Dual CANbus monitor and instrumentation cluster

Eagle Schematic and Board design

/media/uploads/TickTock/canaryr5.zip

/media/uploads/TickTock/sch_r4.jpg /media/uploads/TickTock/lcdsch.jpg /media/uploads/TickTock/brd_r4.jpg

Parts List

qtyinstancepart #packagesupplierDescription
1BAT3Vhttp://www.ebay.com/itm/10x-CR2032-SMD-Battery-Holder-for-CR2032-Battery-/180938057979?pt=LH_DefaultDomain_0&hash=item2a20bfa8fbLithium 2032 coin battery holder
4C1-C4ECST1DC106R6032Tantalium capacitor 10uF
3FC1-FC3ZF1-20-01-T-WThttp://www.samtec.com/cable-systems/idc-ffc/ffc/zero-insertion.aspx20 conductor 1mm pitch flex cable connector (optional)
1FJ-20-R-08.00-4http://www.samtec.com/cable-systems/idc-ffc/ffc/zero-insertion.aspx8\" 20 conductor 1mm pitch flex connector, end reversed (optional)
2H1-H4(DON'T populate H1-H4 headers - solder mbed directly)
1H5http://www.ebay.com/itm/221186042943?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l26491x12 .1\" pitch header (optional)
1H62x6 .1\" pitch header (optional)
2IC1,IC2VP230LMDSOP8http://www.ebay.com/itm/130488665247?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649canbus transciever
1IC3LM1117-5VSOT2235V regulator
5JP*2 pin .1\" jumper header
1mbedLPC1768http://www.ebay.com/itm/200830573509?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649mbed uC
2Q1,Q22N2222SOT23General purpose NPN transistor
1R1R392M12063.9K resistor
4R2,R4-R6R102M12061K resistor
1R3R500M120650 Ohm resistor
2TR1-TR5ZJYS81R5-2PL51TG01http://www.digikey.com/product-detail/en/ZJYS81R5-2PL51T-G01/445-2223-1-ND/765232CM Choke
1Z11N5340BGC1702-15http://www.ebay.com/itm/150878122425?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l26496V, 5W Zener Diode
1X1USBhttp://www.ebay.com/itm/New-Vertical-USB-2-0-A-pcb-connector-socket-USB-A-Type-/300553895292?pt=LH_DefaultDomain_0&hash=item45fa687d7cvertical USB connector
2LCD0,LCD1TFThttp://www.mikroe.com/add-on-boards/display/tft-proto/320x240 LCD with touch screen

Assembly

1) LCD Displays

I found ribbon cable is a nice way to organize the wires to the displays. You'll need 12 conductors and I connected them in the following order:

1LED+
2LED-
3RSTB
4MOSI
5SCLK
6CSB
7X+
8X-
9Y+
10Y-
11VDD
12GND

First I connected all the GND connections (IM0, IM1, IM3, & 2 GND). Do not connect the bottom GND until you have the ribbon cable connected. After making all the ribbon cable connections (connecting the GND of the ribbon cable to the bottom GND pad), solder the GND bar from the previous step to the back of the bottom GND connection. Finally, make a connection from the back side 3.3V pin to IM2. Take a break and repeat for the second display. /media/uploads/TickTock/lcdtop.jpg /media/uploads/TickTock/lcdbot.jpg Once the two displays are complete combine all wires except CS0, CS1, X+, X-, Y+, and Y-. Connect X- of the left display to X+ of the right. Similarly connect Y- of the left display to Y+ of the right. Insulate any exposed wires.

2) PCB

Refer to the schematics to place all the components on the board. If you plan to install into the CANary 3D enclosure, DO NOT install the battery holder or the socket for the mbed and, instead, connect two wires to the VB and GND pads nearby. You will have to install the battery holder against the back wall to avoid interfering with the right-hand display and the mbed will have to be directly soldered. I have not found a socket with a low enough profile to fit in the space provided (depth of enclosure is limited by the space behind the center console). Also, I recommend keeping as much lead as possible on the Zener diode (bending it as shown to clear the back wall). Although it is operating well within parameters, the Zener gets quite hot during extended operation and the leads help dissipate the heat and keep it away from the PCB and other components.

