Robotically Actuated Prevention/Intervention Device Full of Innovative and Responsible Engineering Critical Design Review February 25, 2010 Riley Pack Eric Pahlke Kelly Shuster Greg Stahl RAPID FIRE

PROJECT OVERVIEW The RAPID FIRE system will be able to recognize moving targets in a room, choose the optimal target, and track it. Recognize one or more moving targets using digital cameras. Choose the optimal target, track its movement, and fire a projectile (foam dart or disk) at it. Be capable of fully autonomous operation. Have a user interface that allows for control of modes, manual turret control, and image viewing. Operate off of AC wall power.

BLOCK DIAGRAM Power DSP(s) Control Processor Motors Camera Board(s) with FIFO Digital Connection Analog Connection Power Connection Mechanical

EXPANDABLE HARDWARE ARCHITECTURE Power Supply DSP PCB Motor Controller PCB Camera PCB Data ConnectionPower Connection Camera PCB DSP PCB Motors Up to 4 Cameras per DSP Up to 4 DSPs Currently using 2 DSPs (8 total cameras)

CONTROL PROCESSOR Power DSP(s) Control Processor Motors Camera Board(s) with FIFO Digital Connection Analog Connection Power Connection Mechanical

CONTROL PROCESSOR Receives (x,y) location of optimal target from DSP Communicates with DSP(s) via SPI Triggers PWMs attached to 2 H-Bridges Receives feedback from 2 Optical Encoders Uses negative feedback PI Controller to adjust position Horizontal and Azimuth positions each have their own PI Controller

CONTROL PROCESSOR Processor Selection TI Stellaris LM3S2965 Specifications 50 MHz Maximum Clock Speed 6 PWM Channels 2 Quadrature Encoder Interfaces (QEI) Single-cycle multiply instruction and hardware divide Variety of common interface modules

CONTROL PROCESSOR Plant Controller Target Motor Position from DSP SPI Interface Actual Motor Position from Optical Motor Encoder

CONTROL PROCESSOR K P s + K I Target Position Actual Position J = 0.5*M*R 2 T = Nm = 66.4 oz-in = 80% of Max Efficiency b = 0.045M = 2.3kgR = 4.5 in

CONTROL PROCESSOR K P = 100 K I = 50 t R = 1.5s t S = 5 s 20% overshoot

CONTROL PROCESSOR

CAMERA(S) Power DSP(s) Control Processor Motors Camera Board(s) with FIFO Digital Connection Analog Connection Power Connection Mechanical

CAMERA(S) Camera Selection Toshiba TCM8230MD from Sparkfun Specifications 15 or 30 FPS VGA or QVGA supported Digital Output (YUV422 or RGB 565) Auto Gain Control, Auto White Balance product_info.php?products_id=8667

CAMERA(S) Camera FIFO FIFO to USB Converter 8-bit Parallel Data Glue Logic DCLK VD HD Enable And Write Strobes Debug to PC SDA SCL uC/DSP 8-bit Parallel Data to DSP

CAMERA(S) – TEST BOARD Camera USB-FIFO FIFO SPLD

CAMERA(S) – TEST BOARD Almost Able to Take Sub-QCIF (128 x 96) Resolution Pictures USB Write Speed Too Slow Solution: Upgrade to Faster USB Chip

CAMERA(S) – TEST BOARD FIFO WR USB WR

CAMERA(S) – REVISION 2 Current Camera Status Ready to Order Camera Board Revision 2 Updated USB-FIFO Chip to Allow for 8 MBytes/sec Changed to Asynchronous FIFO to Simplify DSP Interface

CAMERA(S) – CAMERA / FIFO INTERFACE

CAMERA(S) – CAMERA / SPLD INTERFACE

CAMERA(S) – REVISION 2 LAYOUT Camera Level Shifter FIFO USB- FIFO

POWER Power DSP(s) Control Processor Motors Camera Board(s) with FIFO Digital Connection Analog Connection Power Connection Mechanical

POWER Power Supply 12V (Motors) 5V (Optical Encoder & FIFO) Isolated Integrated DC-DC Module from TI 3.3V (DSP I/O Voltage) Linear Regulators from TI 3.3V (Primary I/O Voltage) 2.8V (Camera I/O) 1.5V (Camera Sensor) 1.26V (DSP Core)

POWER ATX12V V W Power Supply 12 V Line Rated to 2 x 16 A 3.3 V Line Rated to 25 A 5 V Line Rated to 25 A

DIGITAL SIGNAL PROCESSOR Power DSP(s) Control Processor Motors Camera Board(s) with FIFO Digital Connection Analog Connection Power Connection Mechanical

DIGITAL SIGNAL PROCESSOR Processes images from CMOS cameras to detect and track moving targets Subtraction for motion detection Blob detection algorithm Replaced open source library with custom algorithm to make integration to DSP easier Communicates with the motor control processor Sends debug data to PC using FIFO to USB USB is an easier debug port than an LCD

