Team Members: Ryan Emerson – CPRE, David Goldberg – EE, David Moline – EE, Mevan Vijithakumara – ME, Brian Wicks – CPRE

Client: Mr. Charles Juel

Faculty Advisors: Dr. John Lamont and Prof. Ralph Patterson III

The Dream Green - Final Phase(May06-03)

Presentation OutlinePresentation Outline

Problem DefinitionProblem DefinitionBackgroundBackgroundHardware DesignHardware DesignSoftware DesignSoftware DesignElectronic ComponentsElectronic ComponentsQuestionsQuestions

AcknowledgementsAcknowledgements

Mr. Charles JuelMr. Charles JuelPrevious Senior Design TeamsPrevious Senior Design TeamsDr. John Lamont and Prof. Ralph Dr. John Lamont and Prof. Ralph Patterson IIIPatterson III

Original Design OverviewOriginal Design Overview

Original Design OverviewOriginal Design Overview(cont.)(cont.)

Manual sliding wedgesManual sliding wedgesEnd lift set either up or downEnd lift set either up or downTedious and time consuming Tedious and time consuming adjustmentsadjustments

Problem StatementProblem Statement

Automation of Dream Green putting surfaceAutomation of Dream Green putting surfaceDevelop simple user interface to control Develop simple user interface to control systemsystemEasily and profitably manufactured end Easily and profitably manufactured end productproductDesign reliable and durable systemDesign reliable and durable systemBuild on and complete work of previous Build on and complete work of previous design teamsdesign teams

Operating EnvironmentOperating Environment

To be used indoors or in other To be used indoors or in other controlled environmentscontrolled environmentsSurface degrades in UV light and canSurface degrades in UV light and can’’t t be used in direct sunlightbe used in direct sunlightReasonable tolerance to everyday Reasonable tolerance to everyday wear and tearwear and tear

Intended Users and UsesIntended Users and Uses

Recreational and professional usersRecreational and professional users–– Sports barsSports bars–– Marketing eventsMarketing events–– Amateur and professional golfersAmateur and professional golfersMinimal learning curve for beginnersMinimal learning curve for beginnersDesigned for 350 lb capacity per Designed for 350 lb capacity per sectionsectionSuitable for all agesSuitable for all ages

AssumptionsAssumptions

Dream Green will not be exposed to direct sunlightDream Green will not be exposed to direct sunlightDesigned for household power (120V, 15A max)Designed for household power (120V, 15A max)No additional loads will be on surface during No additional loads will be on surface during adjustmentsadjustmentsDream Green will be operated on a flat, level Dream Green will be operated on a flat, level surfacesurfaceAll automation equipment will be installed at the All automation equipment will be installed at the factoryfactoryAutomation will not be retrofitted into previously Automation will not be retrofitted into previously sold Dream Greenssold Dream GreensAll sections will be 4 feet longAll sections will be 4 feet long

LimitationsLimitations

Wedges must be used in final designWedges must be used in final designAdjustment transitions in <45 secondsAdjustment transitions in <45 secondsHeight of automation components Height of automation components must fit within +2must fit within +2”” of current structureof current structureAdditional price of automation system Additional price of automation system must be under $1,000 USDmust be under $1,000 USD

Initial Automated DesignInitial Automated Design

DC motor driven wedgesDC motor driven wedgesWedge slides across wood surfaceWedge slides across wood surfaceLED/photodiode position sensorLED/photodiode position sensorDual motor end liftDual motor end liftExternal, similarly sized gearsExternal, similarly sized gears

Hardware Design Hardware Design (Side Lift)(Side Lift)

Standard DC motors used from Standard DC motors used from previous design teamsprevious design teamsGeared DC motors preferred for final Geared DC motors preferred for final designdesignDirect drive configurationDirect drive configurationGuide rails to direct wedgesGuide rails to direct wedgesThreaded brass inserts for wedgesThreaded brass inserts for wedges

Hardware Design Hardware Design (Side Lift)(Side Lift)

Hardware Design Hardware Design (End(End--lift)lift)

Dual wedge systemDual wedge systemGuide rails to direct wedgesGuide rails to direct wedgesCrossbar attached to both wedges Crossbar attached to both wedges Threaded block attached to crossbarThreaded block attached to crossbarSingle geared DC MotorSingle geared DC Motor12V robotic motor (146 oz12V robotic motor (146 oz--in torque)in torque)60 60 -- 100 oz100 oz--in torque requirementin torque requirement

Hardware Design Hardware Design (End(End--lift)lift)