/media/uploads/TickTock/pcbtop.jpg /media/uploads/TickTock/pcbbot.jpg

Once the PCB is populated, solder the LCDs to the PCB. CS0 connects to the right display and CS1 connects to the left. /media/uploads/TickTock/brddis.jpg

3) Testing

1)First step is to buzz out all connections from the LCDs to the pins in the main board
2)Next check the touch screen connections. On the main board, place an Ohm meter across X+ and X-. You should read 700 Ohms. Repeat for Y+ and Y-. Then test the resistance from X+ to Y+. With nothing touching the screens, it should read >100K Ohms and <1K when touching either screen.
3)When all connections are checked, solder in the mbed. Download and install the touch2 program http://mbed.org/users/TickTock/code/touch2/ to test the basic operation of the mbed and touch screens.
tips:
Touch screen is sensitive - excess flux on X+,X-,Y+,Y- connection on mbed can result in flakey operation
If touch is not working, double-check the LCD0_CS and LCD1_CS are not swapped. LCD0_CS must connect to the CS of the LCD that has X- & Y- connected to the mbed. LCD1_CS must connect to the CS of the LCD that has X+ & Y+ connected to the mbed.
4)Once touch2 works, it is time to connect to the OBD connector. I highly recommend double checking all connections from the OBD to the PCB with the cable in place before connecting to the Leaf. Buzz out all the pins in the OBS to make sure none are shorting to each other, Check that the 12V goes to the Zener (and nothing else) and the switched 12V to the resistor divider (and nothing else). Test the ground connection properly connects to ground and nothing else.
5)Once you are confident there are no shorts or wrong connections from the OBD connector, take a deep breath and plug it into your leaf. Touch2 program should come up and function. Unplug and install the latest CANary firmware. Test all features before installing into the enclosure (gids, cellpair, menu system, logging) since installing and removing from the enclosure is a PITA.

/media/uploads/TickTock/pcbdone.jpg /media/uploads/TickTock/functioning.jpg

4) Enclosure

The 3D printer leaves a lot of powder behind - I used a strong spray of water to get it out of all the cracks. The enclosure comes with a rather rough finish. I recommend convincing yourself you like it, then simply lightly sand then paint before assembly. Sanding is very difficult - the nylon is very nicely fused and doesn't want to sand. I tried sandblasting and that didn't work either. I had some limited success with filler and then sanding, but only on the outside - it is too difficult to sand the face.

5) Final Assembly

Revision:
69:6bfdfc002036
Parent:
65:2022fce701d0
Child:
70:0700b769ac15
--- a/main.cpp	Thu Apr 11 18:52:12 2013 +0000
+++ b/main.cpp	Sun Apr 14 01:21:11 2013 +0000
@@ -45,6 +45,11 @@
 PwmOut dled(p23);
 Beep spkr(p21);
 
+// revision string, max 6 characters
+//char revStr[7] = "65"; // gg - revStr is used in 2 places
+//char revStr[7] = "65-gg1"; // gg - and is easy to edit here
+char revStr[7] = "65-gg2"; // gg - ZeroSecTick
+
 bool logEn = false, logOpen = false; 
 bool yesBattLog = false ; // gg - Batt Log
 unsigned char tNavRow = 3 ; // gg - 4x4 touch
@@ -79,6 +84,7 @@
 bool repeatPoll = false;
 bool headlights = false;
 bool tick = false;
+bool ZeroSecTick = false;
 float ledHi = 0.8; // Bright LED value (until config file read)
 float ledLo = 0.1; // Dim LED value (until config file read)
 unsigned short pollInt = 300; // polling interval=5 minutes (until config file read)
@@ -154,14 +160,15 @@
     }
     t = *localtime(&seconds) ;
     strftime(sTemp, 32, "%a %m/%d/%Y %X\n", &t);
-    logMsg(sTemp);
+    logMsg(sTemp); // record RTC
     
     // revision
     //sprintf(sTemp,"CANary firmware rev62\n"); // wrong rev, should be rev63
     //sprintf(sTemp,"CANary firmware rev64\n");
     //sprintf(sTemp,"CANary firmware rev64-gg1\n"); // gg - adding Index screen
-    sprintf(sTemp,"CANary firmware rev65\n"); // gg - commit Index screen
-    logMsg(sTemp);
+    //sprintf(sTemp,"CANary firmware rev65\n"); // gg - commit Index screen
+    sprintf(sTemp,"CANary firmware rev%s\n", revStr); // gg - test Date
+    logMsg(sTemp); // revision
 
