ECE 477 Design Review Team 6  Spring 2011 Left to right: Kirk Iler, Brian Bentz, Stephen Wolf, Fuhe Xu

Outline Project overviewProject overview Project-specific success criteriaProject-specific success criteria Block diagramBlock diagram Component selection rationaleComponent selection rationale Packaging designPackaging design Schematic and theory of operationSchematic and theory of operation PCB layoutPCB layout Software design/development statusSoftware design/development status Project completion timelineProject completion timeline Questions / discussionQuestions / discussion

Project Overview Defender is a basic defense system designed to identify and neutralize hostile targets. It combines a number of modules to create a turret-mounted defense system. Modules: CoilgunCoilgun Motor systemMotor system Image processingImage processing Ethernet connectivityEthernet connectivity

Project-Specific Success Criteria 1.An ability to fire a projectile using magnetic force1.An ability to fire a projectile using magnetic force 2.An ability to aim the projectile by controlling of the azimuth and elevation angles of the barrel2.An ability to aim the projectile by controlling of the azimuth and elevation angles of the barrel 3.An ability to charge a capacitor bank to a variable voltage, up to 400V3.An ability to charge a capacitor bank to a variable voltage, up to 400V 4.An ability to gather images and perform target recognition and tracking4.An ability to gather images and perform target recognition and tracking 5.An ability for a user to enter commands and display the status of the turret through an external interface5.An ability for a user to enter commands and display the status of the turret through an external interface

Block Diagram

Component Selection Rationale CameraCamera –Canon VC-C50i with PTZ Atom BoardAtom Board CapacitorsCapacitors –3900μF –400V max electrolytics(x4). U32L

Microcontroller PIC24FJ64GB002PIC24FJ64GB002 –16bit –64KB flash/8k RAM –16MIPS –3.3V –44 TQFP –5 Timers –1 USB OTG –2 I 2 C –15 remappable pins

Firing Controls - IGBT Criteria:Criteria: –Voltage –Amperage –Heat dissipation, Failure mode –Price Part chosen:Part chosen: –APT200GN60JDQ4 600V, 283/600A600V, 283/600A 640W,.25°C/W640W,.25°C/W $42.60$42.60 No sinkNo sink

Step angle: 1.8°±5%Step angle: 1.8°±5% Rated voltage: 12VRated voltage: 12V Current per phase: 0.4ACurrent per phase: 0.4A Holding torque: 2kg/cmHolding torque: 2kg/cm Mass:0.2kgMass:0.2kg Motor 42BYG023-R

Stepper Motor Controllers DRV8821 from Texas Instruments Controls 2 stepper motors up to 1.5A each 8-40V stepper motors Microstepping modes Edge triggered digital stepping via PWM from Micro

Packaging Constraints Portability – Defender should be easily moved and installed. Weight – lightweight to allow for small motors EMI resistant – To protect circuitry from strong fields present in coil gun. Firing range – Target over a broad area. Keypad – Interface must be easily accessible.

Packaging Layout Four major physical components: – –Base: Divided metal box containing control circuitry, high voltage capacitors, and power supply. – –Rotator: Uses stepper motors to aim the Coil Gun; Mounted on top of Base. – –Coil Gun: Mounted on top of Rotator. – –Camera: Mounted on top of Base.

Schematic/Theory of Operation Subsections: High voltage Control microcontroller Capacitor bank Atom processor Motors

Power Supplies 3.3 V low drop out linear regulator Provides power to the control microcontroller Supplied by rectifier from high voltage system Switching 12 V power supply (4 Amps) Supplies power to the Atom and the motors Supplied by second transformer on Power PCB

Motor Microcontroller Controls 2 direct drive stepper motors with two coils each 10 heat sink grounds to copper heat sink Dedicated I 2 C port expander Commands include reset, direction, decay mode, step mode 1/8 th microsteps Sense resistors and voltage reference limit current to 400 mA

Control Microcontroller Receives commands from Atom Communicates information to and from circuitry I 2 C communication bus (400 kHz) USB connection to atom Bypass capacitors Reset circuit

Other Components The photogates will function by creating a logic high when an object passes through. These will be directly interfaced to general purpose I/O pins. Sends an interrupt directly to the microcontroller to signal available information Microcontroller collects information over I 2 C Keypad Encoder

Performs image processing and system command Communicates with control microcontroller over USB Communicates with user interface over Ethernet. Atom processor

Power PCB Schematic

High Voltage Power Changed to TRIAC circuit to switch power.Changed to TRIAC circuit to switch power. Measure DC voltage using ADC.Measure DC voltage using ADC.

Rectifiers and I2C 12V transformer and bridge rectifier connects to Communication Control PCB.12V transformer and bridge rectifier connects to Communication Control PCB. 3.3V bridge rectifier.3.3V bridge rectifier.

ADC, LED switch, Coil Protection Diodes Capacitor bleed circuit connects to capacitor bank.Capacitor bleed circuit connects to capacitor bank. ADC measures current through a voltage divider.ADC measures current through a voltage divider. Protection diodes anti-parallel to coil.Protection diodes anti-parallel to coil.

Power PCB Layout

Communication PCB Layout

Software Design/Development Status ComputerComputer –Single Executable: GUI - implementedGUI - implemented Java.swing componentsJava.swing components Ethernet - testingEthernet - testing Wrapped in to GUI componentsWrapped in to GUI components Jnetpcap libraryJnetpcap library

Software Design/GUI Prototype

Software Design/Development Status MicrocontrollerMicrocontroller USB interface- not yet begunUSB interface- not yet begun Communicates with atom boardCommunicates with atom board I2C bus to interface to:I2C bus to interface to: Motor microcontrollerMotor microcontroller Charging controlsCharging controls

Software Design/Development Status Atom BoardAtom Board –Single Executable: Ethernet libraries- testingEthernet libraries- testing Winpcap libraryWinpcap library USB libraries- not yet begunUSB libraries- not yet begun PIC family librariesPIC family libraries

Camera status Microsoft Visual Studio 2008 configuredMicrosoft Visual Studio 2008 configured OpenCV image recognition libraries and camera motor libraries installedOpenCV image recognition libraries and camera motor libraries installed Drivers installed for S-Video frame grabber and motor USB to serial cablesDrivers installed for S-Video frame grabber and motor USB to serial cables Image capture functioning on computer intended for compilingImage capture functioning on computer intended for compiling Minor configurations still needed on Atom, which will be running the executablesMinor configurations still needed on Atom, which will be running the executables

Project Completion Timeline 3/11 PCB submission3/11 PCB submission 3/21Atom board Ethernet communication3/21Atom board Ethernet communication Image processing recognizing stationary targets Start populating PCBs and testing 3/28Start programming microcontroller3/28Start programming microcontroller Begin physical packaging 4/10Completed packaging and testing4/10Completed packaging and testing 4/11Start system integration4/11Start system integration 4/18Documentation and paperwork4/18Documentation and paperwork 4/27PSSC Demos4/27PSSC Demos

Questions / Discussion