Ongo01 – OSCARClient – Department of Electrical and Computer Engineering

Faculty Advisor – Ralph Patterson

Team Members –

9 December 2003

2nd Semester Students:Patrick Jordan CprE / MathFarrukh Mian EE James Sweeney CprE / PsychMichael VanWaardhuizen CprE / EEAbdul Qazi CprE

1st Semester Students:Argenis Acosta CprEDaniel Marquis EE Cory Farver CprEAbdallah Mwita CprEMatthew Frerics EE Jason Olson CprEDaniel Humke A EE Fahad Wajid EE

Presentation Overview

Introduction & OverviewMotion ControlPowerSensorsSoftwareGeneral Summary

Introduction

OSCAR is a demonstration robot for use in outreach to students and communityIts goal is to excite and interest students in engineering fieldsComprised of several subsystems, each the responsibility of a subteam

History

ISU Robotics ClubCYbot

Successful DemosWidely remembered, Goal

OSCARNext generation technologiesMore student development

Problem Statement

To successfully integrate all subsystems into a functional, safe and usable robotCreate demonstrations of interest to the public of the OSCAR’s capabilitiesPerform demonstrations for interested groups and for university outreach efforts

Users and Uses

UsersTeam membersOthers who have been trained on the system’s safe operation

UsesOutreach and public relationsEducation of K-12 students

Operating Environment

Indoors or prepared outdoor areasLevel surfacesModerate Temperatures (>65F)Free of obstacles shorter than 2.5ft

Team Structure

SubteamsMotion ControlPowerSensorsSoftware

Subteam Leader Coordination

Motion Control – Ongo01aMembers:Matt Frerichs (EE – 1st) – Team LeaderAlexandre Moulin (ME – 1st)Tom Shedek (ME – 1st)Fahad Wajid (EE – 1st)

Introduction

The Motion Control Subteam of OSCAR is responsible for controlling the movement of OSCAR as a whole as well as the construction and movement of the arm.

DefinitionsDefinitions

H-Bridge – Motor control circuit, controls the direction of the motorPCB – printed circuit board LM629 – Motion control circuit, outputs PWM and direction signals for speed and direction controlPWM – pulse width modulation

Problem Statement

Complete implementation of motion control circuitry that has been designed in previous semesters Re-design motion control circuitry if needed

End ProductDescription

Movement achieved in the base motors of OSCAR Movement achieved in OSCAR’s arm

AssumptionsAssumptions and Limitationsand Limitations

Software will be ready to control the motion control circuitryThe power supplied will be sufficient for the needs of the controllers Sufficient funding will be available

Previous AccomplishmentsPrevious Accomplishments

Motion control circuits designedSome parts of motion control circuits built and preliminary testing started

Milestones

Achieve base motor movement (65% complete)Achieve arm motor movement (65% complete)

Future Work

Work with software team on arm control software Improve performance of gripper and actuatorFind different funding sources in order to implement more up to date solutions

Design ActivitiesDesign Activities

Worked on new motion control scheme with different H-Bridge circuits

Implementation ActivitiesImplementation Activities

H-Bridges soldered on new PCBsAcquire new gripper actuator motor

Testing and Modification ActivitiesTesting and Modification Activities

Tested LM629 motion control boardTested old H-Bridge circuitsTesting of new H-Bridge Circuits

Personnel UtilizationCurrent Hours

OriginalEstimate

RevisedEstimate

Matt Frerichs 60.5 95 63Alex Moulin 38 94 40Tom Shedek 61 93 62Fahad Wajid 49 88 51

Financial ResourcesHours Rate With

HoursMatt Frerichs 60.5 $20.00 $1210.00Alex Moulin 38 $20.00 $760.00Tom Shedek 61 $20.00 $1220.00Fahad Wajid 49 $20.00 $980.00

Other ResourcesQuantity Estimated Actual

Poster 1 $5.00/each $3.00/eachMotion Control Components

1 $62.50 $0.00

Aluminum 1 $50.00 $0.00Machine Shop Usage

1 TBD $0.00

Total $117.50 $3.00/each

Summary

Made progress with OSCAR’s motion control circuitAccomplished some base motion and arm motion

Work accomplishedWork accomplished

Researched new gripper design

Assembled Arm

Created working CAD drawings of arm

Work accomplishedWork accomplishedMachined parts to assemble armDesigned the shoulder to attach the arm to OSCARAssembled the arm