     // Look for new binary on thumbdrive
     // Can't make this work right now since USB doesn't attach the right timestamp (so new binary isn't loaded)
@@ -169,11 +176,11 @@
     lastDMode[whichTouched]=99;//force refresh
     if (cfile!=NULL){ //found a new binary on the thumbdrive so copy it over
         sprintf(sTemp,"New binary found.\n");
-        logMsg(sTemp);
+        logMsg(sTemp); // new binary
         file = fopen("/local/CANary.bin", "wb");
         if (file==NULL){ //failed to open destination
             sprintf(sTemp,"Unable to open destination file.\n");
-            logMsg(sTemp);
+            logMsg(sTemp); // cannot open CANary.bin
         } else {
             tt.set_display(2);
             tt.foreground(White);
@@ -211,10 +218,10 @@
         }
         fclose(cfile);
         sprintf(sTemp,"History Loaded.\n");
-        logMsg(sTemp);
+        logMsg(sTemp); // History loaded
     } else { // create initial file
         sprintf(sTemp,"History not found.  Created.\n");
-        logMsg(sTemp);
+        logMsg(sTemp); // history not found, created
         for(i=0;i<39;i++){
             // Pre-load with 4 mpkWh @ 40 mph
             mph[i]=40*timeConstant[i];
@@ -235,20 +242,25 @@
                 t = *localtime(&seconds) ;
                 strftime(fileName, 32, "/usb/%m%d%H%M.alc", &t); //mmddhhmm.alc
                 //sprintf(sTemp,"Using file %s\n",fileName);
-                //logMsg(sTemp);
+                //logMsg(sTemp); // using alc file ...
                 file = fopen(fileName, "ab");
                 lastDMode[whichTouched]=99;//force refresh
                 if(file==NULL){
                     sprintf(sTemp,"\nUnable to open %s\n\n\n\n",fileName);
-                    logMsg(sTemp);
+                    logMsg(sTemp); // cannot open alc file
                     logEn=false;
                     spkr.beep(1000,0.25);
                 } else {
                     logOpen = true;
                     readPointer=writePointer;
                     sprintf(sTemp,"Starting Can Log %s\n",fileName);
-                    logMsg(sTemp);
-                    logTS();
+                    logMsg(sTemp); // starting alc log file 
+                    
+                    logTS(); // Date Time at start
+                    logErrMsg("Starting"); // Log startup msg for testing
+                    sprintf(sTemp,"Cr%s",revStr);
+                    logErrMsg(sTemp); // gg - log firmware version
+                    
                     spkr.beep(2000,0.25);
                 }
             }//logging enabled
@@ -258,13 +270,13 @@
                 if (file == NULL) {
                     logOpen = false;
                     sprintf(sTemp,"Failed to append log file.\n");
-                    logMsg(sTemp);
+                    logMsg(sTemp); // failed to append 
                     spkr.beep(1000,0.25);
                     logEn=false;
                 } else {
                     if (((writePointer+maxBufLen-readPointer)%maxBufLen)>(maxBufLen*7/8)) { // Hi-water mark
                         sprintf(sTemp,"Write buffer overrun.\n");
-                        logMsg(sTemp);
+                        logMsg(sTemp); // write buffer overrun
                         spkr.beep(1000,0.25);
                     }
                     while (readPointer != writePointer) {
@@ -289,7 +301,7 @@
             seconds = time(NULL);
             t = *localtime(&seconds) ;
             strftime(sTemp, 40, "Sleeping: %a %m/%d/%Y %X\n", &t);
-            logMsg(sTemp);
+            logMsg(sTemp); // sleeping date time
             updateDisplay(0); //Added for turbo3 who has a display override and wants to see the sleep message before going to sleep
             updateDisplay(1);
             //LPC_RTC->CIIR=0x00; // block RTC interrupts
@@ -312,13 +324,14 @@
             seconds = time(NULL);
             t = *localtime(&seconds) ;
             strftime(sTemp, 40, "Waking: %a %m/%d/%Y %X\n", &t);
-            logMsg(sTemp);
+            logMsg(sTemp); // wakeup date time
             if (time(NULL)>(secs+1800)) {
                 logOpen = false; // Start new file if asleep for more than 30 minutes
                 if (secsNoTouch>100) secsNoTouch = 100; // also mostly reset user Idle counter
             } else if (logOpen){ // insert timestamp on each wake if logging enabled (disabled for now)
                 file = fopen(fileName, "ab");
-                logTS();
+                logErrMsg("WakingUp"); // gg - use messeges
+                logTS(); // Date-Time at wakeup
             }
         } // if idle
         
