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Operating Procedures

This section outlines the systematic procedures used by the FEDS 201 Electrical Subgroup to ensure reliable robot operation from build season through competition.

🔍 Pre-Competition Inspection Protocol

Our comprehensive inspection protocol ensures that all electrical systems meet FRC standards and will perform reliably under competition conditions.

Battery and Power Distribution Inspection

Battery Assessment

  1. Voltage Measurement

    • Minimum acceptable: 12.0V under no load
    • Optimal range: 12.4V - 12.8V
    • Record voltage and timestamp

  2. Capacity Testing

    • CCA rating verification: 280-300 CCA on SEAL/SAE setting
    • Load test at 200A for 10 seconds (voltage should stay >10.5V)
    • Internal resistance measurement if available

  3. Physical Inspection

    • Terminal corrosion check and cleaning
    • Case integrity and vent cap security
    • Electrolyte level (if serviceable type)

Power Distribution Hub (PDH)

  1. Connection Verification

    • All power connections torqued to specification
    • Wire gauge appropriate for current rating
    • No signs of overheating or discoloration

  2. Fuse/Breaker Testing

    • Visual inspection for cracks or damage
    • Continuity testing when possible
    • Proper amp rating verification

  3. Voltage Rail Testing

    • 12V main rail under load
    • 5V regulated output (4.75V - 5.25V)
    • 3.3V regulated output (3.15V - 3.45V)

🔧 Competition Day Pit Procedures

When the robot enters the pit area, systematic procedures ensure rapid diagnosis and resolution of any issues.

Initial Assessment Protocol

Step 1: Power Isolation and Safety

1. Disconnect main battery IMMEDIATELY
2. Verify all stored energy is discharged (capacitors, pneumatics)
3. Engage mechanical locks/supports if robot was moving
4. Document time of pit entry and initial conditions

Step 2: Issue Documentation Record all reported problems from drive team:

  • Power Issues: Complete loss, intermittent loss, brownout conditions
  • Control Issues: Unresponsive subsystems, erratic behavior
  • Communication Issues: Driver station disconnects, sensor dropouts
  • Mechanical Issues: Unusual sounds, vibrations, binding

Step 3: Priority Assessment Categorize issues by impact on robot functionality:

  • Critical: Prevents robot operation (power, safety systems)
  • Major: Reduces robot capability (drive, key mechanisms)
  • Minor: Cosmetic or redundant system issues

Systematic Diagnosis Procedure

Power System Diagnosis

Complete Power Loss

  1. Battery Check

    • Voltage measurement (should be >11.5V)
    • Connection security at terminals
    • SB connector inspection and cleaning

  2. Main Breaker

    • Visual inspection for damage
    • Operation test (on/off cycling)
    • Connection torque verification

  3. PDH Inspection

    • LED status indicators
    • Connection security
    • Signs of overheating

Partial Power Loss

  1. Individual Circuit Testing

    • Fuse continuity testing
    • Load isolation testing
    • Wire harness inspection

  2. Load Analysis

    • Current draw measurement
    • Comparison to baseline values
    • Thermal imaging if available

Brownout Conditions

  1. Battery Load Test

    • Voltage under simulated load
    • Internal resistance calculation
    • Capacity verification

  2. Connection Resistance

    • Voltage drop measurements
    • Connection torque verification
    • Corrosion inspection and cleaning

🔄 Repair and Maintenance Procedures

Connector Repair Procedures

Damaged Connector Housing

  1. Assessment

    • Evaluate extent of damage
    • Determine if repair or replacement needed
    • Check availability of replacement parts

  2. Repair Process

    • Cut damaged connector from wire
    • Strip wire to appropriate length
    • Crimp new terminal (follow connector-specific procedures)
    • Insert terminal into new housing
    • Verify proper engagement and retention

  3. Testing

    • Continuity verification
    • Insertion/retention force testing
    • Connection security under vibration

Wire Damage Repair

  1. Minor Damage (Insulation Only)

    • Clean damaged area
    • Apply appropriate insulation (heat shrink preferred)
    • Verify no conductor damage
    • Test for proper insulation resistance

  2. Major Damage (Conductor Affected)

    • Cut out damaged section
    • Strip wire ends appropriately
    • Solder connection with proper flux
    • Apply heat shrink insulation
    • Verify electrical and mechanical integrity

  3. Complete Wire Replacement

    • Remove old wire completely
    • Install new wire of same gauge and type
    • Route properly with strain relief
    • Test all connections thoroughly

Emergency Repair Procedures

Time-Critical Repairs (< 15 minutes)

  • Use pre-made patch cables when possible
  • Apply temporary insulation with electrical tape
  • Use quick-connect terminals for rapid connections
  • Document all temporary repairs for later permanent fix

Competition-Legal Temporary Fixes

  • Wire nuts for conductor splicing (where accessible)
  • Electrical tape for insulation (temporary only)
  • Zip ties for strain relief
  • Wagos for quick connections (where appropriate)
⚠️

Temporary Repair Policy: All temporary repairs must be replaced with permanent solutions at the earliest opportunity. Temporary repairs are only acceptable when they maintain safety and do not violate FRC rules.

📊 Quality Assurance and Testing

Post-Repair Verification

Electrical Testing

  1. Continuity testing of all connections
  2. Insulation resistance verification
  3. Proper voltage levels under load
  4. Current draw comparison to baseline

Functional Testing

  1. System operation verification
  2. Performance comparison to specifications
  3. Integration testing with other subsystems
  4. Stress testing under competition conditions

Documentation Requirements

  1. Record all repairs in maintenance log
  2. Update wiring diagrams if routing changed
  3. Note any deviations from standard procedures
  4. Schedule follow-up inspections if needed

Preventive Maintenance Schedule

Daily (During Competition)

  • Visual inspection of all connections
  • Battery voltage and capacity check
  • RSL functionality verification
  • Major system operational check

Weekly (During Build Season)

  • Detailed connection inspection and retorquing
  • Wire routing and strain relief verification
  • Comprehensive system performance testing
  • Documentation update and backup

Monthly (Off-Season)

  • Complete system teardown and inspection
  • Connector replacement schedule
  • Wire harness refurbishment
  • Component inventory and restocking
📋

Inspection Documentation: All inspections and maintenance activities must be recorded in the robot’s electrical logbook with date, inspector name, findings, and actions taken.

Competition ResourcesStandards & Specifications