Hardware Design Hardware Design

Materials UsedMaterials Used–– ACME threaded carbon steel rodACME threaded carbon steel rod–– Brass threaded inserts and blocksBrass threaded inserts and blocks–– Aluminum angle iron guide railsAluminum angle iron guide rails–– UHMW wedgesUHMW wedges–– Steel cross bar for endSteel cross bar for end--liftliftAdditional considerationsAdditional considerations–– Motor protection circuitMotor protection circuit

Software Design OverviewSoftware Design Overview(Side Lift)(Side Lift)

Human Interface

Motor controller board (4)

Side-lift motor (4)

H Bridge

Rotary Encoder

Software Design OverviewSoftware Design Overview(End Lift)(End Lift)

Human Interface

Motor controller board (3)

Side-lift motor (2)

H Bridge

Rotary Encoder

H Bridge

End-lift motor

Rotary Encoder

Software DesignSoftware Design

Programmed in C using Microchip Programmed in C using Microchip PICC18 compilerPICC18 compilerMore intuitive than AssemblyMore intuitive than AssemblyAdditional libraries for CAN, USART, Additional libraries for CAN, USART, and ADC includedand ADC included

Software DesignSoftware Design (Cont.)(Cont.)

BoardBoard--toto--board communicationsboard communications–– Each board will need to communicate with the Each board will need to communicate with the

user interface boarduser interface board–– Decided to use CAN (Controller Area Network)Decided to use CAN (Controller Area Network)–– Other protocols consideredOther protocols considered

SPI (3SPI (3--wire, hard to share the bus)wire, hard to share the bus)II22C (Not very noise resistant)C (Not very noise resistant)RS232 (DoesnRS232 (Doesn’’t work well in multit work well in multi--hop networks)hop networks)RS485 (Addressing more difficult than CAN)RS485 (Addressing more difficult than CAN)LIN (Not very common)LIN (Not very common)

Software DesignSoftware Design (Cont.)(Cont.)

Human interfaceHuman interface–– Reads user input via keypadReads user input via keypad–– Displays messages with character LCDDisplays messages with character LCD–– Connection to PC for downloading predefined Connection to PC for downloading predefined

holes and gamesholes and games–– MenuMenu

Random holeRandom holePreloaded gamePreloaded gameUserUser--defined configurationdefined configuration

–– Relays commands to motor control boardsRelays commands to motor control boards–– Receives error messages from motor control Receives error messages from motor control

boardsboards

Software Design Software Design (Cont.)(Cont.)

Motor controller boardsMotor controller boards–– Receives messages from interface to Receives messages from interface to

change wedge positionchange wedge position–– Controls motor power and direction with Controls motor power and direction with

National Semiconductor HNational Semiconductor H--BridgeBridge–– Keeps track of motor position with rotary Keeps track of motor position with rotary

encoder and home position switchencoder and home position switch–– Monitors motor currentMonitors motor current

Electronic ComponentsElectronic Components

Parts ConsiderationsParts Considerations–– MicrocontrollerMicrocontroller

User interface User interface –– PIC18F4480 (40PIC18F4480 (40--pin)pin)CAN controllerCAN controllerUSART (serial) controllerUSART (serial) controllerEnough digital I/O pins for LCD and keypadEnough digital I/O pins for LCD and keypad

Motor controllers Motor controllers –– PIC18F2480 (28PIC18F2480 (28--pin)pin)CAN ControllerCAN ControllerPWM OutputsPWM OutputsTimer/CounterTimer/CounterDigital I/O for HDigital I/O for H--bridgebridge

Electronic Components Electronic Components (Cont.)(Cont.)

–– CAN TransceiverCAN TransceiverMicrochip MCP2551Microchip MCP2551Alternatives from Analog Devices, Maxim, etc.Alternatives from Analog Devices, Maxim, etc.

–– Serial/USBSerial/USBMaxim MAX233Maxim MAX233TI TUSB3410TI TUSB3410

–– HH--bridgebridgeNational Semiconductor LMD18200National Semiconductor LMD18200

–– ShortShort--circuit protectioncircuit protection–– Thermal protectionThermal protection–– Integrated current sensorIntegrated current sensor–– Replaces the relays used by previous teamsReplaces the relays used by previous teams

End Product and Other End Product and Other DeliverablesDeliverables

Functional Prototype for evaluationFunctional Prototype for evaluationBill of materials for designBill of materials for designList of suppliers for componentsList of suppliers for componentsEstimated cost for automation systemEstimated cost for automation systemDetailed drawings for manufacturingDetailed drawings for manufacturingUser manualUser manual

ConclusionConclusion

Working Prototype near completionWorking Prototype near completionGoalsGoals–– User friendly, intuitive interfaceUser friendly, intuitive interface–– Easily manufactured designEasily manufactured design–– Reasonably profitable product for clientReasonably profitable product for client

QuestionsQuestions