Future Work

Improve performance of gripper and actuatorAttach the arm to OscarContinue fabricating partsDesign shafts for elbow and shoulderMachine a new handDesign new arm

Summary

Have completed the fabrication and assembly of OSCAR’s arm

Power - Ongo-01cTeam Members:Daniel J. Marquis (EE – 1st) – team leaderHong Nguyen (EE – 2st)

Definitions

DC/DC Power Supply – DC Voltage ‘A’ to DC Voltage ‘B’

DC/AC AC/DC Power Supply – DC Voltage ‘A’ to AC 120V– AC 120V to DC Voltage ‘B’

Presentation Outline

Introduction – to power sub team projectProject Activities – past, present, futureResources & Schedules – where we areConclusions – results & implications

Problem Statement

Primary Problem – Inefficient DC/AC AC/DCSecondary Problem –Sensors wall poweredTertiary Problem – Maintenance / Support

Intended Users & Uses

Users – OSCAR team members(Software, Sensors,

and Motion Control)

Uses – Power OSCAR during demos(The power system is not intended to provide power to non-related devices like home theater systems, full fledged desktop computers, electric lawn mowers, and halogen lamps.)

Assumptions and Limitations

Short DemonstrationsSensitive Power System Isolation Limited Battery Power

End Product(s)

DC-DC power supply system for computerPower budget for OSCAROnboard power supply for sensors (either temporary or permanent)

Previous Accomplishments

DC/DC Converter Designed (Spring ‘02)DC/DC Converter Constructed (Fall ’02)Battery Sensors Installed (Fall ’02)

Present Accomplishments

DC/DC Testing CommencedPower Budget MadeDocumentation updated & posted on web

Concluded DC/DC not up to spec.

Future Required Activities

Maintain Power System (ongoing)Improve Fusing (Spring 2004 & ongoing)Commercial Power Supply Evaluation (Spring 2004)

Approaches Considered and the One Used

Sensor Power- Rechargeable Battery Pack- DC/AC/DC Conversion Setup- DC/DC Converter ( Future)- Run off of PC ( Used Now)

Project Definition Activities

Not Applicable

Research Activities

Not Applicable

Design Activities

Not Applicable (though did improve the previous term’s team’s documentation)

Implementation Activities

Not Applicable

Testing and Modification Activities

Tested DC/DC Power SupplyTested old DC/AC AC/DC System

Other Significant Project Activities

Found DC/DC ConvertersCreated & Posted DocumentationReplaced 3 DC/DC Voltage Regulators (one exploded during a DC/DC power up)Repaired Fried Traces on PC Boards

Two DC/DC Converters Inside Box

DC/DC Converters Outside of Box

Resources & Schedule

Resource 1/2

Current Hours

OriginalEstimate

RevisedEstimate

Daniel J. Marquis 96.25 70 110

Hong Nguyen 70 67 87

Time (as of 7 December 2003)

Overall Hours Spent

Making report51%

Ordering parts1%

Search for / Read

documentation 11%

Research1%

Physical installation and testing

18%

Meetings18%

Resource 2/2

Money (as of 7 December 2003)

Item Estimated Actual Difference (Estimated-Actual)

Project Poster (Cost to Sub-Team) $50.00 $6.00 $44.00

Fuses $0.00 $3.00 -$3.00

Voltage Regulators $0.00 $0.00 $0.00

TOTAL $50.00 $9.00 $41.00

Schedule

Task From Day Month To Day Month Length of Time(total day)

Provide Temp Power

Research testing circuit(DC/DC)Testing DC/DC circuit

Research testing circuit(Monitor Battery)Testing Monitor Battery

Provide Power

21 9

21 9

30 9

21 9

30 9

26 10

23 11

26 10

30 10

26 10

30 10

25 12

45

25

23

25

23

44

Behind due to DC/DC failures

Project Evaluation

Milestone Priority Completion

DC-DC Converters Found High 100%

Power Budget Created High 30%

Battery Status Verified High 100%

Fuse Protection Implemented / Verified High 25%

DC-DC Converters Tested Medium 80%

Battery Indicators Verified Low 0%

Temp Sensor Power Solution Researched Low 25%

Temp Sensor Power Solution Built and Installed Low 90%

Temp Sensor Power Solution Tested Low 90%

Recommendations for additional work

Inline, Accessible FusesCommercial DC/DC

Summary

DC/DCDC/AC AC/DCDocumentationCommercial Solution

Sensors – Ongo-01dMembers:Michael Van Waardhuizen (CprE/EE – 2nd) – Team LeaderFarrukh Mian (EE – 2nd)Cory Farver (CprE – 1st)Daniel Humke (EE – 1st)

