi 4", ["rig service: sequencer,", "envelope interlock, DAQ,", "zeros & tares, logging,", "watchdog heartbeat"], fc=C["hi"]) d.box(3.65, 4.95, 2.85, 1.7, "Bridge DAQ", ["6x NAU7802 24-bit, 1 per bridge", "TCA9548A I2C mux (0x70)", "2x ADS1115: sense, NTC", "LTC4311 pod-bus terminator"]) d.box(3.65, 3.75, 2.85, 0.95, "Excitation", ["LT3042 low-noise 3.30 V, 60 mA"], ec=C["power"]) d.box(3.65, 0.9, 2.85, 2.55, "Flow + air", ["pitot dP: Honeywell ABP2,", "0-10 inH2O, I2C 0x28", "BMP390 ambient (I2C)", "DS18B20 air temp (1-Wire)", "wind-on input (opto)"]) # rig box - right column d.box(6.95, 7.0, 2.9, 1.85, "Arduino Uno + CNC shield v3", ["grbl 1.1: X yaw, Y pitch, Z roll", "2x TMC2209 (yaw, pitch)", "step/dir/enable -> DM542T"], ts=10.2) d.box(6.95, 5.6, 2.9, 1.05, "DM542T roll driver", ["24 V, 2.0 A, 1/8 step"]) d.box(6.95, 3.9, 2.9, 1.3, "Power", ["PSU1 24 V 150 W -> K1 -> drivers", "PSU2 5 V 35 W (logic)"], ec=C["power"]) d.box(6.95, 0.9, 2.9, 2.65, "Safety", ["E-stops S1 (rig) + S2 (station)", "+ watchdog relay contact", "-> safety relay -> K1", "K1 cuts the 24 V motor bus", "aux contacts -> Pi + grbl A0"], ec=C["safety"], tc=C["safety"]) # moving rig d.box(10.65, 7.05, 2.4, 1.85, "Motors", ["yaw NEMA 17 + 30:1 worm", "pitch NEMA 17 + 40:1 worm", "roll NEMA 23 + NMRV030 50:1"], ls=8.3) d.box(13.2, 7.05, 2.35, 1.85, "Limit / home", ["6 NC switches", "(2 per axis, in series)", "junction box on", "the carriage"]) d.box(10.65, 4.1, 2.4, 2.6, "J0 balance breakout", ["DC-37 on a plastic bracket", "on the roll housing", "fed by the 270 deg", "clock-spring loop from", "the spindle wire exit"], ls=8.3) d.box(13.2, 4.1, 2.35, 2.6, "Sensor node", ["Raspberry Pi Pico (USB)", "3x AS5048A encoders", "SCL3300 inclinometer", "(all SPI, < 1 m runs)", "on the sector base"], ls=8.3) # balance + model d.box(10.65, 0.6, 2.4, 2.3, "Balance", ["6 bridges, 24 gauges, 350 ohm", "shared EX bus + remote", "sense, NTC on the", "aft block"], ls=8.3) d.box(13.2, 0.6, 2.35, 2.3, "Pod sensor bay", ["2x BMP390 (base, cavity)", "LSM6DSOX accelerometer", "I2C bus 3, 50 kHz"], ls=8.3) # links g, a, p, m, s = C["digital"], C["analog"], C["power"], C["motor"], C["safety"] d.wire([(2.85, 7.9), (3.65, 7.9)], g, both=True, label="Ethernet", loff=(0, 0.16)) d.wire([(6.5, 7.9), (6.95, 7.9)], g, arrow=True, label="USB", loff=(0, 0.16)) d.wire([(5.05, 7.0), (5.05, 6.65)], g, both=True, label="I2C-1", loff=(0.35, 0)) d.wire([(5.05, 4.7), (5.05, 4.95)], p, arrow=True) d.wire([(4.6, 8.85), (4.6, 9.85), (15.9, 9.85), (15.9, 5.4), (15.55, 5.4)], g, arrow=True, label="USB to the sensor node (high-flex, in the cable chain)", at=0.32) d.wire([(14.4, 8.9), (14.4, 9.55), (8.4, 9.55), (8.4, 8.85)], g, arrow=True, label="limit switches -> D9 / D10 / D12", at=0.42, loff=(0, 0)) d.wire([(9.85, 8.3), (10.65, 8.3)], m, arrow=True, label="yaw, pitch", loff=(0, 0.15), lsize=7.8) d.wire([(9.85, 6.1), (10.25, 6.1), (10.25, 7.55), (10.65, 7.55)], m, arrow=True, label="roll", at=0.75, loff=(-0.22, 0), lsize=7.8) d.wire([(10.65, 5.4), (6.5, 5.4)], a, arrow=True, lw=2.2, label="12-pair shielded trunk, J0 -> J1", at=0.5, loff=(0, 0.15)) d.wire([(11.85, 2.9), (11.85, 4.1)], a, arrow=True, lw=2.2) d.text(11.75, 3.6, "26 x 32 AWG\nPTFE, sting bore", size=7.4, color=a, ha="right", bg="white") d.wire([(13.6, 2.9), (13.6, 3.6), (12.75, 3.6), (12.75, 4.1)], g, arrow=True) d.text(13.7, 3.6, "pod I2C (thin loops\nacross the balance)", size=7.6, color=g, bg="white") d.wire([(8.4, 3.55), (8.4, 3.9)], s, arrow=True, label="K1", loff=(0.25, 