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Research complete from 2026-05-04 session: - M5Stack ESP32 GPIO pinout reference (PLAY) - Gear ratio selection guide for FRC mechanisms (2890) - MegaTag vision localization concept (2890/PhotonVision)
2026-05-04 20:29:19 +00:00
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+---
+title: "Choosing Gear Ratios for FRC Mechanisms"
+tags:
+  - gear ratio
+  - mechanism
+  - design
+  - motor
+  - torque
+  - speed
+  - frc
+  - 2890
+type: training-module
+owner: 2890
+status: active
+sources:
+  - "https://docs.wcproducts.com/frc-build-system/belts-chain-and-gears/gears"
+  - "https://www.frcdesign.org/learning-course/stage1/1B/torque-speed/"
+  - "https://blog.thebluealliance.com/2013/06/24/behind-the-design-understanding-motor-and-gearbox-design/"
+---
+
+# Choosing Gear Ratios for FRC Mechanisms
+
+## Core Principle
+
+**Speed and torque are inversely proportional.** A 4:1 gear reduction gives you 4× the torque but 1/4 the speed.
+
+```
+Gear Ratio = Driven Gear Teeth / Driver Gear Teeth
+
+If ratio = 4:1 (input:output = 1:4):
+  Torque → multiplied by 4
+  Speed → divided by 4
+```
+
+## The Design Process
+
+### Step 1: Define Your Goal
+
+Ask these questions:
+- What does this mechanism need to **do**?
+- How **fast** does it need to move?
+- How **heavy** is the load?
+- What's the **time constraint** (game-specific)?
+
+### Step 2: Calculate Required Output
+
+For each mechanism:
+
+| Mechanism | Key Metric | Typical Range |
+|-----------|------------|---------------|
+| Drivetrain | Top speed | 10-15 ft/s |
+| Elevator | Lift speed | 3-6 ft/s |
+| Arm | Rotation speed | 90-180°/sec |
+| Intake | Roll speed | Fast (1-2 sec) |
+| Shooter | RPM | 3000-6000 RPM |
+
+### Step 3: Match Motor to Load
+
+**NEO Vortex specs (Team 2890's standard):**
+- Free speed: 6784 RPM
+- Stall torque: 3.6 Nm (0.36 kg·m)
+- Peak output: 640W
+- Continuous (40A): ~375W
+
+**Work backward from desired output speed:**
+```
+Required output speed = X RPM
+↓ 
+Account for mechanism reduction (belts, chains, gears)
+↓ 
+Calculate motor speed needed
+↓ 
+Find gear ratio
+```
+
+## Drivetrain Gear Ratio Selection (Team 2890)
+
+Team 2890 uses **L1 and L3** on MK4i modules with NEO Vortex:
+
+| Ratio | Speed | Torque | Use When |
+|-------|-------|--------|----------|
+| **L1** (8.14:1) | ~14.4 ft/s | Lower | High speed needed, less pushing |
+| **L3** (6.12:1) | ~12.8 ft/s | Higher | More pushing power, climbing |
+
+**L1 = faster, less torque. L3 = slower, more torque.**
+
+Swap based on game demands. Field-swappable.
+
+## Mechanism Design Guidelines
+
+### Elevators / Vertical Motion
+
+```
+Motor → Belt reduction → Sprocket → Chain → Carriage
+```
+
+- Target: 3-6 ft/s vertical
+- Common ratios: 4:1 to 10:1 per stage
+- Watch for staging — two-stage elevators need compounding reduction
+
+### Arms / Swing Motion
+
+```
+Motor → Gearbox → Arm
+```
+
+- Target: 90-180°/sec rotation
+- Consider start-up torque (gravity fight at low angle)
+- PID control essential for repeatable positioning
+
+### Shooters / Flywheels
+
+```
+Motor → Gearbox → Wheel
+```
+
+- Target: 3000-6000 RPM wheel speed
+- High reduction = more torque at wheel, faster spin-up
+- Common ratio: 3:1 to 5:1
+
+### Intake Rollers
+
+```
+Motor → Direct or light reduction → Roller
+```
+
+- Target: Fast roll-in (under 2 seconds)
+- Low reduction or direct drive works
+- Rubber roller = good grip, no gear reduction needed
+
+## Motor Sizing Rules of Thumb
+
+1. **Stall torque > Load torque at worst angle**
+2. **Free speed > Desired output speed by 2× minimum**
+3. **Current draw at stall < 80% of breaker rating**
+4. **Continuous torque > Average load torque**
+
+## Common FRC Motor/Gearbox Pairings
+
+| Motor | Typical Gearbox | Output | Use |
+|-------|----------------|--------|-----|
+| NEO Vortex | Built-in 4:1 | 1696 RPM | Drivetrain, mechanisms |
+| NEO Vortex + planetary | External reduction | Variable | Elevators, arms |
+| Falcon 500 | Integrated | 1680 RPM | Drivetrain, high torque |
+| Kraken X60 | Integrated | ~1680 RPM | Newer alternative to Falcon |
+
+## The Calculation
+
+```
+Desired output RPM = X
+Motor free RPM = 6784 (NEO Vortex)
+Total reduction needed = 6784 / X
+
+Example: Want 600 RPM output
+  6784 / 600 = 11.3:1 reduction needed
+
+Split across stages:
+  Stage 1 (belt): 3:1
+  Stage 2 (gearbox): 4:1
+  Total = 12:1 — close to target
+```
+
+## Signs You've Got It Wrong
+
+- **Too fast / not enough torque:** Robot stalls under load, wheels slip
+- **Too slow / too much torque:** Mechanism moves too slowly to be useful
+- **Motor overheating:** Too much load for continuous operation — need more reduction or bigger motor
+- **Brownouts:** Current spikes from stalling — check breaker sizing
+
+## For Team 2890 Students
+
+When designing a mechanism:
+1. **Define the task** — what does it need to do in the game?
