ongo-01 project oscar. project oscar fall 2004 zacharykotlarek cpre 492 davidhawley cpre 492...

Ongo-01Project OSCAR

Project Oscar

Fall 2004

Zachary Kotlarek CprE 492David Hawley CprE 492Michael Larson EE 492Justin Rasmussen CprE

492Gavin Ripley CprE 492Peter Rufino EE 492Jason Sytsma EE 492

Kevin Cantu EE 491Phil Derr EE 491Jawad Haider EE 491Jeff Parent CprE 491

Client Department of Electrical and Computer Engineering

Presentation Date January 27, 2005

Faculty Advisor Ralph Patterson III

Team Members

Initial Information Huy

Project Introduction William, John

Description of Activities Everyone

Resources and Schedules David, Gus

Summary Dung

Project Oscar

Presentation Overview

OSCAR Octagonal Speech-Controlled Autonomous Robot CVS Concurrent versions system Cybot The predecessor to OSCAR drive train The assembly of electrically controlled motion

elements, including the robot’s wheels, gears, belts, and tachometers

End effector The assembly of electrically controlled mechanical arm and gripper

Ethernet A computer network communication protocol GUI Graphical user interface Linear bearing A rolling element that moves on a straight

track SONAR Sound navigation and ranging Tachometer A device for indicating speed of rotation

Project Oscar

List of Definitions

Project IntroductionWilliam, John

General Problem Statement

To capture the interests of visitors and potential students, the department needs an exciting demonstration of the technological capabilities of its students.

Last Semester’s Needs New power system Improve drive train Navigation using SONAR New robotic end effector

General Solution Approach Recreate entire power delivery system Understand and improve existing software base Design a more suitable end effector Develop intelligent coordination of SONAR and drive motion

Project Introduction

Problem Statement


Operating Environment

Indoors (Outdoors with ideal weather) Temperature between 32oF – 100oF Flat surfaces If obstacles are present, they must be at least 2.5 feet high

to be detected


Intended Users and Uses

Users Project OSCAR team members Trained demonstrators Supervised non-technical users

UsesDemonstrate to campus visitors Communicate with operators and audience Autonomous navigation throughout a room or corridor Pick up and place objects Respond to spoken commands


Assumptions and LimitationsAssumptions Operators speak English Demonstrations last under an hour Technical supervisors present during operation

Limitations Software must run in Mandrake Linux SONAR range is 0.5 – 35 feet Wireless Ethernet within 328 feet Must fit through a standard 30-inch doorway Power supply must be rechargeable End effector must fit within top module


End Product Full drive motion capability

Interaction with users via speech recognition software

GUI-driven software package Wireless connection Manual motion control Speech output Room/corridor

navigation Script recording and

playback

Externally rechargeable power supply


Other Deliverables End-user operation instructions

Power system and recharging instructions Software user’s guide

Power system specifications and schematic

SONAR array specifications and schematics

Description of ActivitiesEveryone

Command-line speech output

New motor control for drive motion

End effector assembly was made lighter

Project website was redesigned

Partial description of navigation algorithm

Description of Activities

Previous Accomplishments

Rebuild power delivery system Reroute wiring Install interface panels Consider power inversion and conversion methods Purchase and install new battery Create schematics and user’s manual

Improve software architecture Document existing software Develop wireless control interface Test and document new software Developed a GUI


Present Accomplishments

Create reference base for SONAR array

Build façade for chassis

Improve drive train Fix belt slipping Design tachometer circuitry

Redesign end effector (robotic arm) Design control system

Establish documentation standard


Present Accomplishments


General ApproachResearch

(Re)Design

(Re)ImplementResults Okay?Test

Document

No

Yes

Was it prefabricated?

