Motor Driver Board Assembly Eng

Micom Car Rally Kit

Motor Drive Board Assembly Manual Version3

1.00E Edition 19/06/2006 Japan Micom Car Rally Executive Committee

Motor Drive Board Assembly Manual

Important Notice Copyright *Copyright concerning this manual belongs to the Japan Micom Car Rally Executive Committee. *This manual is protected by the copyright law and the international copyright agreement.

Prohibited Use User must not do the following things. *Selling, advertisement to sell, use, trading, reproduction of this manual for the third party *Assigning the usage right or approval of this manual to the third party *Change or remove part or whole of this manual *Translate this manual without authorization *Use wherein harm might be caused to life and human body by using the content of this manual

Reprinting, reproduction Prior approval of Japan Micom Car Rally Executive Committee is necessary for reprinting and reproduction of this manual.

Liability Restrictions The information described in this manual is carefully prepared to ensure accuracy. However, Japan Micom Car Rally Executive Committee does not assume any responsibility, if any damage occurs due to the description error of this manual.

Other In this manual the model car controlled by microcomputer is defined as the micom car. The information contained in this manual represents information at the time of publication of the manual, and Japan Micom Car Rally Executive Committee is liable to occasionally change this information or specification described in this manual without prior notice. Refer to the information published on the official homepage (http://www.mcr.gr.jp/) of Micom Car Rally when manufacturing micon car.

Contact Address Head Office, Renesas Technology Micom Car Rally Executive Committee 162-0824 Tokyo Shinjukuku, Ageba cho,2-1 Karuko saka, MN Building TEL (03)-3266-8510 E-mail : [email protected]

-1-

Motor Drive Board Assembly Manual

Index (Table of contents) 1. Outline ................................................................................................................. 4 2. Specifications......................................................................................................... 5 2.1. Detailed Specifications ............................................................................................................. 5 2.2. Dimensions ............................................................................................................................ 6 2.3. Function................................................................................................................................. 7 2.4. 10 pin Connector ..................................................................................................................... 8 2.5. Drive System Power Supply Connector........................................................................................ 9 2.6. Motor Connector ..................................................................................................................... 9 2.7. Servo Connector .....................................................................................................................10

3.Assembly ..............................................................................................................11 3.1. Parts Table .........................................................................................................11 3.2. Parts Mounting Position ...........................................................................................................12 3.5. Mounting of IC ......................................................................................................................15 3.6. Mounting the Multi layer Ceramic Condenser ..............................................................................16 3.7. Mounting of Ceramic Condenser ...............................................................................................17 3.8. Mounting of Assembly Resistor .................................................................................................18 3.9. Mounting of LED ...................................................................................................................19 3.10.Mounting of Digital Transistor .................................................................................................20 3.11. Mounting of Tact switch .........................................................................................................21 3.12. Mounting of Bypass ..............................................................................................................22 3.13. Mounting of 3 pins Connector for Servo ....................................................................................23 3.14. Mounting of Coil ..................................................................................................................24 3.15. Mounting of FET ..................................................................................................................25 3.16. Mounting of FET（for 4AM12) ................................................................................................26 3.17. Mounting of 2 pins Connector..................................................................................................27 3.18. Mounting of 10 pins Connector................................................................................................28 3.19.Mounting of Electrolytic Condenser ..........................................................................................29 3.20. Completion ..........................................................................................................................30

4. Condenser Mounting in Motor..................................................................................31 5. About the use of 5-8 batteries for having common power supply. ....................................37 5.1. Power supply configuration of standard kit. .................................................................................37 5.2. Power supply composition by which the driving system voltage is raised...........................................38 5.3. Parts List...............................................................................................................................39 5.4. Replacement of Bypass (Installation) ..........................................................................................40 5.5. Mounting of Resistor ...............................................................................................................41 5.6. Mounting of Multilayer Ceramic Condenser ................................................................................42 5.7. Installation of Volume..............................................................................................................43 5.8. Installation of 3 Terminal Regulator............................................................................................44 5.9. Voltage Adjustment .................................................................................................................45

6. Kit Installation ......................................................................................................47 -2-

Motor Drive Board Assembly Manual

7. Circuit Diagram.....................................................................................................49

-3-

Motor Drive Board Assembly Manual

1. Outline This is a motor drive board/circuit board (Ver..3) manufacturing manual for the micom car rally newly designed in April, 2005. In this circuit board, 2 LED, 1 push switch, 1 servo, and 2 motors can be controlled (though there are 3 LED, 1 is for the power supply monitor). The motors can control [normal rotation], [brake] and [reverse] respectively, and the speed control can carry out fine/minute speed adjustment by using the PWM function of H8/3048F-ONE (reset synchronization PWM mode). Moreover, since the voltage for drive system is approx. 5-15V, it is also possible to tune up by raising the voltage added to the motor (however, it is necessary to add the LM350 addition set). Corresponding standard program is [kit05.c]. It is published on the micom car official homepage.

