We are dancing mechanic

Just as I've started thinking about making a board for a Raspberry Pi based robot, someone goes and makes the mother of all robotics boards - the Gertboard. Curse you Gert Van Loo! Actually it's a very nice piece of kit, but it's bigger and more expensive than the Raspberry Pi itself, and I don't think it's really what I want. It's given me a few ideas though.

Some circuitboards, yesterday

The most powerful component on the Gertboard is the Atmel AVR microcontroller, which is the same chip that's at the heart of the Arduino, but it seems like overkill for my purposes. Do I really need a microcontroller on the robot when I've got a Raspberry Pi sitting next to it? It's cheap, and looks like it's got on-chip D/A converters so I could probably use it to drive the motors with variable speeds, but if I wanted that I could do it more simply and cheaply with my own circuit.

The Gertboard manual suggests that you can vary speed with pulse-width modulation (PWM), but the problem is that the Raspberry Pi only has one part-time PWM output and the switching on the GPIOs isn't fast enough for me to do botched up PWM on those. Maybe one PWM output is enough though - rather than connecting four GPIOs to the motor controller inputs, use the GPIOs to gate the PWM input - yeah, that'd work.

I'd been looking at a separate motor controller board, but wouldn't it be neater and cheaper to put a controller chip on my own board? The Gertboard has an L6203, but that's more expensive than the controller board, is specced way beyond what I need, and only has one channel whereas I'd like two. I'll have to look around and see if I can find the same IC that's on the controller board, or something similar. Would PWM work with the motor controller? Gert reckons it will with his board, and who am I to argue?

Wearing a bra on your head while working on geek
projects turns them into Kelly LeBrock. That guy
should know, he's Iron Man FFS.

Now I'm trying to remember the circuits to do some of these things, but I've forgotten pretty much all of the analogue electronics I learnt at college. Thankfully the intaweb is helping to jog my memory a bit. If I do want variable speed, gating a PWM signal should just be AND gates so that's easy. But I'll probably want something to convert that to a stable DC analogue voltage, which is... an integrator? Can the motors take a PWM input? The GPIOs are 3.3V and the motors take 6V, so I need to step that up and be able to supply up to 2A for each motor. An OP-AMP with positive feedback isn't going to supply enough current so I'll need a hefty power transistor in there... whaddya know, I just re-invented the Low drop-out regulator... Is there an off-the-shelf LDO which lets you provide a variable reference voltage? That's basically what's in a motor controller, so I've come full circle - might as well just get one of those.

As I'm so out of practice with boards I'm a bit apprehensive about doing a complicated board in one go. It's tempting to do a smaller board first, or at least do a larger board in phases and test it between each phase. Just getting battery power to the RPi via a switching regulator would be a good start and confidence boost. At the very least I've got to start getting some schematics drawn up, not worry about exact capacitor values or board layout yet, but just start turning the morass of nebulous ideas into something a bit more coherent.

Whatever I do with the robot, it's going to need some software so that's where I'm spending my time at the moment. I'm trying my hand at cross-compiling as it's going to be faster than compiling on the RPi itself, and it's also harder than a native compile so more interesting. As I've been playing with DOSBox recently I downloaded the source for that, got the Raspbian toolchain and... wait a minute, where's the Makefile? There's a Makefile.am and a Makefile.in, what're they? Turns out they're for the GNU Autotools, which I've never used before.

Learning how to use those and how to cross-compile was a bit much to take on in one go so I took a step back and started with "Hello world". Once I'd mustered the presence of mind to write 5 lines of code which actually compiled natively, I'd got the right toolchain for compiling C++ from Ubuntu to the Raspberry Pi (g++-arm-linux-gnueabihf seems the best bet), and I'd sorted out the libraries, I got an executable which I FTP-ed over to the RPi, SSH-ed in, ran the executable, aaaand.... segmentation fault, my old friend. Next time my "Hello World" is just going to print "Segmentation Fault" so it'll look like it worked whether it did or not. It's barely worth opening up gdb, with a program that simple it's going to be a linking issue so it's probably just a matter of getting the right options in the makefile.

In other news, I've continued getting things to work on DOSBox. Speedball 2 works very nicely, it sounds absolutely awful but early PC games always did. I got UFO: Enemy Unknown working briefly but it was very slow and after I'd faffed about with the config it stopped working. It looks like I should give up on protected mode games until protected mode is improved, which it probably never will be, or DOSBox starts using SDL 2.0 with its improved use of OpenGL. And it seems that others are having much more luck with MAME than I did on my half-arsed attempt, so maybe I'll give it another go one day.

Domo Arigato, Mr Roboto

I apologise if my first post was incomprehensible to non-technical people. I did try, but it's not easy to accommodate an audience ranging from university Electronic Engineering lecturers to drama graduates - I'm torn between getting lost in jargon and getting bogged down explaining what things like SSH are. I suppose I could provide some hyperlinks?

When I ordered a Raspberry Pi I was told I'd have a six week wait, but against expectations I got it 10 days later. The trouble is that I ordered parts with long lead times, thinking they'd still turn up before the RPi, and a lot still hasn't turned up. Two key components are missing - a power supply and an HDMI-DVI adaptor. I think I can use my iPad charger temporarily, and get by with composite video to our aging telly, but I've not had time to try yet due to spending the last couple of days being ill and a dad.