No

Yes

PerformanceCostTime

Select


Project DefinitionTotal Weight

Points:39 Urgency

Scaling Factor:

28% Highest High Medium Low Lowest

Software Highest Develop control

infrastructure

High

Develop SONAR array

testing software

Develop GUI for control and

sensor structures

Effort Medium Develop remote

interface

Develop scripts and macros for

demonstrations

Test newly-developed software

Low Document existing

softwareDocument new

software

Lowest

Priority Weight (larger = greater priority) 9 8 7 6 5 4 3 2 1


Project DefinitionTask System priority Project priority

Characterize sonar array through testing 23% 6%

Develop navigation algorithms for sensor array 21% 6%

Write SOPs for sonar testing 15% 4%

Create sonar array reference materials 13% 4%

Document sonar testing from S04 8% 1%

Research imaging and image processing options 8% 2%

Test newly developed software 10% 3%

Develop SONAR array testing software 21% 6%

Develop control infrastructure 21% 6%

Develop remote interface 15% 4%

Develop GUI for control and sensor structures 15% 4%

Develop scripts and macros for demonstrations 13% 4%

Document existing software 10% 3%

Document new software 8% 2%

Reroute wiring, install panels and external connections 9% 3%

Design controllers for end effector motors 11% 3%

Create wiring documentation 9% 3%

Test new end effector assembly 5% 2%

Design suspension system for drive train 7% 1%

TOTAL 100%

Yellow = percentage value forced for conformity to 100% total requirement

* List has been truncated to fit in this space


Project Definition

Tasks grouped under milestones to assign overall priority

# Milestone Priority (%)

1 Drive motion 29

2 Speech Output 2

3 External Façade 1

4 End Effector 16

5 Navigation 38

6 Suspension 1

7 Research 1

8 Demonstration / Presentation 3

9 Project Reporting 9


ResearchPower conversionCurrent power inverter (DC/AC) is not rated to supply

necessary power to computer.

Many alternative products considered. DC ATX power supply is too expensive. DC/DC converter cannot supply computer’s

demand. New DC/AC inverter is the best solution.

Purchase of new inverter delayed until this semester.


Researcht = 0

Channel A

Channel Bforward

Channel Bbackward

Rotation

forwardbackward

Input voltage

+ 5.0 V

+ 2.5 V


Research

Optical Encoder

Motor Controller

Computer Serial

???

Available solutionsIntegrated motion control package (LM62xN, HCTL-20xx)• EXPENSIVE

Computer-based control (Java or LabVIEW)• Have to create software algorithm (takes time)• Pentium II with Linux

Create own circuit• Speed: Frequency-to-voltage converter• Direction: Phase decoder


Design

F2V

Op. Enc.

ChB MUX

DC Bias

Direction

To Motor Controller

Phase Decoder

ChA

Tachometer Interface


DesignTachometer Interface

Phase DecoderLS7184 – LSI Computer Systems• Frequency of CLOCK is proportional to frequency of

inputs• UP/DN is constant value



2:1 Analog Multiplexer switch

AD8170AN – Analog Devices

SELECT chooses between IN0 and IN1, sends it to Vout



Frequency–to–Voltage conversion

LM2907N-8 – National Semiconductor

Input pulse train

CresCsmoothRsmooth

Smoothing Filter

Adjustable Gain Control

Vcc

Out to MUX


DesignPower system

Power demand identified

Safety measures implemented

Schematic developed


Design

•Previous code updated and extended

•Layers of abstraction added to the previous design

•Wireless adapter added

•Operating system upgraded to Mandrake v.10.1

•Network communication protocol designed

Software Architecture


Design End effecter Previous design was unacceptable

Design ConstraintsSize Total Cost-Reuse old system components

Retractable ‘Buildable’ Design Features

Retracting/Pivoting ShoulderElbow JointWrist PivotLocking Wrist


ImplementationPower system

Schematic followed Moving objects avoided Wires secured to chassis


ImplementationPower system

End user accesses battery through interface panel

Battery charger modified


Implementation Drivetrain Modification

Existing Drivetrain exhibited wheel ‘slop’ and belt rubbing

Cause was found to be poor bushing system

Loose bearing allowed wheel to slide and translate

Solution: a press fit polymer bearing to eliminate all unwanted motion


Implementation

A simple and cost-effective look for OSCAR Cam Lock system prevents theft and damage of OSCAR’s

internals

Façade and Lock System


ImplementationGUI and wireless adapters

Functionality is divided into four main sections

• Movement Controls • Speech • Sensor display • Scripts


Project Documentation Technical appendices added to standard project

documents Technical drawings Electrical specifications Technical methods used User’s Manual

