Download - VITL Interim Review 1 (IR #1)
VITL April 21, 2023
VITLInterim Review 1
(IR #1)
Friday, April 21, 2023ASEN 4028
Team Members: Ryan Hickman, Chris Homolac, Jen Krupp, Kyle Ligon,
Heather Love, Alex Paulson, Kathryn Rash, Veronica Vertucci
Vehicle for Icy Terrain Locomotion2
VITL April 21, 2023
Overview
• IR1 Checklist & Resolution of RFA• Design Summary & Updates
– Mechanical– Electrical– Software
• Current Issues• Test Plan• Schedule Progress• Budget Progress
Vehicle for Icy Terrain Locomotion3
VITL April 21, 2023
IR1 Checklist & Resolution of RFA
• RFA resolved– Signal Condition and
Buffering added to circuit
– Main switch and fuse added to design
• IR1 Checklist– Completed Electronics
package overview with Trudy Schwartz
– Completed Mechanical Drawing package overview with Matt Rhode
– Completed Software package overview with Scott Palo
Vehicle for Icy Terrain Locomotion4
VITL April 21, 2023
Design Summary: Major Design Changes
• Reduced design to single PIC architecture• Replaced Laser sensor with bumpers and
IR sensors to detect obstacles and removed Gyro
• Structure made of folded sheet metal with Al 60601-T6 Cross beams
• New motor & gearhead – Maxon EC 40 & GP 52 C – Better obstacle climbing and shock absorption
• Resized suspension motor mounts to allow for new motor & gearhead
Vehicle for Icy Terrain Locomotion5
VITL April 21, 2023
Design Summary
• RC controlled • Rocker-Boogie
suspension• Center spiked wheels
are motorized• IR sensors for obstacle
and cliff detection• Accelerometer for slope
detection• Minimal internal layout
changes since CDR– Dummy payload and
power supply mass included
20 in24.25 in
13 in
IR Cliff Detection
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VITL April 21, 2023
Design Summary
Vehicle for Icy Terrain Locomotion7
VITL April 21, 2023
Design Summary
Side View
Front View
Min FOS = 12
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VITL April 21, 2023
Electronics Overview
Circuit Board
Main Switch
Receiver
IRSensors
Rover Physical Boundary
RCAccess Panel
Fuse
VoltageRegulator
Encoders
Amplifiers
Battery
Status LEDs
GND(16 AWG)
GND(16 AWG)
5V(22 AWG)
GND(16 AWG)
Motors
Chassis Mounted
GND
Vehicle for Icy Terrain Locomotion9
VITL April 21, 2023
Buffer/Signal Conditioning Circuit
Vehicle for Icy Terrain Locomotion10
VITL April 21, 2023
Wiring
• Each device will have its own connection to board
• Twisted wiring with shield wrap will be used
• Adhesive mounts placed along base of rover
• Cable ties to secure wire
Vehicle for Icy Terrain Locomotion11
VITL April 21, 2023
PCB Layout
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VITL April 21, 2023
3D PCB
Vehicle for Icy Terrain Locomotion13
VITL April 21, 2023
Software Updated
Vehicle for Icy Terrain Locomotion14
VITL April 21, 2023
Current Issues
• Accuracy of fabrication time estimates– Overestimated time and still have margin– Will improve as more machining is done
• Holes for wiring– Have excess wire so holes can be more accessible
• Software processing time to stop– Time each algorithm and motor breaking before integration– Extend bumpers and cliff detector further– Drive at minimum speed to allow for more processing time
• Time/Labor intensive encoding software for motors– Allocated more time from margin for software development
Vehicle for Icy Terrain Locomotion15
VITL April 21, 2023
Testing Basics
• Types: – Inspection– Demonstration– Analysis– Interface
• Two sets:– Component and assembly
function testing– Requirement verification testing
• Number of Tests: 34• Total testing time: ~100
hours
Acceptance – Component Testing
Integration – Assembly Testing
System – Full System Testing
Vehicle for Icy Terrain Locomotion16
VITL April 21, 2023
Testing GoalsAerial View of Mission ProfileComplex/Critical Tests
• Functional Tests– Wheel Traction– Motor-Gear Head
Operation– Motor Breaking– Suspension Obstacle
Clearance– IR Proximity Sensor Cliff
and Obstacle Detection– Encoder Accuracy
• Requirement Verification– Obstacle Detection
(Performed with Suspension Obstacle Clearance)
– Mission Life– Temperature– Efficiency/Accuracy
Vehicle for Icy Terrain Locomotion17
VITL April 21, 2023
T-100.10. Wheel Traction
• Purpose: – Make sure the wheels provide traction with minimal slipping on a ground surface of concrete
• Main Equipment: – 0º, 5º, 10º, 15º, and 20º sloped concrete at least 5 feet in length– Integrated vehicle – Remote control– Level– Tape measure– Timer
• Expected Duration: 4-6 hours• Expected Location: CU Parking Garage, Folsom Hill, Colorado Ave.,
Handicap ramps near Engineering Center• Metric for Success: Vehicle-measured distance traveled needs to be
within 0.37 inches from the actual distance traveled. This is assuming the track is 5 feet long and the rover travels the whole distance.