@@ -344,7 +357,7 @@
                 sMode = 1;
             }
             //sprintf(sTemp,"%d,%d ",lastTouch.x,lastTouch.y);
-            //logMsg(sTemp);
+            //logMsg(sTemp); // touch x,y - for debug
             touched = false; // clear interrupt flag
         }
         //---------------
@@ -358,7 +371,7 @@
                 secsNoTouch +=2; // increment to prevent double touch
                 sMode = 1;
                 //sprintf(sTemp,"button %d %d,%d %d\n",i,buttonX(lastTouch.x,3),buttonY(lastTouch.y,3),lastTouch.x);
-                //logMsg(sTemp);
+                //logMsg(sTemp); // button parms - for debug
                 switch (sMode) {
                     case 0: // no select
                         break;
@@ -429,7 +442,7 @@
                                     dMode[whichTouched] = effScreen ; // GoTo EFF Screen
                                 } else if (dMode[whichTouched]==config1Screen) {
                                     sprintf(sTemp,"Saving config file.\n");
-                                    logMsg(sTemp);
+                                    logMsg(sTemp); // saving config
                                     saveConfig();
                                     spkr.beep(2000,0.25);
                                 } else if (dMode[whichTouched]==playbackScreen) { // faster
@@ -459,9 +472,10 @@
                                     lastDMode[whichTouched ^ 1]=99; // repaint other screen (^ = XOR)
                                     
                                     //sprintf(sTemp,"Changed Skin to %d.\n");
-                                    //logMsg(sTemp);
+                                    //logMsg(sTemp); /// changed skin - for debug
                                     //saveConfig();
                                     //spkr.beep(2000,0.25);
+                                    
                                 } else if (dMode[whichTouched] == indexScreen) { // gg - index
                                     dMode[whichTouched] = dteScreen ; // GoTo DTE Screen
                                 }else{
@@ -506,21 +520,21 @@
                                             lastDMode[whichTouched]=99;//force refresh
                                             if(file==NULL){
                                                 sprintf(sTemp,"Unable to open /usb/playback.alc\n");
-                                                logMsg(sTemp);
+                                                logMsg(sTemp); // no playback.alc
                                                 spkr.beep(1000,0.25);
                                             } else {
                                                 playbackOpen = true;
                                                 playbackEn=true;
                                                 playback.attach(&playbackISR,playbackInt);
                                                 sprintf(sTemp,"Starting playback\n");
-                                                logMsg(sTemp);
+                                                logMsg(sTemp); // start playback
                                                 spkr.beep(2000,0.25);
                                                 can1.attach(&doNothing);// Stop recieving CAN data
                                                 can2.attach(&doNothing);
                                             }
                                         } else {
                                             sprintf(sTemp,"Must stop logging first\n");
-                                            logMsg(sTemp);
+                                            logMsg(sTemp); // Must stop logging first
                                         }
                                     } else {
                                         playback.detach();
@@ -634,7 +648,8 @@
             laccOn=accOn;
             if(!accOn&&!logEn&&userIdle&&!playbackEn){
                 //sprintf(sTemp,"Display Off %4.2f\n",accV);
-                //logMsg(sTemp);
+                //logMsg(sTemp); // display off - for debug
+                
                 dled = 0; // turn off display if car off and logging disabled and no user activity
             }else if(!headlights){
                 dled = ledHi;
@@ -685,7 +700,7 @@
             }
             updateDTE=true;
             if(logCP)
-                logPackVoltages(); // Turbo3
+                logPackVoltages(); // Turbo3, only call
             tick=false;
         }
 
@@ -704,7 +719,7 @@
                 for(i=0;i<120;i++){
                     if(!feof(file)){
                         fscanf(file,"%5c%8c",&header,&data);
-                        logCan(header[0],CANMessage(0x7ff&((header[4]<<8)+header[3]), data, 8));
+                        logCan(header[0],CANMessage(0x7ff&((header[4]<<8)+header[3]), data, 8)); // Playback
                     }else{
                         fclose(file); // restart
                         file = fopen("/usb/playback.alc", "rb");