+2. **Pick the motor** — NEO Vortex is standard on 2890
+3. **Calculate the speed you need** — game constraints (time limits, field size)
+4. **Work backward** — gear ratio = motor speed / desired output speed
+5. **Split across stages** — belt + gearbox is easier than single-stage high ratio
+6. **Test and tune** — PID tuning can fix some speed issues, but wrong gear ratio can't be fixed with software
+
+## Related
+
+- [[swere-modules]] — MK4i gear options for drivetrain
+- [[neo-vortex-motor]] — motor specs
+- [[spark-flex]] — controller configuration
+- [[motor-basics]] — understanding motor curves
+
+---
+*Research from web search — gear ratio design for FRC mechanisms*
+*Queue: research complete — stored in wiki*
--- a/training/modules/megatag.md
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+---
+title: "MegaTag — Robot Localization with AprilTags"
+tags:
+  - megatag
+  - apriltag
+  - vision
+  - localization
+  - limelight
+  - photonvision
+  - odometry
+  - frc
+  - 2890
+type: training-module
+owner: 2890
+status: active
+sources:
+  - "https://docs.limelightvision.io/docs/docs-limelight/pipeline-apriltag/apriltag-robot-localization"
+  - "https://docs.yagsl.com/fundamentals/swerve-drive"
+---
+
+# MegaTag — Robot Localization with AprilTags
+
+## What Is MegaTag?
+
+MegaTag is a **Limelight-specific** robot localization system that uses AprilTags + IMU (gyro) data to determine the robot's position on the field. It's not a Limelight-only concept — similar approaches exist with PhotonVision + WPILib pose estimators — but "MegaTag" specifically refers to Limelight's implementation.
+
+**Key point:** Team 2890 uses **PhotonVision**, not Limelight. MegaTag documentation is useful for understanding the **concept** of vision-based odometry fusion, but the implementation uses PhotonVision's pose estimator + WPILib's `SwerveDrivePoseEstimator`.
+
+## MegaTag vs. MegaTag2
+
+| Feature | MegaTag 1 | MegaTag 2 |
+|---------|-----------|-----------|
+| Data source | AprilTag vision only | AprilTag + IMU fusion |
+| Accuracy | Good when tags visible | Better — gyro corrects drift |
+| Drift | Accumulates over time | Reduced by gyro correction |
+| Tag visibility required | Yes | Yes (but less sensitive) |
+
+**MegaTag 2** fuses robot orientation data from the IMU with vision pose. This means even if vision is slightly noisy or a tag is partially visible, the gyro steadies the reading.
+
+## How It Works (Conceptual)
+
+```
+AprilTag camera → Robot pose (x, y, rotation)
+        ↓
+Gyro heading → Corrections / steadying
+        ↓
+Pose Estimator → Combines:
+  - Wheel odometry (always drifting)
+  - Vision pose (accurate but intermittent)
+        ↓
+Final robot position (fused)
+```
+
+## For Team 2890 (PhotonVision)
+
+Team 2890 runs PhotonVision on Raspberry Pi, AprilTags on the field. The equivalent fusion happens in WPILib:
+
+```java
+// SwerveDrivePoseEstimator fuses:
+// 1. Wheel odometry (always running, drifts)
+// 2. Vision measurements (accurate when tags visible)
+
+SwerveDrivePoseEstimator estimator = new SwerveDrivePoseEstimator(
+    kinematics,
+    gyro.getRotation2d(),           // IMU heading
+    modulePositions,                // wheel encoders
+    new Pose2d(x, y, rotation)       // initial estimate
+);
+
+// Add vision measurement when tag visible:
+estimator.addVisionMeasurement(
+    photonPoseEstimator.getEstimatedPosition(),
+    Timer.getFPGATimestamp()
+);
+```
+
+## The Key Concept for Students
+
+**Robot localization = knowing where you are on the field.**
+
+AprilTags give you a reference point. The gyro gives you orientation. Fusing them gives you accurate, stable position tracking even when:
+- Only one tag is visible
+- Tags are partially obscured
+- Robot is moving fast
+
+This is critical for:
+- Autonomous paths that need to return to same spot
+- Field-relative driving with joystick
+- Score estimation / match strategy
+
+## Common Issues and Troubleshooting
+
+| Problem | Likely Cause | Fix |
+|---------|--------------|-----|
+| Pose always offset in same direction | Camera calibration wrong | Check camera tilt, height, direction |
+| Pose jumps when tag visible | Vision trusting single reading | Add filtering, check timing |
+| No pose when tags visible | Camera not processing tags | Check PhotonVision pipeline |
+| Odometry drifts despite vision | Vision not being added to estimator | Check `addVisionMeasurement` call |
+| Gyro disagrees with vision | Gyro calibration issue | Re-calibrate gyro, check wiring |
+
+## Connection to Training
+
+For students learning swerve odometry:
+1. **Wheel odometry** — always tracking, always drifting
+2. **Vision pose** — accurate when AprilTags visible
+3. **Pose estimator** — fuses both for best of both worlds
+4. **Field constants** — AprilTag positions, field dimensions must be correct
+
+The MegaTag concept (vision + gyro fusion) is the same regardless of whether you use Limelight or PhotonVision. Understanding it helps students debug pose estimation issues.
+
+## Related
+
+- [[photonvision]] — Team 2890's vision system
+- [[swere-modules]] — MK4i with encoders for odometry
+- [[systemcore]] — upcoming controller with improved processing
+
+---
+*Research from web search — MegaTag concept for FRC vision localization*
+*Queue: research complete — stored in wiki*