CVS repository utilized

Filing cabinet reorganized Paper copies of all documentation filed

CD hard backup of files left with Dr. Patterson

Project tracking template


Testing and ModificationSONAR testing Verify the operation of the model 6500 SONAR modules Measure the time required for the ECHO signal


Future Required Activities

Task Student Type Semester

Implement tachometer unit circuit boards EE Spring 2005

Implement end effector assembly ME Spring 2005

Design control circuits for end effector motors EE Spring 2005

Fix SONAR array EE/CprE Spring 2005

Characterize SONAR array EE Spring 2005

Implement speech-recognition feature (HW and SW) CprE Spring 2005

Implement control circuits for end effector motors EE Fall 2005

Build top-level façade for end effector deck (any) Fall 2005

Implement control software for end effector CprE Fall 2005

Implement navigational software algorithm CprE Fall 2005

Current feature set to be fully implemented before developing new features

Remote and auto drive motion Remote and auto end effector Auto navigation and object avoidance Speech command input

Resources and SchedulesDavid, Gus

Resources and Schedules

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rsTask resources Additional resources Additional

resource requirements

Visitor demonstrations

Project planning and tracking

Troubleshooting SONAR array


Financial Requirement

Battery $135.96

Total Other $192.48

Façade materials $17.56

Deliverables$38.96

Labor $8,242.50

Donated Resources

Power system materials Various gauges of wire Wire ties and labels

Wireless Ethernet card (x2)

27GB hard drive


Financial Requirement


Project ScheduleAmbitious schedule Tasks collected into groups Milestones are group

deadlines First demonstration

Oct 19 Class presentation

Nov 18 Industrial review

Dec 7

SummaryDung

What went well Acquiring materials Software development Design of the end effector Demonstrations

What did not go well Unanticipated hardware flaws (SONAR array)

What technical knowledge was gained Operation of frequency-to-analog converters, digital-to-

analog converters, and BasicX microcontrollers Writing and rewriting sections of the code base Use of Microsoft Project, AutoCAD, SolidWorks

Summary

Lessons Learned

What non-technical knowledge was gained Proper documentation methods Effort coordination

What would be done differently if you could do it over again

Plan development time for sensor troubleshooting Accurately determine end product status before planning

project

Summary

Lessons Learned

Anticipated potential risks Ordered parts do not arrive on time

Solution: Allow extra time for delivery

Failure to complete assigned tasksSolution: Get help from other team members

Cost of development exceeds expectationSolution: Delay purchase or seek alternate solution

Failure to attend a meetingSolution: Take notes and inform absent members

Anticipated risks encountered Failure to complete assigned tasks Failure to attend a meeting

Summary

Risks and Risk Management

Unanticipated risks encountered Failure of the sensor system

Solution: Test all hardware to find defect

Wheel tachometers do not use expected interfaceSolution: Design an interface circuit for the optical encoders

Code interface could not send any commands to move the robotSolution: Restructure old software using new Java classes

Resultant change in risk managementReview documentation of past semesters to accurately anticipate risksassociated with existing implementation

Summary

Risks and Risk Management

Summary

Closing Summary

Bring project back on track with purpose and scope

Create useable paper trail for future team members

Substantial, lasting progress to be made in next year of project

ongo-01 project oscar. project oscar fall 2004 zacharykotlarek cpre 492 davidhawley cpre 492...

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