DIGITAL SIGNAL PROCESSOR DSP Selection TI TMS320VC5501 Slightly lower performance than original selection, but QFP package greatly reduces cost and risk. Specifications 300 MHz, up to 600 MIPS Hardware Memory Interface Used for SDRAM, FIFOs, FIFO to USB Hardware I2C and SPI Controllers I2C used to control cameras and I/O expanders, and for boot loader SPI used to transfer data to the motor controller Driver Library Available from TI

DIGITAL SIGNAL PROCESSOR PCB Four layer board DSP SDRAM Hardware support for 4 cameras IO and I2C expanders allow multiple cameras to send data through the DSP’s External Memory Interface FIFO to USB converter (same as on camera boards) allows the DSP to send images and computation results to a PC Status: Schematic and Layout 100%, almost ready to order

DIGITAL SIGNAL PROCESSOR PCB Boot loader DSP has an I2C EEPROM boot mode Use an ATMEGA32 AVR to transfer code from RS- 232 to I2C EEPROMs Isolation All signals from the DSP connecting off the board are isolated to protect the DSP (ISO7240 from TI) The 3.3V DC-DC converter for the DSP is isolated (DCR from TI)

DIGITAL SIGNAL PROCESSOR PCB Power 5V from MC PCB Power 5V from MC PCB DSP USB Debug I/O Expanders To Camera PCB Memory Bus I2C Power Connection Isolators/ Level Shifters Isolated 3.3V DC-DC 1.26V VREG I2C Switch LEDs/ Debug SDRAM AVR Programming Port EEPROMs GPIO SPI Data to MC PCB RS232

DIGITAL SIGNAL PROCESSOR PCB LAYOUT DSP Boot loader SDRAM ISOLATORS I/O Expanders To Cameras To MC USB RS232

DIGITAL SIGNAL PROCESSOR PCB LAYOUT DSP Boot loader SDRAM ISOLATORS I/O Expanders To Cameras To MC USB RS232

MOTION DETECTION ALGORITHM Subtract Current Image From Previous Break Difference Image Into an n-by-n Grid Accumulate Location and Count of All Pixels in Region with Difference Above Threshold RegionNorm > NORM_MIN? Mark Region as Having Motion Checked Each Region? No Yes No Yes Find Largest Connected Set of Regions Find Centroid of Regions in Largest Set of Connected Regions Start

MOTORS/MECHANICAL Power DSP(s) Control Processor Motors Camera Board(s) with FIFO Digital Connection Analog Connection Power Connection Mechanical

MOTORS/MECHANICAL Two rotating platforms have been created One platform for azimuth, one for elevation Rotation achieved using turntables (Lazy Susan) DC motors used to rotate platforms Controlled with H-Bridge with PWM control Protection for deactivation feedback voltage from motor inductance Digital optical encoder used for position detection

MOTORS/MECHANICAL Turntable Selection Shepherd 9548 Purchased from Home Depot Specifications 500 lb Load Capacity 6 in. x 6 in. Size

MOTORS/MECHANICAL Motor Selection Robot MarketPlace ML-50 Specifications 120 RPM 730 mA Nominal Current 3.3 A Stall Current 320 oz-in Stall Torque oducts/ML-50.html

MOTORS/MECHANICAL Encoder Selection Avago AEDB-9140-F12 Specifications Optical Encoder 256 Cycles/Revolution 1024 Signal Changes/Revolution Fits Motor Shaft ocs/AV EN

MOTORS/MECHANICAL H-Bridge Selection Texas Instruments DRV X 3A Full Bridge Continuous Output (2 X 6A peak) or 1 X 6A Full Bridge Continuous Output (1 X 12A peak) Controlled With PWM up to 500kHz Self-Protection Circuits

CONTROL PROCESSOR/MECHANICAL INTERFACE DSP H-Bridge Motor Mechanical Interface Encoder Relative Angular Position Changes Current SDA SCL uC PWM Output x2

DIVISION OF LABOR TaskRiley PackEric PahlkeKelly ShusterGreg Stahl Camera BoardPSSS DSP Board Hardware SPS DSP SoftwarePSS Motor Control Board SPS Motor Control Software PS MechanicalSP PowerSP User InterfaceSSSP P = PrimaryS = Secondary

EXPENSES

SCHEDULE

MILESTONE 1 Mechanical System Complete Control System Can Move Platform to Desired Position DSP Board Populated and Verified Functional Camera Board Populated Camera Board Sending Pictures to Computer Power Distribution Works with All Boards

MILESTONE 2 Control System Tuned Correctly DSP Interfaced with One Camera DSP Running Correct Algorithms DSP Sending Targeting Positions to Control System

DESIGN EXPO Full System Operating Correctly with One or More Cameras Technical Manual User Manual

Questions? Kelly Shuster Riley Pack Eric Pahlke Greg Stahl