In this manual, • • •

Motor drive board (Ver.2) is abbreviated as [Drive board 2] Motor drive extension board (Ver.2) is abbreviated as [extension board 2] Motor drive board (Ver.3) is abbreviated as [Drive board 3]

▲Installed Micrm Car

-4-

Motor Drive Board Assembly Manual

2. Specifications 2.1. Detailed Specifications The list of the specification of each drive board is given below. Name

Motor Drive Board (Ver.2)

Motor Drive Extension Board (Ver.2)

Motor Drive Board (Ver.3)

Abbreviation

Drive Board 2

Extension Board 2

Drive Board 3

Sales Date

April 2002

April 2005

April 2005

Composition

Operates as a unit.

Operates in combination with drive board 2. Cannot operate as a unit.

Operates as a unit.

Normal rotation, free, brake

Normal rotation, reverse, brake

Normal rotation, reverse, brake

Port A

Port B

Port B

PWM

PWM use for every 1 channel

Reset synchronization PWM mode use

Reset synchronization PWM mode use

Cycle

motor：1ms servo：16ms Individually setting possible

motor：16ms servo：16ms Individually setting not possible 4AM12×1 piece Or, 2SJ type ×2 pieces +2SK type ×2 pieces.

motor：16ms servo：16ms Individually setting not possible

Operation of motor Connection with CPU board

Used FET Control system voltage Drive system voltage

4AM12×1 piece

2SJ type ×4 pieces + 2SK type ×4 pieces or 4AM12×2 pieces

DC5.0V±10%

DC5.0V±10%

DC5.0V±10%

5 - 15V

5 - 15V

5 - 15V

When drive system voltage is above 6V, the servo...

It is necessary to remove the Circuit adjusted to constant 6V

The pattern is on the board and parts of the LM350 addition set are installed beforehand.

The pattern is on the board and parts of the LM350 addition set are installed beforehand.

Standard program

kit2.c or kit04.c

kit05.c

kit05.c

Dimensions

Maximum W80×D50×H15mm (actual)

Maximum W80×D60×H20mm (actual)

Maximum W80×D65×H20mm (actual)

Other

Stop sales as soon as the stock of 4AM12 is over.

Though the circuit is different, it is functionally same hence, the same program is used.

Note: Related to respective board Motor Drive Board (Ver.2)＋Motor Drive Extension Board (Ver.2)＝Motor Drive Board (Ver.3)

-5-

Motor Drive Board Assembly Manual

2.2. Dimensions There are 6 holes for installing the board. The kit and the board are fixed by using 4 large round holes. The installation of the kit is the same as drive board 2.

70 5 10

30 65

80

-6-

Motor Drive Board Assembly Manual

2.3. Function Given below is the drive board 3, after the parts have been mounted. 10 pin connector

LED for power supply

Drive system

LED0

power supply

LED1

connector

Push switch

Connector for servo

Left motor connector

10 pin connector

Drive system Power supply connector

Right motor connector

Connect to CPU board with flat cable. Connect with the connector of port B (J3). Power supply to the motor and servo. The control system parts such as 74HC08, 74HC14, and 74HC32 operate on 5V supplied from 10 pin connector. Though it corresponds to the input voltage of 6V in a standard kit, when the voltage is more, it is necessary to adjust the voltage added to the servo to 6V. When parts of the LM350 addition set are added, the voltage of the servo can be made constant.

Right motor connector

Connects to the right motor.

Left motor connector

Connects to the left motor.

Connector for Servo

Connects to the servo. Sequence of the signal by 3 pin is, [1: servo signal, 2: + power supply, 3: GND]. The servo maker with a different sequence should replace the pin on the servo side.

LED for power supply

Glows when the voltage is supplied to the power supply connector.

-7-

Motor Drive Board Assembly Manual

LED0

Connects to bit6 of port B of CPU board connected to 10 pin connector. LED0 is switched on/off by setting this bit for output.

LED1

Connects to bit7 of port B of CPU board connected to 10 pin connector. LED0 is switched on/off by setting this bit for output.

Push Switch

Connects to bit0 of port B of CPU board connected to 10 pin connector. Checks whether or not the switch is pushed by reading the state and setting this bit for the input.

2.4. 10 pin Connector Connects with the CPU board with a flat cable.