Faculty Advisor: Professor Ralph Patterson IIIClient: Department of Electrical and Computer Engineering

Iowa State University

Outline

Problem StatementEnd Product DescriptionAssumptions & LimitationsPrevious and Current AccomplishmentsTechnical ApproachesCurrent ActivitiesResourcesConclusion

Definitions

Azimuth The horizontal angular distance from a reference direction, usually the northern point of the horizon, usually measured clockwise.Micro-controller A microcontroller is an embedded, complete system. A microcontroller typically includes small amounts of memory, timers, and I/O ports.Basic-X24 BasicX-24 is one of the most powerful BASIC programmable microcontrollers.Thermistor A resistor made of semiconductors having resistance that varies rapidly and predictably with temperature

Problem Statements

OSCAR requires functional sonar system for navigation (has not functioned since Spring 2002)Temperature sensors does not operateCompass sensor does not operate

Solution Approaches

Research replacement sonar systems, compass systemTest hardware components individuallySimplify software components

End Product Description

Functional sonar arrayFunctional compassFunctional temperature sensor

Operable by on board computer without assistance

AssumptionsAssumptions and Limitationsand Limitations

Power system will provide adequate and stable enough powerSonar detect distances from only 1.33 - 35 feet (+/- 3%)The compass sensor must be allowed 2.5 to 3.5 seconds to settle from rotational displacement

Limitations cont.

The compass sensor must be positioned to have a tilt of no more than +/- 5° with respect to the ground. A successful compass reading can only be done on flat terrain.The compass sensor may have limited accuracy (+/-5° Azimuth) due to electromagnetic interference from drive motors, computers and power supplies The sonar will not experience electromagnetic noise such that prevents proper operation

Previous AccomplishmentsPrevious Accomplishments

Completed sensors system:8 directional sonar arrayCompassTemperature Sensor

Malfunction left unsolved, array semi-functional at end of last semester, requiring a connection board rework/replacement

Sonar System

Present Accomplishments

Replacement of the microcontrollerNetworked OSCAR’s hard drives Researched alternative sonar systemResearched alternative compass circuitsMiscellaneous repairsInitial functional testing of our projects subsystems.

Future Activities

Research into sensor extensibilitySystem maintenanceReplacement of compass to provide increased accuracyMapping algorithm

Approach 1

Replacement of old system with new technology:

Pros: A fresh start, re-evaluation of necessary capabilitiesCons: Would require a large amount of money, brand new system isn’t guaranteed to work

Approach 2

Testing & Repair of existing circuitryPros: Certain that system worked once, low costCons: Errors and bugs difficult to find, especially in hardware, existing system may break again

Chose approach 2 for budgetary reasons.

Design & Implementation ActivitiesDesign & Implementation Activities

Redesign of a connection boardReplacement of microcontrollerHardware repairs for system integrityNetworking of OSCAR hard drives

Testing and Modification ActivitiesTesting and Modification Activities

Complete testing of 3 microcontrollers to establish if replacement was necessaryTesting of software for PC and microcontroller to establish operating system dependenceTesting of sonar modules, compass, and temperature sensor for functionality

Personnel UtilizationCurrent Hours

OriginalEstimate

RevisedEstimate

Michael VW 45 27 45Farrukh Mian 33 27 40Cory Farver 85 26 75Dan Humke 41 25 45

Personal Util. cont.