Ooh I see evil...

I've been thinking some more about a robot project, though at this stage it's still about checking feasibility and costs without too much detail. The RPi will be the heart of it, connected by the GPIOs to an off-the-shelf motor controller, possibly via something to protect the RPi, that much is straightforward. As I see it there are two main problems to solve: connectivity and power.

The robot needs to provide some kind of remote access to the RPi for a telnet or ssh session, and preferably a fast enough link to send back real-time lo-res video. Wi-fi seems like an obvious choice for this but the RPi isn't designed to support most USB Wi-Fi dongles without a powered hub. It's designed for "low-power" devices, taking no more than 100mA - the "unit load" in USB 2.0. The polyfuses used on the USB ports are rated at 140mA, and they have quite a bit of resistance so at high currents the voltage supplied can drop significantly below 5V. You can perform what's called a PiPass, short-out the fuse with a small resistor, but I'd rather not solder stuff directly to my RPi if I can help it and reckon fuses are generally added for a good reason. So my options are:

1. Find a Wi-Fi dongle which draws less than 140mA, can tolerate a supply drop of about a volt, and has a linux driver compatible with the RPi's ARM processor.
2. Use a Y-cable to connect to both USB ports.
3. Feed external power into the Wi-Fi dongle.
4. Use a different type of connection.

Would a low-power dongle compromise on range and signal strength, so drop-out more easily? I'm yet to find one which I'm certain will work. I recall reading somewhere that Y-cables violate the USB spec and I'd kinda like having the other port available, so I'm leaning towards option 3. What's needed is effectively a mobile 1-port powered USB 2.0 hub. Could I put together something which supplies the power without knackering the signal integrity of the data lines? As the data lines are a twisted pair I guess they're completely independent of the power rails, but is the shielding connected to ground? Though it should be a short trip from the RPi's USB port, over a cable which is maybe 10cm long to a new port, at 480 MBit/s does it still have to be treated as a transmission line with matched impedance? Perhaps I'm just being paranoid and it'll be a cinch, but I'd better dig out the spec to answer some of these questions.

Ideally everything would be powered off a single battery pack. The RPi can be powered over GPIO, it needs a steady 5V supply and can draw up to 1.2A. The motors I'm looking at each take 6V and have a 360mA stall current, and that's just for the low power versions - HP ones stall at a whopping 1.8A, though if I could provide that the extra speed/torque would be tempting (200cm/s? Practically light speed). Power also needs to be provided for the motor controller and connectivity in whatever form it might take. Will four AA batteries be up to the task? Rechargeables can do about 2500mAh, I doubt I'd get much more than an hour out of them even if the power were consumed really efficiently, but it'd depend on how much work the RPi was doing and how much the motors were moving. As a battery drains its voltage can vary quite significantly, so I'll have to use regulators and if I do that I might as well go with something mightier and step it down to the right voltage(s).

So I'm looking at putting together a custom board to do those things. Though I might be able to get away with one voltage regulator, I expect I'll need two - one giving me 5V for the RPi and the extra USB power, the other giving me 6V for the motors and controller. The RPi will need a switched supply to keep a nice, steady voltage, I might get away with a linear regulator for the motors but if there's a controller on the same circuit I'd have to check that could take a voltage drop, and a switched supply would be more efficient, helping prolong the battery life. I'd also like to detect when the battery voltage is getting low so I can cut off the motor power, with luck keeping the RPi up long enough to shut down cleanly.

Making a board like that should be well within my abilities. At college our end of year one project was to make a switch-mode power supply, and though IIRC I only got a C that was pretty good for the marker I had. That was running off the mains, so it had a step-down transformer and rectification which I wouldn't need for this project where it'd be DC-DC. My worry is that as I've gravitated towards digital electronics I've learnt a lot of theory but not really had much experience with boards or more practical considerations like impedance matching, decoupling capacitors, etc. Still, half of the point of this project would be to re-acquaint myself with all that stuff.

Once I've recalled enough of my college education to pick the right resistor and capacitor values, I'll just need a stack of soldering kit, bit of Veroboard™ and a bunch of components, just like the good ol' days. Then I need some time to spend on it. If Micro Men is to be believed Steve Furber single-handedly soldered the Acorn Proton prototype overnight, but the guy's a god among men. Still, once I've finalised the design I should be able to put it together in a couple of hours I reckon.

I'm also wondering how to make it more than just an over-complicated RC car. It'd be good to add a camera, even if that proved to be no more useful than helping me find things I'd stored under the bed. It'd be really good if the robot could process the images and do its own path-finding, but creating a model of the world off a single camera is pretty hard. I could add a pump and a bag for the world's smartest Roomba™? That reminds me - anti-stair sensors might be an idea as that's how my BigTrak met its demise...


Finally, I was thinking about naming the robot. For some reason "Harvey" sprang to mind immediately, I've no idea why. It'll be a wall-banger of sorts I guess. I also like "Joey", after the robot from Beneath a Steel Sky who starts the game as a small card and gets inserted into different chassis as the plot progresses. There's also "Nigel", the robot from Gozilla: The Series who gets destroyed every episode. Any other suggestions welcome.