2

4

6

8

10

1

3

5

7

9

Top view

2 3

Signal, direction (Note) － board←PB7 board←PB6

4

board←PB5

Servo signal

5

board←PB4

Right motor PWM

Stop

6

board←PB3

7

board←PB2

Direction of right motor rotation Direction of left motor rotation

Normal rotation Normal rotation

8

board←PB1

Left motor PWM

Stop

Start

9

board→PB0

Push switch

Pushed

Not pushed

10

－

GND

Pin number 1

Details

“0”

“1”

on on

off off

Details

+5V LED1 LED0

PWM signal Duty ratio is set with ITU4_BRB

PWM signal Start

PWM signal Duty ratio is set with ITU4_BRA

Reverse Reverse PWM signal Duty ratio is set with ITU3_BRB

Note: PB7 is port B of the H8 microcomputer bit 7. “board→PBO” reads the output signal from drive board to microcomputer port (the port is input). “board←PBO” inputs the output signal from the microcomputer by the drive board and starts.

-8-

Motor Drive Board Assembly Manual

2.5. Drive System Power Supply Connector Connects to the power supply for the motor and the servo.

1 2 Top View

Number

Direction

1 2

Details GND Power supply input 5-15V

－ IN

2.6. Motor Connector Connects with the motor

Left Motor

1

Right Motor

2

1

Top View Number 1 2

Direction OUT OUT

2

Top View

Normal rotation 0V Voltage

-9-

Reverse Voltage 0V

Brake 0V 0V

Motor Drive Board Assembly Manual

1

Ｍ

2

Normal rotation

1

Ｍ

2

1

Reverse

Ｍ

2

Brake

2.7. Servo Connector Connects with the servo. If the connector on the servo side becomes a pin allocation as shown in the table, then it can be connected as it is. However, if not then the pin is replaced. Generally, black is for GND signal, red for power supply, white or yellow for PWM signal.

3 2 1 Top View Number 1 2 3

Direction OUT PWM signal output OUT Note: refer below OUT GND

Details

Example of Servo side connector 1：Yellow PWM signal 2：Red Voltage 3：Black GND Note: The power supply of 2 pins is switched over with JP1. JP1

Details

Shorts between 1-2

Select this if the drive system voltage is 6V or more. The voltage adjusted to a constant of 6V by LM350 is output. (Necessary to add parts of LM350 addition set)

Shorts between 2-3

Select this if the drive system voltage is 6V or more. Is connected directly to the drive system power supply.

- 10 -

Motor Drive Board Assembly Manual

3.Assembly 3.1. Parts Table Part no. U1

Part name Board C-MOS IC

80×75×1.6t HD74HC32

Model

Maker

Quantity 1 Renesas Technology Limited 1

U2 U4

C-MOS IC C-MOS IC

HD74HC14 HD74HC08

Renesas Technology Limited Renesas Technology Limited

CN2

Straight type pin header

HIF3FC10PA2.54DSA 10PStraight type male

Hirose Electric co. Limited

1

CN1, 4,5

Pin header

IL-2P-S3EN2 2PStraight Tin plating type male

Japan Aviation Electronics Industry, Limited

3

CN3 SW1 LED1-3 FET1, 3,5,7 FET2, 4,6,8

3P connector Baton switch Light emitting diode FET FET

XG8V0331 B3F-1050 TLR123 Red color 2SJ530(L) 2SK2869(L)

Omron Corporation Limited Omron Corporation Limited Toshiba corporation Limited Renesas Technology Renesas Technology Limited

1 1 3 4 4

RA1

Assembly resistor

M9-1 8element 1common 1kΩ BI Technology Japan Limited

1

R1

Resistor

R2, 3,4,10, 11,12

Resistor

R5, 9

Resistor

R7, 8

Resistor

C1, 3,4,5,7,15

Multi layer condenser

C2

2.2kΩ 1/8W (Red, red, red Every company golden) 10kΩ 1/8W (Brown, black, Every company orange, golden) 1kΩ 1/8W (Brown, black, Every company red, golden) 9.1kΩ 1/8W (White, brown, Every company red, golden) Ceramic

1 1

1 6 2 2

0.1uF

Every company

6

Electrolyze condenser

SMG160E102MJ16S 1000uF/16V

Nippon Chemi-Con Corporation Limited

1

C6

Electrolyze condenser

ESMG100E102MJC5S 1000uF/10V

Nippon Chemi-Con Corporation Limited

1

C9, 10

Ceramic condenser

4700pF

Every company

2

C12

Electrolyze condenser

ESMG160E101ME11D 100uF/16V

Nippon Chemi-Con Corporation Limited

1

Ceramic condenser

0.01uF

Every company

6

L1

Coil

TSL0808S-4R7M3R5-PF 4.7µH/3.8A

TDK

1

TR1-12

Digital transistor

BA1A4M

NEC Nihon Inter Electronics D1 Diode 10E1 1A Corporation Limited Besides, thread solder diameter 0.6mm, 2m levels are necessary though it is not included in the kit.