0)) d.wire([(9.5, 6.65), (9.5, 7.0)], p, arrow=True) d.wire([(2.85, 6.2), (3.2, 6.2), (3.2, 0.2), (8.9, 0.2), (8.9, 0.9)], s, arrow=True, label="station E-stop loop (J7)", at=0.62, loff=(0, -0.15)) d.wire([(3.65, 7.4), (3.5, 7.4), (3.5, 0.6), (7.9, 0.6), (7.9, 0.9)], s, arrow=True, label="watchdog heartbeat (GPIO22)", at=0.72, loff=(0, 0.15)) d.wire([(2.85, 1.6), (3.65, 1.6)], a, arrow=True, label="tubes", loff=(0, 0.15)) d.save("block") # ====================================================================== (b) power + safety def power_safety(): d = D(16, 10.6, "Power distribution, E-stop chain and grounding", "Cutting the 24 V motor bus is the safe stop; the self-locking worm gearboxes hold every axis where it is") ac, p, s, gr = C["ac"], C["power"], C["safety"], C["shield"] # mains d.box(0.4, 7.6, 2.4, 1.55, "AC inlet", ["IEC C14, 2 A fuse,", "switch; PE -> chassis"], fc="white", ec=ac, tc=ac) d.box(3.4, 8.25, 2.6, 0.9, "PSU1 24 V 150 W", ["Mean Well LRS-150-24"], ec=p) d.box(3.4, 6.65, 2.6, 0.9, "PSU2 5 V 35 W", ["Mean Well LRS-35-5"], ec=p) d.wire([(2.8, 8.6), (3.1, 8.6), (3.1, 8.7), (3.4, 8.7)], ac, lw=2.2) d.wire([(3.1, 8.6), (3.1, 7.1), (3.4, 7.1)], ac, lw=2.2) d.text(3.18, 7.85, "L, N", size=8, color=ac) # 24 V d.wire([(6.0, 8.7), (6.75, 8.7)], p, lw=2.2) d.fuse(6.4, 8.7, "F1 8 A") d.dot(6.75, 8.7, p) # K1 contacts (2 poles drawn as one) d.wire([(6.75, 8.7), (7.25, 8.7)], p, lw=2.2) d.ax.plot([7.25, 7.75], [8.7, 8.88], color=s, lw=2, zorder=4) d.ax.plot([7.75, 7.75], [8.62, 8.78], color=s, lw=1.5, zorder=4) d.text(7.5, 9.08, "K1 (NO, 2-pole,\n16 A DC)", size=7.8, color=s, ha="center") d.wire([(7.75, 8.7), (8.35, 8.7)], p, lw=2.2) d.dot(8.35, 8.7, p) d.text(8.22, 8.5, "motor bus", size=7.8, color=p, ha="right") d.wire([(8.35, 8.7), (8.35, 9.2), (9.25, 9.2)], p, lw=2.0) d.fuse(8.8, 9.2, "F2 5 A") d.wire([(8.35, 8.7), (8.35, 8.25), (9.25, 8.25)], p, lw=2.0) d.fuse(8.8, 8.25, "F3 4 A") d.box(9.25, 8.82, 1.45, 0.78, "DM542T", ["roll driver"], ts=9, ls=7.8, dy=0.2) d.box(9.25, 7.87, 1.45, 0.78, "CNC shield", ["2x TMC2209"], ts=9, ls=7.8, dy=0.2) # 24 V unswitched control d.wire([(6.75, 8.7), (6.75, 7.95), (6.95, 7.95)], p, lw=1.6) d.fuse(6.95 + 0.25, 7.95, "F4 1 A", w=0.3) d.wire([(7.35, 7.95), (7.6, 7.95)], p, lw=1.6) d.text(7.65, 7.95, "24 V control: safety relay,\nK1 coil, box fan, stack light", size=7.8, color=p) # 5 V d.wire([(6.0, 7.1), (6.6, 7.1)], p, lw=2.0) d.dot(6.6, 7.1, p) d.wire([(6.6, 7.1), (7.3, 7.1)], p, lw=2.0) d.fuse(6.95, 7.1, "F5 3 A", w=0.3) d.box(7.3, 6.72, 1.5, 0.78, "Rig Pi 4", ["5.1 V, 3 A"], ts=9, ls=7.8, dy=0.2) d.wire([(8.8, 7.1), (9.2, 7.1)], C["digital"], lw=1.6) d.text(9.25, 7.1, "USB 5 V -> Uno, Pico,\nsensor node", size=7.8, color=C["digital"]) d.wire([(6.6, 7.1), (6.6, 5.9), (7.0, 5.9)], p, lw=1.8) d.fuse(6.85, 5.9, "F6 0.5 A", w=0.3) d.box(7.15, 5.55, 1.35, 0.7, "LC filter", ["10 uH + 100 uF"], ts=8.8, ls=7.6, dy=0.2) d.wire([(8.5, 5.9), (8.8, 5.9)], p, lw=1.8) d.box(8.8, 5.45, 1.9, 0.9, "LT3042", ["3.30 V low-noise,", "200 mA max"], ts=9, ls=7.6, dy=0.19) d.wire([(9.75, 5.45), (9.75, 5.0)], C["analog"], lw=2.0, arrow=True) d.text(9.75, 4.82, "EX+ bus: 6 bridges (6 x 9.4 mA)\n+ 6 NAU7802 AVDD ~ 65 mA", size=7.8, color=C["analog"], ha="center", va="top") # ground star d.zone(0.4, 0.4, 10.3, 4.05, "STAR GROUND (one point, in the rig box)", color=C["gnd"]) cx, cy = 4.3, 2.2 d.ax.add_patch(Circle((cx, cy), 0.22, fc="white", ec=C["gnd"], lw=2, zorder=5)) d.text(cx, cy, "SP", size=9, weight="bold", ha="center", color=C["gnd"], z=6) spokes = [("PSU1 0 V", 1.2, 3.6), ("PSU2 0 V", 1.2, 2.95), ("Pi GND", 1.2, 2.3), ("NAU7802 + ADS1115 AGND", 1.2, 1.65), ("LT3042 GND (EX- bus)", 1.2, 1.0), ("bridge trunk shields\n(box end only)", 7.3, 3.55), ("chassis / PE (one bond)", 7.3, 2.55), ("motor cable shields\n-> chassis glands", 7.3, 1.5)] for lab, x, y in spokes: right = x > cx x0 = x - 0.08 if right else x + 0.12 + 0.072 * len(lab) d.wire([(x0, y), (cx + (0.22 if right else -0.22), cy)], C["gnd"] if "shield" not in lab else gr, lw=1.4, ls="-" if "shield" not in lab else "--") d.text(x, y, lab, size=8.2, ha="left", color=C["ink"], bg="white") d.note(0.6, 0.85 - 0.1 + 0.0, "", size=8) d.text(5.55, 0.58, "Sting, balance body and rig frame are bonded to PE through the steel frame; gauges are insulated " "from the balance (> 10 Gohm at 50 V).", size=7.8, color=C["sub"], ha="center") # ------------------------------------------------ safety chain (right) d.zone(10.95, 0.4, 4.8, 9.15, "E-STOP / SAFETY CHAIN", color=s) x1, x2 = 11.75, 13.0 # channel 1, channel 2 d.text(11.2, 8.85, "24 V control", size=8.3, color=p) d.wire([(11.2, 8.65), (13.55, 8.65)], p, lw=1.6) for x in (x1, x2): d.wire([(x, 8.65), (x, 8.3)], s, lw=1.6) y = 8.3 for lab in ("S1 rig E-stop", "S2 station E-stop (J7)", "WD watchdog relay"): for i, x in enumerate((x1, x2)): d.nc_switch(x, y, color=s, vertical=True, size=0.55) d.text(x2 + 0.18, y - 0.27, lab, size=8.0, color=s) d.wire([(x1, y - 0.55), (x1, y - 0.75)], s, lw=1.6) d.wire([(x2, y - 0.55), (x2, y - 0.75)], s, lw=1.6) y -= 0.75 d.box(11.35, 3.75, 3.95, 1.25, "Safety relay", ["Omron G9SE-201 (or PNOZ s3): CH1, CH2,", "manual reset S3, outputs 13-14 / 23-24"], ec=s, tc=s, ts=9.5, ls=7.8, dy=0.22) d.wire([(x1, y), (x1, 5.0)], s, lw=1.6, arrow=True) d.wire([(x2, y), (x2, 5.0)], s, lw=1.6, arrow=True) d.no_button(13.75, 5.35, "S3 reset", color=s) d.wire([(14.17, 5.35), (14.6, 5.35), (14.6, 5.0)], s, lw=1.4) d.wire([(13.75, 5.35), (13.45, 5.35), (13.45, 5.0)], s, lw=1.4) # K1 coil d.wire([(12.4, 3.75), (12.4, 3.25)], s, lw=1.6) d.ax.add_patch(Rectangle((12.1, 2.75), 0.6, 0.5, fc="white", ec=s, lw=1.6, zorder=5)) d.text(12.4, 3.0, "K1", size=9, weight="bold", ha="center", color=s, z=6) d.text(12.85, 3.0, "coil 24 V; contacts in the\nmotor bus (left)", size=7.8, color=s) d.wire([(12.4, 2.75), (12.4, 2.45)], s, lw=1.6) d.gnd(12.4, 2.45) # aux signals d.text(11.15, 1.75, "Aux contacts / sensing to software:", size=8.3, weight="bold", color=C["ink"]) for i, t in enumerate(("S1/S2 aux NC -> opto -> Pi GPIO17 (E-STOP OK)", "motor bus after K1 -> opto -> Pi GPIO27", "E-stop aux -> grbl A0 (abort, pull-up)", "Pi GPIO22 10 Hz heartbeat -> WD relay")): d.text(11.2, 1.43 - i * 0.26, t, size=7.8, color=C["sub"]) d.save("power_safety") # ====================================================================== (c) steppers def steppers(): d = D(16, 10.6, "Stepper drivers, motors and limit switches (grbl 1.1 on Arduino Uno + CNC shield v3)", "Axes in grbl units of DEGREES: X = yaw, Y = pitch, Z = roll. Drivers are disabled after each move ($1) - " "the worm gearboxes hold position while data are taken") g, m, p = C["digital"], C["motor"], C["power"] ux, uw = 5.7, 3.7 top = 8.85 rows = [("D2", "X STEP", "yaw TMC2209"), ("D3", "Y STEP", "pitch TMC2209"), ("D4", "Z STEP", "-> DM542T PUL+"), ("D5", "X DIR", "yaw TMC2209"), ("D6", "Y DIR", "pitch TMC2209"), ("D7", "Z DIR", "-> DM542T DIR+"), ("D8", "STEPPERS EN", "all; -> DM542T ENA+"), ("D9", "X LIMIT", "yaw switches"), ("D10", "Y