Personal Hours (204 Hours Total)

MichaelDanCoryFarrukh

Financial ResourcesActual Financial Costs

Item Without Labor With Labor

Previous Semester $40.00 $40.00

Sensor $ - $ -

Transducer (2) $ - $ -

Board Etching $ - $ -

Poster Printing $12.00 $12.00

Miscellaneous Parts $57.00 $57.00

Subtotals $109.00 $109.00

Labor at $10.75 per hour

Previous Session $2,931.75

Farver, Cory $913.75

Humke, Daniel $440.75

Mian, Farrukh $354.75

VanWaardhuizen, Michael $483.75

Subtotals $5,124.75

Totals $109.00 $5,233.75

Schedule

Summary

Sensors did not function at beginning of the semesterHardware problems mid-semesterReplaced faulty hardwareSystem works, in testing for accuracyIntegration with OSCAR for navigation to come

Software – Ongo01eMembers:James Sweeney (CprE – 2nd) – team leaderAbdul Nasir (CprE – 2nd) Patrick Jordan (CprE – 2nd) Jason Olson (CprE – 1st) Abdallah Mwita(CprE – 1st) Argenis Acosta (CprE – 1st)

Introduction

The software sub-team on OSCAR is charged with developing the software controls to OSCAR’s hardware and also creating demonstrations utilizing that hardware.

Problem Statement

Create a simple software interface for OSCAR system using Java Deploy effective code and document versioning systemExplore available upgrade paths, both hardware and softwareEnsure portability of code

Design Objectives

Create new low level IO interface for Motion Control Verify that existing demonstrations work with new interfaceDevelop new demonstration capabilitiesSet up system to organize all of OSCAR’s code and documentation in one repository.

Past Accomplishments

Initial, functional code baseInterface with Motion Control LM 629Speech Capabilities via ViaVoiceInitial arm interface code

Present Accomplishments

Successful interface with sensorsDelivery of new Motion Control interfaceDeployment of a versioning systemReplacement of malfunction computerImplementation of wireless networkTransition to complete Java solution

AssumptionsAssumptions and and LimitationsLimitations

The motion control hardware on OSCAR is functional.End-effector will be complete. Sensors are functional and interface via RS232Sufficient resources will be available

End ProductDescription

Code and document repository for use by entire team Code to run during OSCAR demonstrations. Documentation detailing the operation of the OSCAR software.

Approaches Considered

Further development on Windows 98Lacks device supportDifficult to find programming resources

Upgrade to more recent Windows OSNot designed for embedded developmentlow level interface code difficult to create

Approach Used

GNU/Linux OS based solutionGrowing use in undergraduate curriculumExtensive developer supportEmbedded versions readily availableSignificant assistance available from community

Research ActivitiesOS Choice

Low level IO major concernMust be easily picked up by students

Motion Control BoardsSimplify Motion Control interfaceExpensive, must find willing donor

New, lower power computing solutionSeveral solutionsCost major concern

Design and Implementation

ActivitiesRe-implementation of low level IORe-factoring of existing software to ensure portability

Testing and Modification

Modification of existing code to ensure portabilityTesting of Motion Control interfaceTesting of Sensors interface

Technical Approach

Sensors Hardware

Motion ControlHardware

JNI

Serial Port

I/O Card

Java Codebase

Technical Approach

Java Codebase

Sensors Hardware

Motion ControlHardware

Java Comm API

Personnel UtilizationCurrent Hours

OriginalEstimate

RevisedEstimate

Jason Olson 54 63 58Abdul Nasir 34 64 40Patrick Jordan 65 65 67James Sweeney 69 61 70Abdallah Mwita 28 64 30Argenis Acosta 64 63 65

Resource Utilization

Item Projected Cost Actual Cost

802.11b Card $40 $0 (on loan)

Replacement Computer

Unprojected $0

Poster(Entire Team)

$50 $50

Milestones

Configure and deploy CVS server for team use. (100% complete)Code portable and IO tested on multiple OS’s (65% complete)Demonstration code to run during OSCAR demonstrations (50% complete)

Future Work

Complete the arm code; dependent on arm construction Refinement of the speech code and demonstration code Purchase of new lower power computer

Summary

CVS deployed and populatedIO interface changed by Motion Control, new code developedPortability of code base reviewedOptions for alternate OS paths have been evaluatedWireless access, improved interfaces on the way

Lessons Learned

Importance of intra-team communicationNecessity of evaluating changes effects on whole projectThe value of versioning systems in large group settings

Risks and Risk Management

Emergent circular dependencyUse of redundant development paths

Team failure because of single subteamfailure

Created several possible development tracks that can be pursued

Code or document lossUse of CVS with central backup

Closing Summary

Fully functioning sensors suiteMotion Control has new demonstrated functional interfaceSoftware has deployed new low level code for new Motion Control interfaceDemos will be ready after testing and revision on new low level code, returning OSCAR to a functional state

Questions?