- 11 -

12 1

Motor Drive Board Assembly Manual

3.2. Parts Mounting Position This is the part-mounting diagram of the board. It is possible to solder while seeing parts table and mounting diagram if one is accustomed to it but there are lot of small parts so match and refer next paragraphs for explanation about mounting.

- 12 -

Motor Drive Board Assembly Manual 3.3. Mounting of Number

Resistor Part name

R1

Resistor

R2, 3,4,10, 11,12

Resistor

R5, 9

Resistor

R7, 8

Resistor

Model Maker 2.2kΩ 1/8W (Red, red, red, Every company golden) 10kΩ 1/8W (Brown, black, Every company orange, golden) 1kΩ 1/8W red, golden) 9.1kΩ 1/8W red, golden)

(Brown, black, (White, brown,

Quantity 1 6

Every company

2

Every company

2

Approx. 5mm 1. First, Resistor is mounted. There are total 11 resistors. It is mounted after confirming the resistor value with the parts table number and resistor value.

2. Wires are bent in such a way that all resistors become of approximately 5mm width as shown in the photo. If it is bent from the root of the resistors, it becomes approximately 5mm. Strength is not applied to the root of the resistor, because the surface of the resistor will break if bent with force.

Note: R6 is not mounted.

- 13 -

Motor Drive Board Assembly Manual 3.4. Mounting of

Diode

Number D1

Part name

Model

Diode

10E1 1A

K

Maker Quantity Nihon Inter Electronics 1 Corporation Limited

A Approx7.5mm

1. Diode is mounted. There is a direction. Component having a white mark is cathode (K). The opposite is anode (A).

2. Lead wires are bent so that approximate width becomes 7.5mm as shown in the photo.

- 14 -

Motor Drive Board Assembly Manual

3.5. Mounting of IC Number U1 U2 U4

Part name C-MOS IC C-MOS IC C-MOS IC

Model HD74HC32 HD74HC14 HD74HC08

1. IC is mounted. There is a specific direction. It is mounted, by matching U shaped dented part of upper side and U shaped part of the board. IC is 74HC32, 74HC08 and 74HC14 from the right side. The shape is same but functions are different. Ensure no mistake is made.

Maker Quantity Renesas Technology Limited 1 Renesas Technology Limited 1 Renesas Technology Limited 1

2. When mounting, whole body is inserted fully inside as shown in c marked photograph. Take care so as not to float as shown in × marked photograph.

U shaped part comes on top

- 15 -

Motor Drive Board Assembly Manual

3.6. Mounting the Multi layer Ceramic Condenser Number C1, 3,4,5,7,15

Part name Multi layer condenser

Ceramic

Model 0.1uF

Maker Every company

1. 6 Multi layer Ceramic condensers are mounted. The blue component bears [104].

Quantity 6

2. As there is no direction for Multi layer Ceramic condenser hence it can be mounted in any direction however, mounting in the direction of [104] simplifies the reading. [104] becomes PF pF 10×104=100,000=0.1µF

- 16 -

Motor Drive Board Assembly Manual

3.7. Mounting of Ceramic Condenser Number C9,10

Part name Ceramic condenser

Model 4700pF

1. The Ceramic condenser is mounted and bears [472].

Maker Every company

Quantity 2

2. As there is no direction for Ceramic condenser hence it can be mounted in any direction, however mounting in the direction that of [472] simplifies the reading. [472] becomes 47×102[pF]=4,700[pF]

- 17 -

Motor Drive Board Assembly Manual

3.8. Mounting of Assembly Resistor Number

Part name

RA1

Model

Assembly resistor

Maker

M9-1 8element 1common 1kΩ BI Technology Japan Limited

1Mark of a pin ▼

Quantity 1

1

2 3456789 1

2

3

4

5

6

7

8

9

1. Assembly resistor is mounted. This is a component of 9 pins. There are directions for Assembly resistor. The one with 1 pin inserted is vertical line.

2. Assembly resistor is a component wherein multiple resistors having same value are entered as common terminal of 1 pin. 2-9 pins become Resistors respectively. Current Assembly resistor has 8 Resistors of 1kΩ entered in it.

The part where [1] is written and the vertical line of assembly resistor are matched /aligned.

▲ 1Mark of pin

- 18 -

Motor Drive Board Assembly Manual

3.9. Mounting of LED Number LED1-3

Part name Light emitting diode

Model TLR123 Red color

Maker Quantity Toshiba Corporation Limited 3

－

＋ － ＋ －＋ －＋ 1. Next, Light emitting diode (LED) is mounted. There are directions for LED. The long lead wire is [+ side] and the short lead wire is [side].

2. The long lead wire is inserted where the [+] is written on the board. When LED is seen from the top view, it is not round but partly flat part. If the flat part is seen carefully, it is as shown in the above photograph. The flat part is used as a marker when the lead wire gets cut and [+] side or [-] side is not understood clearly.

