rover_wiring_standard.docx

ROVER WIRING STANDARD

Wire Identification & Annotation Guide

This document defines the standard for identifying, labelling, and tracking every wire in the rover. All team members must follow this standard when adding wires to the wire register spreadsheet or physically labelling harnesses.

1. Wire ID Format

Every wire has a single unique ID that encodes its type, system, route, and destination connector. The format is:

[NUM]-[TYPE]-[SYS]-[FROM]-[TO]-[CONN]

Example:

201-P-DRV-PWB-SPL-RKL

Power wire #201 in the Drive system, from the Power Board to the Splitter, plugging into the RKL connector.

Segment Values Meaning Example

NUM 101--999 3-digit wire 201 number; grouped by
system (see legend)

TYPE P or D P = Power wire | D P = Data / signal
wire

SYS 3-letter System the wire DRV code belongs to

FROM 3--5 letters Abbreviated source PWB device (silkscreen
preferred)

TO 3--5 letters Abbreviated SPL destination device

CONN Silkscreen Connector label on RKL text the TO device being plugged into

2. Wire Numbering

The 3-digit number groups wires by system so any number immediately identifies its domain. Numbers are assigned sequentially within each range as wires are added to the register.

Range Code System Devices

100 PWR Power BMS, Fuse, Kill Switches, Power Board, Buck Converters, Fans

200 DRV Drive Splitter, Brushless Controllers, Drive Motors, Rocker, Headlights, Switches

300 COM Communications Jetson, Raspberry Pi, Network Switch, USB Hub, CANable, POE, Antenna, GPS, UART Board, Pantilt

400 ARM Arm Arm PD, Arm Box, Arm Brushed, ESCs, Motors, Encoders, Limit Switches, ToF, Laser

500 SCI Science Science-Arm board

600 --- (reserved)

700 --- (reserved)

800 --- (reserved)

900 --- (reserved)

Ranges 600--900 are reserved for future systems. Do not use them without updating this document first.

3. Wire Type Flag (P / D)

The single letter after the wire number identifies what the wire carries:

P --- Power wire: carries voltage to supply a device (24V, 12V, 5V rails, motor power).
D --- Data wire: carries a signal (CAN, USB, Ethernet, UART, PWM, encoder, sensor).

If a cable physically bundles both power and data (e.g. a servo cable with signal + supply), treat it as P and note the signal type in the Notes column of the register.

4. Device Abbreviation Dictionary

Use these 3-letter codes for the FROM, TO, and CONN segments. Silkscreen names are preferred over J-numbers because they are self-describing. Where the silkscreen is longer than 5 characters, the abbreviated form below is used in the Wire ID; the full silkscreen text is stored in the End Connector column of the wire register.

Code Silkscreen Board / Device System

PWB Power Board Power Board PWR

BMS BMS Battery Management PWR Sys.

FUS Fuse Fuse PWR

MKS Kill Switch MKS Kill Switch (MKS) PWR

SKS Kill Switch SKS Kill Switch (SKS) PWR

BK1 Buck 24→12V Buck Converter PWR 24→12V

BK2 Buck 24→5V Buck Converter 24→5V PWR

FAN Fans Fans PWR

SPL Splitter Drive Splitter Board DRV

BRL Brushless L Brushless Ctrl DRV (Left)

BRR Brushless R Brushless Ctrl DRV (Right)

BRF Brushless F Brushless Ctrl DRV (Front)

MOL Drive Motor L Drive Motor (Left) DRV

MOR Drive Motor R Drive Motor (Right) DRV

MOF Drive Motor F Drive Motor (Front) DRV

RKL J17 Rocker L Rocker Switch (Left) DRV

RKR J18 Rocker R Rocker Switch DRV (Right)

HD1 Headlight 1 Headlight #1 DRV

HD2 Headlight 2 Headlight #2 DRV

HD3 Headlight 3 Headlight #3 DRV

SWT Switches Switches (J23 RKS) DRV

JET Jetson J6 Jetson COM

RPI RBPi ARM J7 Raspberry Pi COM

HAT Pi Hat Raspberry Pi Hat COM

NSW Network Switch Network Switch COM J8

HUB USB Hub USB Hub COM

CAN CAN J27 CANable COM

POE POE POE Injector COM

ANT Antenna J10 Antenna COM

GPS GPS1 / GPS2 GPS Unit COM

URT UART UART Board (Sonia) COM

PAN Pantilt Pantilt Assembly COM

PIT Pitch Servo Pitch Servo COM

YAW Yaw Servo Yaw Servo COM

TOC ToF sensor ToF Sensor (Pantilt) COM (Pantilt)