LIMIT", "pitch switches"), ("D12", "Z LIMIT", "roll switches"), ("D11", "spindle PWM", "not used"), ("D13", "spindle dir", "not used"), ("A0", "ABORT", "E-stop aux NC"), ("A1", "FEED HOLD", "spare"), ("A2", "CYCLE START", "spare"), ("GND", "0 V", "DM542T PUL-/DIR-/ENA-"), ("USB", "serial 115200", "rig Pi")] rh = 0.37 h = rh * len(rows) + 0.5 d.box(ux, top - h, uw, h, "Arduino Uno + CNC shield v3", [], ts=10.5) pin_y = {} for i, (pin, fn, to) in enumerate(rows): y = top - 0.62 - i * rh pin_y[pin] = y col = C["grey"] if "not used" in to or to == "spare" else g d.ax.add_patch(Rectangle((ux + 0.12, y - 0.13), 0.55, 0.26, fc=col, ec="none", zorder=4)) d.text(ux + 0.395, y, pin, size=8, ha="center", color="white", weight="bold", z=5) d.text(ux + 0.8, y, fn, size=8.3, weight="bold", z=5) d.text(ux + 2.05, y, to, size=8, color=C["sub"], z=5) # TMC2209 boxes d.box(10.55, 7.55, 2.15, 1.3, "TMC2209 X (yaw)", ["shield socket X, 1/8 step", "1.2 A rms (set Vref)"], ts=9, ls=7.8, dy=0.21) d.box(10.55, 5.95, 2.15, 1.3, "TMC2209 Y (pitch)", ["shield socket Y, 1/8 step", "1.2 A rms (set Vref)"], ts=9, ls=7.8, dy=0.21) d.box(10.55, 2.3, 2.15, 3.1, "DM542T Z (roll)", ["external driver, 24 V", "SW: 2.0 A rms, 1600 pulse/rev", "opto inputs, common", "cathode (5 V logic)", "", "PUL+ <- D4", "DIR+ <- D7", "ENA+ <- D8", "PUL-/DIR-/ENA- <- GND"], ts=9, ls=7.8, dy=0.22) for pin, ybox in (("D2", 8.35), ("D5", 8.1), ("D3", 6.65), ("D6", 6.4)): d.wire([(ux + uw, pin_y[pin]), (10.2, pin_y[pin]), (10.2, ybox), (10.55, ybox)], g, lw=1.2, arrow=True) for pin, yb in (("D4", 4.0), ("D7", 3.78), ("D8", 3.56)): d.wire([(ux + uw, pin_y[pin]), (9.95 - 0.08 * ("D4", "D7", "D8").index(pin), pin_y[pin]), (9.95 - 0.08 * ("D4", "D7", "D8").index(pin), yb), (10.55, yb)], g, lw=1.2, arrow=True) d.wire([(ux + uw, pin_y["GND"]), (10.3, pin_y["GND"]), (10.3, 3.34), (10.55, 3.34)], C["gnd"], lw=1.2, arrow=True) d.text(10.2, 9.05, "(on the shield: socket traces)", size=7.5, color=C["sub"], ha="center") d.wire([(ux + uw, pin_y["D8"]), (9.75, pin_y["D8"]), (9.75, 7.3), (10.55, 7.3)], g, lw=1.0, ls=":") # motors mot = [("NEMA 17 yaw", "2.0 A, 0.59 N-m class; 30:1 worm", 8.35), ("NEMA 17 pitch", "same motor; 40:1 worm, 20T pinion", 6.25), ("NEMA 23 roll", "1.2-1.9 N-m, 2.8 A; NMRV030 50:1", 3.6)] cols = ("#111111", "#2e7d32", "#c62828", "#1565c0") for name, sub, yc in mot: d.ax.add_patch(Circle((14.55, yc), 0.42, fc="#e8eaee", ec=C["ink"], lw=1.4, zorder=4)) d.text(14.55, yc, "M", size=12, weight="bold", ha="center", z=5) d.text(13.6, yc + 0.68, name, size=9, weight="bold", ha="left") d.text(14.55, yc - 0.55, sub, size=7.3, color=C["sub"], ha="center", va="top") for k, c in enumerate(cols): yy = yc + 0.24 - k * 0.16 d.ax.plot([12.7, 14.15], [yy, yy], color=c, lw=1.6, zorder=3) d.text(13.4, 9.5, "A+ A- B+ B- (colours vary by vendor -\nidentify coil pairs with a meter)", size=7.4, color=C["sub"], ha="center") d.text(12.78, 5.0, "motor cables: 4-core\nshielded, shield ->\nchassis gland", size=7.3, color=m) # 24 V d.wire([(11.6, 1.45), (11.6, 2.3)], p, lw=1.8, arrow=True) d.text(11.6, 1.25, "24 V motor bus (after K1)\n-> DM542T V+/GND and shield VMOT", size=7.8, color=p, ha="center", va="top") # limit switches d.zone(0.35, 2.15, 4.95, 6.95, "LIMIT / HOME SWITCHES (NC, wired in series per axis)") sw = [("D9", "yaw", "-16 deg (home)", "+16 deg"), ("D10", "pitch", "-7 deg (home)", "+21 deg"), ("D12", "roll", "-95 deg (home)", "+185 deg")] for i, (pin, ax_, a1, a2) in enumerate(sw): y = 8.1 - i * 2.05 d.text(0.55, y + 0.45, f"{ax_} -> {pin}", size=9, weight="bold") d.gnd(0.7, y - 0.02) d.wire([(0.7, y - 0.02), (0.7, y), (1.0, y)], C["gnd"], lw=1.4) d.nc_switch(1.0, y, a1, color=C["ink"], size=0.5, lsize=7.8) d.wire([(1.5, y), (2.45, y)], C["ink"], lw=1.4) d.nc_switch(2.45, y, a2, color=C["ink"], size=0.5, lsize=7.8) d.wire([(2.95, y), (3.55, y)], g, lw=1.4) d.ax.add_patch(Rectangle((3.55, y - 0.16), 0.5, 0.32, fc="white", ec=C["sub"], lw=1, zorder=5)) d.text(3.8, y, "RC", size=7.5, ha="center", z=6) d.wire([(4.05, y), (ux, y), (ux, pin_y[pin]), (ux + 0.12, pin_y[pin])], g, lw=1.4, arrow=True) d.text(0.55, 2.8, "RC = 1 k + 100 nF at the Uno pin (internal pull-up);\nshielded 8-core cable J5, shield to chassis " "at the box.\nAn open circuit or broken wire reads as 'limit hit'.", size=7.8, color=C["sub"], va="center") # grbl settings d.box(0.35, 0.3, 9.1, 1.65, "Key grbl settings (degrees)", [ "$100 = 5310 (yaw) $101 = 7947 (pitch) $102 = 222.2 (roll) steps/deg at 1/8 step", "$110 = 180 $111 = 120 $112 = 1080 deg/min (3, 2, 18 deg/s -> 15.9, 15.9, 4.0 kHz; grbl max ~30 kHz)", "$5 = 1 (invert: NC switches) $21 = 1 hard limits $22 = 1 homing $20 = 1 soft limits $1 = 25 ms idle -> disable", "compile with STEP_PULSE_DELAY 10 (DM542T needs 5 us DIR set-up) $0 = 10 us pulse"], ts=9.5, ls=7.9, dy=0.27, fc="white") d.save("steppers") # ====================================================================== (d) bridge wiring def bridge(): d = D(16, 10.6, "Strain-gauge bridge wiring", "Shared 3.30 V excitation bus with remote sense; one 24-bit NAU7802 per bridge (simultaneous, ratiometric)") a, p, gr = C["analog"], C["power"], C["shield"] # ---------------- one bridge in detail (left) d.zone(0.35, 3.25, 7.6, 6.0, "ONE BRIDGE IN DETAIL (M1, forward pitch neck)") T, B, L_, R_ = (2.2, 8.15), (2.2, 4.25), (0.95, 6.2), (3.45, 6.2) d.resistor(T, R_, "T1 top (+)", color=C["ink"], lpos=(0.5, 0.25)) d.resistor(R_, B, "B1 bottom (-)", color=C["ink"], lpos=(0.6, -0.2)) d.resistor(T, L_, "B2 bottom (-)", color=C["ink"], lpos=(-0.55, 0.25)) d.resistor(L_, B, "T2 top (+)", color=C["ink"], lpos=(-0.5, -0.2)) for q in (T, B, L_, R_): d.dot(*q, C["ink"]) d.text(2.2, 8.4, "EX+", size=9, weight="bold", ha="center", color=p) d.text(2.2, 3.98, "EX-", size=9, weight="bold", ha="center", color=C["gnd"]) d.text(0.75, 6.2, "SIG-", size=9, weight="bold", ha="right", color=a) d.text(3.5, 5.93, "SIG+", size=9, weight="bold", ha="left", color=a) d.text(2.2, 6.2, "4 x 350 ohm\nCEA-13-..-350", size=7.6, ha="center", color=C["sub"]) # terminal pads on the balance d.ax.add_patch(Rectangle((4.15, 4.0), 0.55, 4.45, fc="#fff7e6", ec=C["warn"], lw=1.2, zorder=3)) d.text(4.42, 8.62, "pads on\naft block", size=7.4, ha="center", color=C["warn"]) pads = {"EX+": 8.15, "S+": 7.6, "SIG+": 6.45, "SIG-": 5.65, "S-": 4.8, "EX-": 4.25} for k, y in pads.items(): d.term(4.42, y, C["warn"]) d.wire([T, (4.42, 8.15)], p, lw=1.6) d.wire([(2.45, 8.15), (2.45, 7.6), (4.42, 7.6)], p, lw=1.0, ls="--") d.text(3.35, 7.75, "sense taps at the bridge", size=7.0, color=p, ha="center") d.wire([R_, (3.8, 6.2), (3.8, 6.45), (4.42, 6.45)], a, lw=1.6) d.wire([L_, (0.6, 6.2), (0.6, 5.65 - 0.0), (0.6, 3.6), (3.95, 3.6), (3.95, 5.65), (4.42, 5.65)], a, lw=1.6) d.wire([B, (4.42, 4.25)], C["gnd"], lw=1.6) d.wire([(2.45, 4.25), (2.45, 4.8), (4.42, 4.8)], C["gnd"], lw=1.0, ls="--") # cable path d.ax.add_patch(Rectangle((4.95, 3.85), 1.0, 4.75, fc="#eef1f5", ec=gr, lw=1.0, ls="--", zorder=1)) d.text(5.45, 8.78, "sting +\nspindle", size=7.4, ha="center", color=gr) d.text(5.45, 3.63, "32 AWG PTFE,\npairs twisted", size=7.0, ha="center", color=gr, va="top") d.ax.add_patch(Rectangle((6.05, 3.85), 0.35, 4.75, fc="white", ec=C["ink"], lw=1.2, zorder=3)) d.text(6.22, 8.8, "J0", size=8.5, weight="bold", ha="center") for k, y in pads.items(): col = p if "EX+" in k or k == "S+" else (C["gnd"] if k in ("EX-", "S-") else a) d.wire([(4.42, y), (6.22, y)], col, lw=1.4) d.term(6.22, y) d.text(7.0, 8.15, "trunk pair 1\n(EX doubled)", size=7.0, color=p, ha="center") d.text(7.0, 7.6 - 0.05, "pair 2", size=7.0, color=p, ha="center") d.text(7.0, 6.05, "own shielded\npair", size=7.0, color=a, ha="center") d.text(7.0, 4.5, "pair 1 / 2", size=7.0, color=C["gnd"], ha="center") for y in pads.values(): d.wire([(6.22, y), (7.95, y)], C["ink"], lw=0.8, ls=":") # ---------------- rig box side (bottom-left) d.zone(0.35, 0.3, 7.6, 2.7, "RIG BOX (J1)") d.box(0.55, 0.55, 2.2, 2.05, "NAU7802 #1", ["VIN1P <- SIG+", "VIN1N <- SIG-", "AVDD <- EX bus", "REF = AVDD", "mux ch0, 0x2A"], ts=9, ls=7.6, dy=0.22) d.box(2.95, 0.55, 2.2, 2.05, "LT3042 3.30 V", ["OUT -> EX+ bus", "(J1 pins 1-2)", "GND -> EX- bus", "-> AGND star"], ts=9, ls=7.6, dy=0.22, ec=p) d.box(5.35, 0.55, 2.4, 2.05, "ADS1115 #1 (0x48)", ["A0-A1: S+ / S- at the", "balance (remote sense)", "A2-A3: EX at the box", "-> k = V_bal / V_box"], ts=9, ls=7.6, dy=0.22) d.text(4.15, 3.12, "Input RC per channel: 100 ohm series + 0.1 uF differential (+ 10 nF to AGND each side).", size=7.6, color=C["sub"], ha="center") # ---------------- harness (right) d.zone(8.3, 0.3, 7.45, 8.95, "6-BRIDGE HARNESS AND J0 PINOUT (DC-37, 26 conductors used)") bridges = ["M1", "M2", "Y1", "Y2", "L", "A"] bx0, by0 = 8.65, 7.9 d.wire([(bx0 - 0.05, 8.45), (11.6, 8.45)], p, lw=2.4) d.text(bx0, 8.65, "EX+ bus (pads)", size=7.8, color=p) d.wire([(bx0 - 0.05, 4.05), (11.6, 4.05)], C["gnd"], lw=2.4) d.text(bx0, 3.85, "EX- bus (pads)", size=7.8, color=C["gnd"]) for i, b in enumerate(bridges): cy = 7.75 - i * 0.62 cx = 9.4 pts = [(cx, cy + 0.22), (cx + 0.28, cy), (cx, cy - 0.22), (cx - 0.28, cy)] d.ax.add_patch(Polygon(pts, closed=True, fc="white", ec=C["ink"], lw=1.2, zorder=4)) d.text(cx - 0.45, cy, b, size=8.6, weight="bold", ha="right") d.wire([(cx, cy + 0.22), (cx, cy + 0.32), (cx + 0.55, cy + 0.32), (cx + 0.55, 8.45)], p, lw=0.9) d.wire([(cx, cy - 0.22), (cx, cy - 0.3), (cx + 0.75, cy - 0.3), (cx + 0.75, 4.05)], C["gnd"], lw=0.9) d.wire([(cx + 0.28, cy), (11.6, cy)], a, lw=1.3) d.wire([(cx - 0.28, cy), (cx - 0.28, cy - 0.12), (cx + 0.95, cy - 0.12), (cx + 0.95, cy - 0.08), (11.6, cy - 0.08)], a, lw=1.0) d.text(11.35, cy + 0.14, f"NAU7802 ch{i}", size=6.8, color=a, ha="right") d.text(8.55, 3.2, "NTC 10k on the aft block -> ADS1115 #2\npod 3V3 / GND / SDA / SCL -> I2C bus 3 (LTC4311)", size=7.6, color=C["sub"], va="top") # pinout table rows = [("1, 2", "EX+ (doubled)"), ("3, 4", "EX- (doubled)"), ("5, 6", "SENSE+, SENSE-"), ("7, 8", "M1 SIG+, SIG-"), ("9, 10", "M2 SIG+, SIG-"), ("11, 12", "Y1 SIG+, SIG-"), ("13, 14", "Y2 SIG+, SIG-"), ("15, 16", "L SIG+, SIG-"), ("17, 18", "A SIG+, SIG-"), ("19, 20", "NTC a, b"), ("21, 22", "pod 3V3, GND"), ("23, 24", "pod SDA, SCL"), ("25, 26", "spare (pair)"), ("27-36", "not used"), ("37", "braid / overall shield"), ("shell", "isolated from housing")] tx, ty = 12.0, 8.55 d.text(tx, ty + 0.05, "J0 / J1 pin", size=8.2, weight="bold") d.text(tx + 1.15, ty + 0.05, "signal", size=8.2, weight="bold") for i, (pn, sig) in enumerate(rows): y = ty - 0.3 - i * 0.29 if i % 2 == 0: d.ax.add_patch(Rectangle((tx - 0.08, y - 0.14), 3.6, 0.28, fc="#f1f4f9", ec="none", zorder=2)) d.text(tx, y, pn, size=7.9) d.text(tx + 1.15, y, sig, size=7.9) d.text(tx - 0.05, 2.55, "Trunk J0 -> J1: 12 individually\nshielded pairs, 24 AWG, high-flex.