- 19 -

Motor Drive Board Assembly Manual

3.10.Mounting of Digital Transistor Number TR1-12

Part name Digital transistor

Model BA1A4M

Maker

Quantity 12

NEC

Processed 2.5

2.5

ECB 1. Next, 8 Digital transistors are mounted. When seen from the side where number is written, from the left side it is emitter (E), collector(C), Base (B). As E and B are written on the board, it is mounted by matching the directions. It is turned in advance so that the space between mounting support becomes approximately 2.5mm.

2. Digital transistor has built-in Resistor as shown in above figure. BA1A4M has built in resistors of 10kΩ in the Base and in between Base Emitter. There are transistors which have various built-in Resistor values. Power output is changed by adding "0" (0V) and "1" (5V) to the base as well as logic IC, for built in Resistor. Therefore, it is called as Digital transistor. According to the maker, it is also called as transistor with built-in Resistor (it is same).

６個

６個

On this side the model name is written.

- 20 -

Motor Drive Board Assembly Manual

3.11. Mounting of Tact switch Number SW1

Part name Tact switch

1. Next, the Tact switch is mounted.

Model B3F-1050

Maker Omron Corporation Limited

Quantity 1

2. It is soldered after confirming that tact switch comes in contact with the board. There are no directions.

- 21 -

Motor Drive Board Assembly Manual

3.12. Mounting of Bypass Number

Part name Excess lead wire

Model

Maker

Quantity

Process

Approx. 2.5mm 1. Next, bypass is mounted. Lead wire cut with in the parts so far is used. It is processed in this [ コ ] shape with a width of 2.5mm.

2. It is bypassed to the JP1 part. If voltage is less than 6V, then bypassing is done between 2-3. When power supply voltage is more than 6V, then bypassing is done between 1-2 when adding LM350 addition set to 6V by which the voltage of the servo is stabilized. In the photograph, bypassing between 2-3 is shown.

- 22 -

Motor Drive Board Assembly Manual

3.13. Mounting of 3 pins Connector for Servo Number CN3

Part name 3P Connector

Model XG8V0331

1. Next, 3pins connector for servo is mounted.

2.

- 23 -

Maker Omron Corporation Limited

Quantity 1

There are no particular directions. It is soldered as shown in photograph. As compared to other components it cannot tolerate heat, so it should not be heated too much for long time with the soldering iron. This is the part where the connector for the servo is pulled out frequently. hence avoid cold soldering.

Motor Drive Board Assembly Manual

3.14. Mounting of Coil Number L1

Part name Coil

Model TSL0808S-4R7M3R5-PF 4.7µH/3.8A

1. Coil is mounted. It is part bearing L1, of parts mounting diagram.

Maker TDK Limited

Quantity 1

2. There are no particular directions. It is soldered as shown in photograph.

- 24 -

Motor Drive Board Assembly Manual

3.15. Mounting of FET Number FET1, 3,5,7 FET2, 4,6,8

Part name FET FET

Model 2SJ530(L) 2SK2869(L)

1. Next, FET is mounted. There are 4 nose, each of 2SJ530 and 2SK2869. 2SJ530 is mounted on the part where 2SJ is written and 2SK2869 is mounted on the part where 2Sk is written on the board.

Maker Renesas Technology Limited Renesas Technology Limited

Quantity 4 4

G D S 2. From the left riｇｈｔ it is Gate (G), Drain (D) and Source (S). As "G" and "S" are written on the board also, it is mounted by matching the directions.

Note: Gate terminal of MOS-FET has low tolerance for static electricity it should be handled with care.

Note: Cold soldering should be avoided. - 25 -

Motor Drive Board Assembly Manual

3.16. Mounting of FET（for 4AM12) Number

1

Part name FET Module

10

1

Model 4AM12

10

1. FET module; 4AM12, used in motor drive board (Ver.2) can be replaced with 2 2SJ530 and 4 2SK2869. It is necessary to have 2 No.s of 4AM12. 1 pin towards the notch and the opposite side is 10 pins.

10

Maker Renesas Technology Limited

1

10

Quantity 2

1

2. Once it is mounted, it appears as shown in the photograph.

- 26 -

Motor Drive Board Assembly Manual

3.17. Mounting of 2 pins Connector. Number CN1, 4,5

Part name

Model IL-2P-S3EN2 2P straight tin plated type,

Pin header

male

Maker

Quantity

Japan Aviation Electronics Industry Limited.

3

1 1 2

1 2

1

2

As seen from top

2

1. Next, 2 pins connector is mounted. There are 3 brown colored connectors.

2. When seen from top if there is a projection at back, 1 pin is left side and 2 pin is the right side. Utmost care should be taken, in order to have correct mounting direction.

