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Module 3 — Power & Battery Management

Objective: avoid brownouts and manage batteries safely.

Prereqs: Wired board and breaker map.

Steps

  • Size breakers appropriately; balance loads across the PDH/PDP.
  • Test and log batteries; set pass/fail criteria; retire weak packs.
  • Secure battery mounts and cables; verify strain relief.
  • Use correct gauge for high-current runs; keep lengths short where possible.
  • Verify PDH/PDP firmware where applicable; check logs for brownouts after drive tests.

Deliverables

  • Battery log with pass/fail, rotation plan, and breaker map.
  • Battery handling SOP (charge, cooldown, retirement, transport).

Resources

  • Battery testing: chiefdelphi.com/t/paper-frc-battery-guide/117671

Instructions (numbered)

  1. Create breaker map and balance loads across PDH/PDP.
  2. Use correct gauge for high-current runs; minimize length; secure mounts and strain relief.
  3. Test batteries (internal resistance/voltage under load); log results and set pass/fail criteria.
  4. Rotate batteries; retire weak packs; define charge/cooldown/transport SOP.
  5. Verify PDH/PDP firmware; check logs for brownouts after drive tests.

Example

  • Breakers: 40A drive, 30A mechanisms; battery IR < 12 mΩ passes; weak packs tagged “practice only.”

Best practices

  • Label and date batteries; track cycles.
  • Keep cables short and well-strained; avoid sharp bends.
  • Review logs after drive tests to catch brownouts early.

Common mistakes

  • Reusing weak batteries in matches.
  • Undersized wire for high loads; long runs causing voltage drop.
  • No SOP for charging/cooling/transport.

Checklist

  • Breaker map balanced
  • Correct gauge and strain relief on high-current runs
  • Battery tests logged; pass/fail set
  • Rotation/retirement plan in place
  • PDH/PDP firmware/log check done

Recommended tools

  • Battery tester (IR/voltage), labeler, torque tool for lugs, log viewer for PDH/PDP/brownouts.

Sample log (template)

  • Date:
  • Battery IDs tested:
  • Results (IR/voltage):
  • Pass/Fail and notes:
  • Actions (retire/rotate):

Photos/diagrams

  • [Placeholder: battery board layout with labels and breaker map]