Steps:1. Determine slope and initial
position.2. Drive the vehicle using remote
control for 5 ft and then stop.3. Record end position.4. Compare actual and vehicle-
measured distance traveled.5. Repeat.
Vehicle for Icy Terrain Locomotion18
VITL April 21, 2023
• Purpose: – Verify that the motors and gear heads can drive the vehicle system on inclined surfaces in all directions with use of the PIC
• Main Equipment: – 0º, 5º, 10º, 15º, and 20º sloped concrete at least 5 feet in length– Integrated vehicle – Remote control– Level– Tape measure– Timer– Protractor
• Expected Duration: 4-6 hours• Expected Location: CU Parking Garage, Folsom Hill, Colorado Ave., Handicap ramps near Engineering Center• Metric for Success: The vehicle shall be observed to turn an angle no less than
180º and move up the slopes with a speed that does not deviate by more than 5%
T-100.20. Motors with Gear Heads Operation
Steps:1. Determine slope and initial
position and orientation.2. Drive the vehicle using remote
control for 5 ft, turn, drive another 5 ft, and then stop.
3. Record end position and rotation angle.
4. Compare actual and vehicle-measured distance traveled.
5. Repeat.
Vehicle for Icy Terrain Locomotion19
VITL April 21, 2023
T-100.22. Motor Braking• Purpose:
– Ensure that the motors stop the vehicle on inclined surfaces under a full load in a reasonable distance (~1 inch)
• Main Equipment:– Integrated vehicle– Remote control– Tape measure– Level– Timers– 0º, 5º, 10º, 15º, and 20º sloped concrete at
least 10 feet in length• Expected Duration: 4-6 hours• Expected Location: CU Parking Garage,
Folsom Hill, Colorado Ave., Handicap ramps near Engineering Center
• Metric for Success: Stop in ~1 in to avoid the obstacle detection device hitting the front wheels and assuming the wheels are moving at 1 rpm, the vehicle needs to stop in a maximum of 8 seconds
Vehicle commanded to stop
Vehicle fully stopped
Steps:1. Determine the slope and
initial position.2. Drive the vehicle using
remote control for 10 ft and stop. Time the stop period and distance.
3. Record the end position and time and distance to stop.
4. Repeat.
Vehicle for Icy Terrain Locomotion20
VITL April 21, 2023
T-100.30. Suspension Obstacle Clearance
• Purpose: – Prove that the vehicle and
suspension allow for obstacle clearance
• Main Equipment:– Integrated vehicle– 1 in x 3 ft obstacles– Level– Tape measure– Protractor– 0º, 5º, 10º, 15º, and 20º sloped
concrete at least 5 feet in length• Expected Duration: 2-4 hours• Expected Location: CU Parking
Garage, Folsom Hill, Colorado Ave., Handicap ramps near Engineering Center
• Metric for Success: Suspension arm deflection angle = the slope being traversed, suspension arm deflection distance = the height of the obstacle.
Steps:1. Setup the obstacle.2. Record the suspension front and rear
arm initial positions.3. Drive the vehicle using remote
control so that the suspension is half way on top of the obstacle.
4. Stop the vehicle.5. Measure the deflection of front and
rear arm relative to initial position.6. Repeat.
Vehicle for Icy Terrain Locomotion21
VITL April 21, 2023
T-200.20. IR Proximity Sensors – Cliff Detection
• Purpose: – Verify that the IR proximity sensor
detects the presence of cliffs (drop-offs greater than 3 inches) and steep downward slopes
• Main Equipment:– IR proximity sensor– Power supply– Computer– Obstacle detection software– Surface of variable height and slope
(cardboard boxes)– Calibration material (Paper with various
shades of black and white)– Wiring
• Expected Duration: 1 hour• Expected Location: ITLL or Space Grant• Metric for Success: Software response
when the “ground” gets farther than 3 inches away.
Steps:1. Setup the obstacle.2. Record the suspension front and
rear arm initial positions.3. Drive the vehicle using remote
control so that the suspension is half way on top of the obstacle.
4. Stop the vehicle.5. Measure the deflection of front
and rear arm relative to initial position.
6. Repeat.
Raised Surface of Variable Height and Slope
Vehicle for Icy Terrain Locomotion22
VITL April 21, 2023
T-200.21. IR Proximity Sensors – Obstacle Detection
• Purpose: – To verify that the IR proximity
sensors and detection mechanism can detect obstacles greater than 3 inches in height.