- 27 -

Motor Drive Board Assembly Manual

3.18. Mounting of 10 pins Connector Number CN2

Part name Straight type pin header

Model

Maker

HIF3FC10PA2.54DSA 10P Straight type male

Quantity

Hirose Electric co. Limited

1

2

4

6

8

10

1

3

5

7

9

As seen from top 1. Next, 10 pins connector is mounted.

2. Seeing from Top with the cut part below, 1 pin in lower left, 2 pin in upper left, 9 pin in lower right, and 10 pin in upper right.

- 28 -

Motor Drive Board Assembly Manual

3.19.Mounting of Electrolytic Condenser Number

Part name

Model

Maker

Quantity

C2

Electrolytic condenser

SMG160E102MJ16S 1000uF/16V

Nippon Chemi-Con Corporation Limited

1

C6

Electrolytic condenser

ESMG100E102MJC5S 1000uF/10V

Nippon Chemi-Con Corporation Limited

1

C12

Electrolytic condenser

ESMG160E101ME11D 100uF/16V

Nippon Chemi-Con Corporation Limited

1

C2

C6

C12 ＋

＋ － －

＋

－

＋

＋

1000uF 100uF 10V 1000uF 16V 16V 1. Next, the electrolytic condenser is mounted. There are 3 electrolytic condensers. C2 is [1000µF/16V], C6 is [1000µF/10V], and C12 is [100µF/16V].

＋ 2. There are mounting directions for electrolytic condenser. Long lead wire is plus (+) side. White line is written on the minus side of the main unit of the condenser. It is mounted by matching the plus side of the board with long lead.

- 29 -

Motor Drive Board Assembly Manual

3.20. Completion

After it is completed. The directions are confirmed by repetitively watching for defective soldering and errors in mounting parts. The operation test is carried out as per the operation confirmation manual.

- 30 -

Motor Drive Board Assembly Manual

4. Condenser Mounting in Motor

Note: The wire is removed

1. 6 ceramic condensers are kept ready bearing [103] on them. There is no polarity. [103] becomes 10X103pF=10,000pF=0.01[µF]

2. Finished product of the gearbox is kept ready. Is removed if installed in kit. Wire is also removed. While soldering to the motor high capacity soldering iron (high wattage) is used. Above 60W is OK.

103

90° bend

3. Leg of one ceramic condenser is bent as shown in photograph.

4. The side with straight (not bent) legs is cut at about 6-7 cm.

- 31 -

Motor Drive Board Assembly Manual

Soldering

5. Condenser is soldered as shown in photograph.

6. Side surface of the motor case and the condenser are soldered. The motor case is covered with the oxide coating, and it is extremely difficult to solder on it, hence is cut down using a cutter and sand (emery) paper in order to carry out proper soldering without any difficulty.

Bend at 90° 3 0 1 7. Remaining lead is cut.

8. Leg of one ceramic condenser is bent as shown in photograph.

9. The side having straight (not bent) legs is cut at about 6-7 cm.

10. Condenser is soldered as shown in photograph.

- 32 -

Motor Drive Board Assembly Manual

Soldering 11. Side surface of the motor case and the condenser are soldered. The motor case is covered with the oxide coating, and it is extremely difficult to solder on hence is cut using a cutter and sand (emery) paper in order to carry out proper soldering without any difficulty.

12. Remaining lead is cut.

103

Approx. 17mm 13. Both legs are bent as shown in photograph.

14. Bend in the [⊃] character (shape) approximately at 17mm width.

- 33 -

Motor Drive Board Assembly Manual

4～5mm

15. The lead is cut by about 4-5mm.

16. Soldering is done between motor terminals as shown in the photograph.

17. Finally wire is attached.

- 34 -

Motor Drive Board Assembly Manual

18. Another set is made the same way. 2 sets are prepared.

- 35 -

Motor Drive Board Assembly Manual ● Effectiveness of Ceramic Condenser. 8 batteries are tied serially in driving system of the micom car, and step down voltage of 5V is given by LM2940-5 in control system. Wave forms are observed. PWM of motor is in 100% No Load condition. The noise is ridden not only in the drive system power supply, but also in the control Control system voltage system voltage 5V which 5V consists of 3-terminal regulator. CPU is not reset since it is only about 1µs. However, due to noise if it is reset then the CPU state may Driving system voltages not be consider as abnormal. Even in the state when sensor does not react after lifting the 10V kit somehow it enters the crank mode occasionally. When Noise is mixed in the sensor signal then all white lines are appeared as cross line detection and malfunctioning. Control system voltage

5V

Driving system voltages

10V

Next, the wave forms were observed again by fitting a ceramic capacitor of 0.01µF between terminals of the motor. It is noted that the noise has reduced than before. Also entering in to crank mode does not occur. But still the noise is more.