\nPair shields + overall " "shield to\nAGND at the rig box ONLY.\nAt J0 the sting braid joins the\noverall shield; the " "shell is\nisolated from the roll housing.", size=7.6, color=C["sub"], va="top") d.save("bridge") # ====================================================================== (e) Pi pin map def pinmap(): d = D(16, 10.6, "Raspberry Pi 4 (rig computer) pin map, I2C addresses and the sensor node", "Physical header pins, BCM GPIO numbers; unused pins grey. Station Pi uses no GPIO (Ethernet only).") names = {1: "3V3", 2: "5V", 3: "GPIO2 SDA1", 4: "5V", 5: "GPIO3 SCL1", 6: "GND", 7: "GPIO4", 8: "GPIO14 TXD", 9: "GND", 10: "GPIO15 RXD", 11: "GPIO17", 12: "GPIO18", 13: "GPIO27", 14: "GND", 15: "GPIO22", 16: "GPIO23", 17: "3V3", 18: "GPIO24", 19: "GPIO10 MOSI", 20: "GND", 21: "GPIO9 MISO", 22: "GPIO25", 23: "GPIO11 SCLK", 24: "GPIO8 CE0", 25: "GND", 26: "GPIO7 CE1", 27: "ID_SD", 28: "ID_SC", 29: "GPIO5", 30: "GND", 31: "GPIO6", 32: "GPIO12", 33: "GPIO13", 34: "GND", 35: "GPIO19", 36: "GPIO16", 37: "GPIO26", 38: "GPIO20", 39: "GND", 40: "GPIO21"} use = {1: ("3V3 -> TCA9548A, NAU7802 DVDD, ADS1115", "pwr3"), 2: ("5 V in (from PSU2 via F5)", "pwr5"), 3: ("I2C-1 SDA -> TCA9548A (100 kHz)", "i2c"), 5: ("I2C-1 SCL", "i2c"), 7: ("I2C-3 SDA -> LTC4311 -> pod bus", "i2c"), 29: ("I2C-3 SCL (dtoverlay=i2c3)", "i2c"), 11: ("in: E-STOP OK (opto)", "safe"), 13: ("in: MOTOR POWER present (opto)", "safe"), 15: ("out: WATCHDOG heartbeat 10 Hz", "safe"), 16: ("in: WIND ON (tunnel drive, opto)", "io"), 18: ("out: stack light (MOSFET)", "io"), 12: ("out: box fan PWM", "io"), 37: ("1-Wire DS18B20 air temp (4k7 pull-up)", "io"), 31: ("in: ADS1115 ALERT/RDY (optional)", "io"), 19: ("SPI0 reserved (ADS1263 upgrade)", "spare"), 21: ("SPI0 reserved", "spare"), 23: ("SPI0 reserved", "spare"), 24: ("SPI0 CE0 reserved", "spare"), 8: ("UART debug console", "spare"), 10: ("UART debug console", "spare")} colmap = {"pwr3": "#e67e22", "pwr5": C["power"], "gnd": "#222222", "i2c": C["digital"], "safe": C["safety"], "io": C["analog"], "spare": "#b0b7c0", None: "#d5d9df"} hx0, hx1, ytop, dy = 5.55, 6.05, 9.15, 0.385 d.ax.add_patch(FancyBboxPatch((hx0 - 0.3, ytop - 19 * dy - 0.3), 1.1, 19 * dy + 0.6, boxstyle="round,pad=0,rounding_size=0.06", fc="#1f3b2d", ec="none", zorder=2)) for n in range(1, 41): r = (n - 1) // 2 x = hx0 if n % 2 else hx1 y = ytop - r * dy kind = use.get(n, (None, None))[1] if names[n] == "GND": kind = "gnd" fc = colmap[kind] d.ax.add_patch(Circle((x, y), 0.14, fc=fc, ec="white", lw=1.0, zorder=4)) d.text(x, y, str(n), size=6.3, ha="center", color="white", weight="bold", z=5) lab = names[n] + (" " + use[n][0] if n in use else "") col = C["ink"] if n in use and use[n][1] != "spare" else C["sub"] if n % 2: d.text(hx0 - 0.4, y, lab if n not in use else f"{use[n][0]} {names[n]}", size=7.6, ha="right", color=col, weight="bold" if n in use and use[n][1] != "spare" else "normal") else: d.text(hx1 + 0.4, y, lab, size=7.6, ha="left", color=col, weight="bold" if n in use and use[n][1] != "spare" else "normal") d.text((hx0 + hx1) / 2, ytop + 0.45, "40-pin header", size=8.5, ha="center", weight="bold") # USB / Ethernet box d.box(0.35, 0.3, 4.6, 1.25, "USB + Ethernet", ["USB: Uno (grbl) -> /dev/grbl (udev rule by serial no.)", "USB: Pico node -> /dev/sensornode", "Ethernet -> station Pi (static IP, " "UDP/TCP rig protocol)"], ts=9.2, ls=7.6, dy=0.25, fc="white") # I2C map d.box(10.55, 4.35, 5.2, 4.95, "I2C address map", [ "I2C-1 (100 kHz) -> TCA9548A mux 0x70", " ch0 NAU7802 M1 0x2A", " ch1 NAU7802 M2 0x2A", " ch2 NAU7802 Y1 0x2A", " ch3 NAU7802 Y2 0x2A", " ch4 NAU7802 L 0x2A", " ch5 NAU7802 A 0x2A", " ch6 ADS1115 #1 0x48 (sense), #2 0x49 (NTC)", " ABP2 pitot 0x28, BMP390 ambient 0x77", " ch7 spare", "I2C-3 (50 kHz, LTC4311) -> pod, via J0/J1", " BMP390 base 0x76, BMP390 cavity 0x77,", " LSM6DSOX accelerometer 0x6A", "1-Wire GPIO26: DS18B20 air temperature"], ts=9.5, ls=7.7, dy=0.3, fc="white") d.box(10.55, 0.35, 5.2, 3.7, "Sensor node: Raspberry Pi Pico", [ "USB to the rig Pi (power + CDC serial, 100 Hz)", "SPI0: GP18 SCK, GP19 MOSI, GP16 MISO", " GP17 CS roll AS5048A (spindle end)", " GP20 CS pitch AS5048A (pinion shaft)", " GP21 CS yaw AS5048A (pinion shaft)", " GP22 CS SCL3300 inclinometer (roll housing)", "3V3(OUT) -> sensors (AS5048A in 3.3 V mode)", "1 MHz, 100 ohm series at each driver; < 1 m runs", "AS5048A SPI mode 1; SCL3300 mode 0"], ts=9.5, ls=7.6, dy=0.3, fc="white") d.legend(8.5, 5.0, [("3.3 V", "#e67e22", "-"), ("5 V", C["power"], "-"), ("ground", "#222222", "-"), ("I2C", C["digital"], "-"), ("safety I/O", C["safety"], "-"), ("other I/O", C["analog"], "-"), ("spare / reserved", "#b0b7c0", "-")], w=1.9) d.save("pinmap") # ====================================================================== (f) harness route def harness_route(): d = D(16, 6.6, "Balance cable route and bore fill", "26 conductors of 32 AWG PTFE (OD ~0.017 in) from the gauges to J0; fill = conductor area / hole area") a = C["analog"] stages = [("Pod sensor bay", "2x BMP390 + LSM6DSOX;\n4 wires through the puck\nwire hole d .188", 0.4), ("Balance", "24 gauges -> pads on the\naft block; model-side wires\ncross as thin loops", 2.75), ("Entry hole d .188", "26 x 32 AWG\nfill 21 %", 5.1), ("Spigot bore d .250", "fill 12 %", 6.9), ("Sting bore d .300", "17.45 in; braid sleeve\nover the bundle; fill 8 %\n(25 % with braid)", 8.7), ("Spindle exit d .250", "radial, x = 20.53 in;\nPTFE grommet; fill 12 %", 10.85), ("Clock-spring loop", "270 deg (-90..+180) in\nthe gearbox-adapter\nwire window -> J0", 13.05)] w = 1.95 for i, (t, s_, _) in enumerate(stages): x = 0.4 + i * 2.25 d.box(x, 2.6, w, 2.1, t, [], ts=9.0, fc=C["hi"] if i in (2, 3, 4, 5) else C["fill"]) d.text(x + 0.12, 3.95, s_, size=7.7, color=C["sub"], va="top") if i < len(stages) - 1: d.wire([(x + w, 3.65), (x + 2.25, 3.65)], a, lw=2.2, arrow=True) d.wire([(0.4 + 6 * 2.25 + w / 2, 2.6), (0.4 + 6 * 2.25 + w / 2, 1.75)], a, lw=2.2, arrow=True) d.box(10.7, 0.35, 4.95, 1.4, "J0 DC-37 -> 12-pair shielded trunk -> J1", ["high-flex (cable-chain) cable, ~4 m,", "through the pitch and yaw service loops"], ts=9.2, ls=7.8, dy=0.25) d.text(0.45, 1.7, "Check: 32 AWG PTFE OD 0.017 in -> 26 x 0.000227 = 0.0059 in^2.\n" "Pull-through guideline <= 40 % fill: every hole passes; the d .188 entry hole is the bottleneck.\n" "Calibrate with all wires installed - the loops that cross the flexures carry a little load.", size=8.3, color=C["ink"], va="center") d.text(0.45, 0.6, "Flag: gearbox adapter WT-6C-204 wire window is drawn for +-90 deg; bench calibration needs " "-90..+180 deg -> check / widen it.", size=8.3, color=C["warn"], weight="bold", va="center") d.save("harness_route") if __name__ == "__main__": block() power_safety() steppers() bridge() pinmap() harness_route()