• Main Equipment:– IR proximity sensors (3)– Power supply– Computer– Obstacle detection software– Obstacle (cardboard boxes)– Calibration material (Paper with
various shades of black and white)– Wiring
• Expected Duration: 1 hour• Expected Location: ITLL or Space
Grant• Metric for Success: Software
response when the obstacle detection mechanism gets closer than 3 inches away.
Steps:1. Turn on power supply, set to 5 V, and
turn off. 2. Connect power supply and sensors.
Connect sensors to software platform.3. Turn on power supply.4. Vary distance of obstacle and record
the distance when the sensors detect too close a distance.
5. Turn off power supply.6. Repeat.
Vehicle for Icy Terrain Locomotion23
VITL April 21, 2023
T-200.60. Encoder Accuracy
• Purpose: – Verify correct pulse counts
from the encoder for motor rotations.
• Main Equipment:– Encoders– Amplifier– Motor– Duel power supply– PIC/PIC programmer– Computer/Software
• Expected Duration: 2 hours• Expected Location: ITLL,
Senior Projects room, or Space Grant
• Metric for Success: Encoder data matches each other within 5 pulse counts
Steps:1. Turn on power supply, set to 5 V and
11.1 V, and turn off. 2. Connect one power supply to amplifier
and motor. Connect other power supply to encoder and amplifier. Connect everything to the PIC.
3. Turn on power supply.4. Command motor operation at varying
speeds, recording the encoder data.5. Turn off power supply and motor.6. Compare encoder data.7. Repeat.
Motor
Amplifier
Encoder 1 Encoder 2
Vehicle for Icy Terrain Locomotion24
VITL April 21, 2023
T-2.3. Mission Life• Purpose:
– Make sure that all components do not fatigue or degrade significantly during 3.5 days of operation
• Main Equipment:– Integrated vehicle– Timer– Backup timer for
redundancy/preventative measures– Misc. testing equipment for other
integrated vehicle tests• Expected Duration: 84 hours• Expected Location: CU Parking Garage,
Frozen lake, Concrete sidewalks, Handicap ramps, etc.
• Metric for Success: Vehicle operation at 75% initial performance values (measured at the beginning of testing) at the end of 84 hours of testing
Step:1. For any system vehicle
test during which it is driven, the test must be timed and recorded.
Vehicle for Icy Terrain Locomotion25
VITL April 21, 2023
T-3.4. Temperature
• Purpose: – Make sure that the drive
system can still drive the vehicle in a 0ºC environment, even if performance is degraded
• Main Equipment: – Thermometer– Integrated vehicle– Remote Control– Level surface (ice or
concrete)• Expected Duration: 1 hour• Expected Location: CU Parking
Garage or frozen lake• Metric for Success: In a 0ºC
environment, component operation at 75% their performance value at room temperature
Steps:1. Record the temperature.2. Perform any of the system tests
for terrain crossing, level movement, or inclination in a 0º C environment.
Vehicle for Icy Terrain Locomotion26
VITL April 21, 2023
T-3.6. Efficiency/Accuracy• Purpose:
– Make sure the onboard software and encoders accurately report the position of the vehicle after traveling any distance. The accuracy required is equal to of the total distance traveled.
• Main Equipment: – Integrated vehicle– Remote control– Tape measure, String– Surveying equipment (if available)– Chalk or ink– Concrete or ice surface of considerable
length• Expected Duration: 7 hours• Expected Location: CU Parking Garage,
sidewalks, frozen lake• Metric for success: Accuracy of the
sensors and software ≥ 0.62% Difference ≤ (total distance traveled)*(0.0062)
Steps:1. Determine slope and initial
position.2. Drive the vehicle in pre-turn-
determined paths. 3. Record end position.4. Compare actual and vehicle-
measured distance traveled.5. Repeat for the remaining
paths.