Next, in addition to the terminal between the motor, a ceramic condenser of 0.01µF was mounted between the terminal and the case. The noise is almost non-existent. The effect is seen. However, PWM is 100% at this time when there is no load condition, so if load is applied and ON/OFF is carried out then it may again differs. Anyway, after fitting up the condenser noise level decrease remarkably.

- 36 -

Motor Drive Board Assembly Manual

5. About the use of 5-8 batteries for having common power supply. 5.1. Power supply configuration of standard kit. In standard kit, power supply system is divided in 2 systems; namely control system and driving system. Precaution is taken so that CPU is not reset regardless of the amount of current consumed on motor servo side. Power supply configuration of standard kit is as shown in following figure.

Right motor

PB

5V PA

CPU board

Motor drive board P7 Left motor

Sensor sub board

5V 5V to servo.

5V

Sensor board

5V

CPU, sensor, motor drive

Driving

board etc. control system

supply for right and left

power supply

motor and servo

4 No. AA battery

system

power

4 No. AA battery

Flow of power supply system is shown in following figure. Motor drive board Sensor Board

5V

Sensor sub

5V

board

CPU board

Control system power supply Driving system power supply

5V

5V

Control

Driving

Right motor

system

system

Left motor

circuit

circuit

Servo

LM2940-5

LM350

5V

Control system power supply

4 nos. AA battery

- 37 -

Driving system power supply

4 nos. AA battery

Motor Drive Board Assembly Manual

5.2. Power supply composition by which the driving system voltage is raised. If voltage of drive system is raised (battery is increased), rotation speed of motor can be raised. If 6 batteries are used for motor power supply, it becomes 7.2V and if 8 batteries are used it becomes 9.6V. However, battery cannot be added because the number of the battery to be used has been determined to be not more than eight. Then, the battery is made common for control system and drive system. Motor does not have problem even with 9.6V but damage is incurred if the CPU voltage-exceeds 5.5V, as certified operating voltage is between 4.5-5.5V. Thus, 3 terminal regulators are attached and the voltage control system of CPU is adjusted to a constant of 5.0V. However, with battery common to motor and CPU, the power consumption is very high and if it is below 4.5V then CPU gets reset. When the battery is shared, precaution must be taken while resetting CPU. When parts of [LM350 addition set]are added, the voltage of 6V or more is used and LM2940-5 generates voltage of 5V that is used by the control system of CPU, and LM350 generates voltage of 6V that is used by the servo. 6V is made with three terminal regulators for the control system 5V and servo.

5.0V

Right motor

PB

9.6V PA

Motor drive board

CPU board P7

＋ LM350 addition set Left motor

9.6V

Sensor sub board 6V to the servo.

9.6V when rechargeable battery is used. 12V in case of alkaline battery.

9.6V

Sensor board 8 common powers Supply batteries

Flow of the power supply system is shown in the following diagram. Motor drive board Sensor Board

5.0V

Sensor sub

5.0V

board

CPU board

5.0V

Control

Driving

system

system

circuit

circuits

5.0V

Control system power supply

LM2940-5

Drivesystem power supply

LM350

9.6V Power supply 8 nos. AA batteries

- 38 -

9.6V 9.6V

6V

Right motor Left motor

Servo

Motor Drive Board Assembly Manual

5.3. Parts List These are parts of the LM350 addition set. Part number

Part name

Model

Maker

Quantity

U3

3 terminal regulator

LM2940-5

National Semiconductor Japan Limited

1

U5

3 terminal regulator

LM350T

National Semiconductor Japan Limited

1

R6

Resistor

240Ω 1/8W (Red, brown, golden)

Every company

1

C8, 11

Multi-layer condenser

0.1uF

Every company

2

VR1

Volume

CT-6P5kΩ

Nidec Corporation Electron Co. Ltd.

ceramic

- 39 -

yellow,

Copal.

1

Motor Drive Board Assembly Manual

5.4. Replacement of Bypass (Installation) Part No.

Part name

Model

Bypass

Maker

Quantity 1

Removed, when in between 2-3

Short-circuited between 1-2 with lead wire

1. Removed, when there is a bypass between 2-3 in the JP1 part.

2. Short between 1-2.

1-2 間を ショート

- 40 -

Motor Drive Board Assembly Manual

5.5. Mounting of Resistor Part No. R6

Part name Resistor

Model Maker 240Ω 1/8W （ Red, Yellow, Every company Brown, Golden）

Quantity 1

Approx.5mm

1. Next, resistor is installed.

2. Lead wire is bent so as to get the width of approx. 5mm as shown in the photograph. If the lead of the resistor is bent from the base of the resistor it becomes approx. of 5mm width. Care should be taken not to apply more strength to the leads as surface of the resistor may crack if leads are bent with force.