APD Arm PD Board Arm PD Board ARM

ABX Arm Box Board Arm Box Board ARM

ABR Arm Brushed Arm Brushed Board ARM Board

ESE Elbow ESC Elbow ESC ARM

ESS Shoulder ESC Shoulder ESC ARM

ESW Waist ESC Waist ESC ARM

GRM Gripper Motor Gripper Motor ARM

WPM Wrist Pitch Wrist Pitch Motor ARM Motor

WRM Wrist Roll Motor Wrist Roll Motor ARM

GRE Gripper Encoder Gripper Encoder ARM

WPE Wrist Pitch Wrist Pitch Encoder ARM Encoder

WRE Wrist Roll Wrist Roll Encoder ARM Encoder

LS1 Limit Switch 1 Limit Switch 1 ARM

LS2 Limit Switch 2 Limit Switch 2 ARM

LSG Limit Switch Limit Switch ARM Gripper (Gripper)

TOA ToF sensor (Arm) ToF Sensor (Arm) ARM

LAS Laser Laser ARM

SCA Arm/Sci J22 Science-Arm Board SCI

When adding a new device, choose a 3-letter code not already in this table, add it here, and update the wire register legend sheet before assigning it to any Wire ID.

5. Wire Register Spreadsheet

5.1 Column Definitions

The wire register is the single source of truth for all wiring. Each row is one wire. The columns are:

Column Example Column Example

Wire ID 201-P-DRV-PWB-SPL-RKL End 2 --- Device Splitter

Description Power board to splitter End 2 --- RKL Connector

System DRV Length TBD

End 1 --- Device Power Board Gauge (AWG) TBD

End 1 --- J17 Harness ID H-DRV-01 Connector

Wire Colour Red Status DRAFT

Notes

5.2 Status Values

Every wire must have a status. Never leave it blank.

Status Meaning

DRAFT Wire identified in diagram; length and gauge not yet confirmed

MEASURED Physical length measured; gauge selected

MADE Wire cut, crimped, and labelled

ROUTED Wire physically installed in rover

COMPLETE Wire tested and verified end-to-end

5.3 Harness IDs

Wires that are physically bundled together in the same sleeve or conduit share a Harness ID. Format: H-[SYS]-[NN], e.g. H-ARM-01. A single wire with no bundle leaves the Harness ID blank. The harness grouping does not affect the individual Wire ID.

6. Rules & Edge Cases

Wire IDs are permanent. Once assigned and entered in the register, never change a Wire ID even if the wire is re-routed. Update the description and device columns instead.
No blanks in Wire ID, Type, System, or Status. Use TBD for Length and Gauge when not yet known.
Cross-system wires use the source system code. A power wire going from PWB to a drive splitter is P-PWR, not P-DRV.
Connector names with spaces: remove the space and run the words together or use only the most distinctive word (e.g. 'CAN J27' becomes CAN, 'GPS + PanTilt' becomes GPS).
Two wires between the same devices on different connectors: they will naturally differ in the CONN segment (e.g. 201-P-DRV-PWB-SPL-J1 vs 202-P-DRV-PWB-SPL-J2). No suffix needed.
Physical wire labels: print or write the Wire ID on both ends of every wire, as close to the connector as possible.

7. Quick Reference

[NUM]-[TYPE]-[SYS]-[FROM]-[TO]-[CONN]

Real examples from this rover:

101-P-PWR-BMS-FUS-IN BMS output to fuse

201-P-DRV-PWB-SPL-RKL Power board J17 to splitter

301-D-COM-PWB-CAN-J27 Power board CAN to CANable

401-P-ARM-PWB-APD-PWR Power board to Arm PD board

402-D-ARM-ABR-GRM-IN Arm brushed board to gripper motor

501-D-SCI-PWB-SCA-J22 Power board Arm/Sci to science board