Vehicle for Icy Terrain Locomotion27
VITL April 21, 2023
Spring Semester ScheduleMotors Shipping
Motors Shipping
Shipping Materials,Batteries and electronics
Shipping Sensors
Acquisition of Electronics and Sensors
Acquisition of raw Materials
Manufacture Suspension and Frame
Manufacture Suspension and Frame
Manufacture Wheels
Manufacture Wheels
Power board
Power testing
Battery Testing
IR 1 2/5
Preliminary Algorithms
Complete PCB
Manufacture Component Boxes
Integration of Mechanisms
Electronics and Sensor Testing
IR 2 3/5
Maunfacture Testing Structure
Full System Integration
Final Algorithms
Manufacture Margin
Last Machining Day 3/16
Outdoor Testing
Spring Break (margin)
Incline/Obstacle Testing
Testing Margin
Final Review
11/19 12/3 12/17 12/31 1/14 1/28 2/11 2/25 3/11 3/25 4/8 4/22 5/6 5/20 6/3 6/17November December January February March April May June
Final Review
Poster Due 4/23
Report Draft Due 4/23
Design Exposition 4/28
Finalize Final Report
Final Report 5/3
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VITL April 21, 2023
Cost Expenditures
ElementsExpected
CostActualCost
CostDifference
Drive Subsystem $1,224 $1,965 $741
Wheels $400 $217 -$183
Motors (w/ Gear Heads) $674 $1,359 $684
Suspension (Includes Large Fasteners) $150 $389.78 $240
Sensors & Software $882 $50 -$832
Laser $780 $0 -$780
Servo $89 $0 -$89
IR Proximity Sensors $13 $50 $38
C&DH/COMM $1,148 $618 -$530
CPU $38 $0 -$38
Amplifiers $645 $322.40 -$323
Encoders $230 $212 -$18
RF RX & Crystal $85 $64.98 -$20
Misc. Parts $150 $18.56 -$131
ElementsExpected
CostActualCost
CostDifference
Structures $99 $211 $112
Frame $54 $148.52 $95
Cables $20 $62.50 $43
Component boxes $25 $0 -$25
Power $45 $5 -$40
Battery Charger $45 $5 -$40
Dummy Mass $20 $12 -$8
Shipping $300 $172 -$128
Management $500 $91.06 -$409
Total $4,217 $3,124 -$1,642
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VITL April 21, 2023
Cost ExpectationsElements Expected Cost
Drive Subsystem $77
Suspension $76.50
Sensors & Software $12
Accelerometer $12
C&DH/COMM $166
Data Storage $6
PCB/Assembly $110
Misc Parts $50
Structures $50
Connecters $50
Obstacle Detection Material $30
Thermal $25
Insulation $25
Elements Expected Cost
Testing $95
Obstacle Material - Wood $45
Tape Measure $50
Miscellaneous Parts $100
Shipping $50
Management $250
Total $824
Expenditures $3124
Expected $824
Outreach $500
Subtotal $4448
25% Margin $1112
Total $5560
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VITL April 21, 2023
Additional Slides
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VITL April 21, 2023 Tasks Status Planned Start Planned End Actual Start Actual End Expected Start Expected End
Motors Shipping In Progress 12/08/06 02/15/07 01/08/07 02/21/07
Shipping Materials Complete 12/22/06 01/16/07 01/16/07 01/22/07
Manufacture Suspension and Frame 50% 01/16/07 01/22/07 01/29/07 02/12/07
Shipping Electronics/Sensors Complete 01/22/07 02/09/07 01/16/07 02/05/07
Preliminary Battery Testing Complete 02/05/07 02/09/07 01/26/07 01/31/07
Preliminary Algorithms 50% 01/19/07 02/15/07 01/19/07 02/15/07
IR 1 Complete 02/05/07 02/05/07
Preliminary Board layout/testing 01/30/07 02/12/07
Complete PCB 02/12/07 02/16/07
Manufacture Wheels Spikes 75% complete 02/05/07 03/02/07 01/26/07 02/12/07
Manufacture Component Boxes Removed 02/12/07 02/16/07
Integration of Mechanisms 01/22/07 02/16/07 02/12/07 02/23/07
Electronics and Sensor Testing 02/19/07 02/23/07
IR 2 03/05/07 03/05/07
Maunfacture Testing Structure Removed 02/27/07 03/12/07
Full System Integration 03/05/07 03/23/07
Final Algorithms 02/16/07 03/09/07
Manufacture Margin 03/12/07 03/16/07
Last Machining Day 03/16/07 03/16/07
Outdoor Testing 03/19/07 03/23/07
Spring Break (margin) 03/26/07 03/30/07
Incline/Obstacle Testing 04/02/07 04/13/07
Testing Margin 04/16/07 04/20/07
Final Review 04/16/07 04/17/07
Poster Due 04/23/07 04/23/07
Report Draft Due 04/23/07 04/23/07
Design Exposition 04/28/07 04/28/07
Finalize Final Report 04/23/07 04/27/07
Final Report 05/03/07 05/03/07
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VITL April 21, 2023
EDMU Internal Layout: Top View
Batteries
Laser Range
Proximity Sensor
Gyroscope & Accelerometer
Motor Controller
Science Payload
C&DH board &
Receiver
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VITL April 21, 2023
EDMU System Architecture
Motor Controller
C&DH board & Receiver
Suspension & Drive Train
Science Payload exploded
Science electronics
Radiation Sensor
Magnetometer
Pan Cam
Sonar
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VITL April 21, 2023
EDMU System Architecture: Front View
Science Payload
Batteries
Sonar sensor
Laser Range
Motor Controller
Motors
C&DH Board and Receiver
Proximity sensor