- 41 -

Motor Drive Board Assembly Manual

5.6. Mounting of Multilayer Ceramic Condenser Part No. C8, 11

Parts name Multilayer condenser

ceramic

Model 0.1uF

1. 2 Multilayer ceramic condensers are mounted.

Maker Every company

Quantity 2

2. These condensers are mounted on the part where C8 and C11 is written.

- 42 -

Motor Drive Board Assembly Manual

5.7. Installation of Volume Part No. VR1

Parts name Volume

1. Next, volume is installed.

Model CT-6P5kΩ

Maker Nidec Corporation electron Co., Ltd.

Quantity Copal

1

2. It is necessary to adjust the output voltage with the volume before the servo is installed. Servo should not be connected till this is done.

- 43 -

Motor Drive Board Assembly Manual

5.8. Installation of 3 Terminal Regulator Number

Parts name

Model

Maker

Quantity

U3

3 terminal regulator

LM2940-5

National Semiconductor Japan Limited

1

U5

3 terminal regulator

LM350T

National Semiconductor Japan Limited

1

LM2940-5

LM350

1

2

3

1

2

3

1. Next, 3 terminal regulator is installed. IC bearing [LM2940-5] and [LM350]. When it is seen from the side where the characters are written, left is 1Pin and right is 3 Pin.

2. There are directions for 3 terminal regulators. Fit Pin 1 to the place where 1 is written on the board. It is OK, when mounted as per the photograph. Servo is not yet connected!!

LM2940-5

LM350

- 44 -

Motor Drive Board Assembly Manual

5.9. Voltage Adjustment Mounting of parts is complete.Repeated visual inspection for any soldering defect, installation of parts and confirm the directions of mounting. Next, servo voltage is adjusted by volume. 10 pin connector and the Servo are not yet connected!!

1. Voltage is added to the power supply connector without inserting the connector in the servo and 10 pin connector. More than 6 batteries are connected in the series.

2. First of all, it is checked whether or not 5V of control system generated with LM2940-5 has a normal output. While having the tester in the voltage measurement mode, + side to 1 Pin and – side to 10 Pin of the 10 pin connector is assigned.

Black, (-) side of tester

2

4

6

8

10

1

3

5

7

9

Place, seen from above.

Red, (+) side of tester

3. Care should be taken so as, not to touch the pins other than pin 1 and pin 10.

4. Voltage within the range of 4.75-5.25V(5V±5%), is normal. Check whether input voltage is above 7V, when voltage is low, and for wrong mounting of the component or short circuit when voltage is high.

- 45 -

Motor Drive Board Assembly Manual

5. Next, the voltage of the servo is checked. In 2 Pin of the CN3 connector, connect the Red side of the tester to (+) side of the CN3 connector and Black side of the connector to (-) side of the CN3 connector. Be careful so as not to touch 1 pin.

Voltage lowers

6. Voltage is 9.53V. If the Servo is connected as it is, it gets damaged. Voltage is adjusted by the volume.

Voltage rises

7. Voltage is adjusted by VR1. Voltage increases by the clockwise rotation and decreases by anti-clockwise rotation.

8. Voltage becomes 6.0V by adjusting it by volume. Adjust according to the servo to be connected because ratings are as per the servo. Servo having the rating 7.2V or voltage rating other than this is also available. Here, adjustment of the servo voltage is completed.

- 46 -

Motor Drive Board Assembly Manual

6. Kit Installation

1. Assembled drive board 3 is installed in the kit. Drive board is placed by matching the hole of the board and Stud of the kit.

2. Kit is kept.

3. Fixes with the screw from the kit in 4 places.

- 47 -

Motor Drive Board Assembly Manual

To CPU board port B

10 Pin connector

Power supply

Servo

Left motor

Right motor

4. Connector is connected to the board and is completed. * Check whether moves normally [Operations Confirmation Manual]. * Understand control program from [Program description manual]. * Write the program in the micro car and run the program.

- 48 -

- 49 -

Power supply

For drive force

Power supply circuit

From CPU port PB

10 Pin connector

Push switch

Right motor

Right motor “0” ´Normal rotation “1” ´ Reverse Rotation

Left motor “0” ´Normal rotation “1” ´ Reverse Rotation

Left motor

Servo

Switch, LED

Servo

FET gate signal delay circuit

UP: When directly connected to power supply DOWN: When 3 terminals are used

Right motor

Left motor

Microcomputer car rally Executive Committee Motor drive board circuit (Vol.3) circuit diagram

Motor Drive Board Assembly Manual

7. Circuit Diagram

Motor Drive Board Assembly Manual Note: U3, U5, R6, VR1, C8 and C11 are components of LM350 addition set and C13, C14 are not mounted. (Motor value added)

- 50 -