ECE 477 Final Presentation Group 1  Fall 2005 Kwun Fung Yau Chad Carrie Zubin Rupawala Manoj Jacob

Outline Project overviewProject overview Block diagramBlock diagram Professional componentsProfessional components Design componentsDesign components Success criteria demonstrationsSuccess criteria demonstrations Individual contributionsIndividual contributions Project summaryProject summary Questions / discussionQuestions / discussion

Project Overview Remote Controlled vehicle with a water cannon mounted on a pan/tilt turret along with a cameraRemote Controlled vehicle with a water cannon mounted on a pan/tilt turret along with a camera Controller by a remote user at a PC via b Wireless (UDP) and navigated by the video cameraController by a remote user at a PC via b Wireless (UDP) and navigated by the video camera Intuitive PC interface (designed to be controlled like an FPS game – Mouse + WASD)Intuitive PC interface (designed to be controlled like an FPS game – Mouse + WASD) Sensors mounted on vehicle for obstacle avoidanceSensors mounted on vehicle for obstacle avoidance

Block Diagram Micro-controller PWM Pan / Tilt servosSteering servoDrive train ATD IR sensors Water Pump / Cannon Wireless Webcam Wireless Router USERPCUSERPC

Professional Components Constraint analysis and component selection rationaleConstraint analysis and component selection rationale Patent liability analysisPatent liability analysis Reliability and safety analysisReliability and safety analysis Ethical and environmental impact analysisEthical and environmental impact analysis

Constraint Analysis (Chad) Power SupplyPower Supply - Large current needs (turned out to need less current than planned) less current than planned) - Several different voltage requirements Microcontroller – Freescale MC9S12NE64CPVMicrocontroller – Freescale MC9S12NE64CPV –CodeWarrior – reliable IDE –80 pins (38 general IO pins) –Built in Ethernet interface –ATD (for analog infrared sensors) –Emulated PWM (motors and servos) –Rabbit RCM3000 has no ATD! –Can program with BDM

Constraint Analysis (Chad) Water PumpWater Pump - Hargraves Advanced Fluidic Solutions LTC W diaphragm pump - 30 psi - planned on 5 feet of water travel - ~ 25 feet of actual water travel WebcamWebcam - Linksys WVC11B - Wireless - Capable of b format - Built-in Web Server

Constraint Analysis SensorsSensors - 6x Sharp GP2Y0A02YK (~ 4 foot range) (analog) BatteryBattery VDC battery pack from Hummer H VDC battery pack, 2400mAh Pan/Tilt servos – Devantech SR0FXPan/Tilt servos – Devantech SR0FX - Pre-built for pan and tilt motions - Would have been cheaper and better to build our own build our own

Constraint Analysis Vehicle PlatformVehicle Platform –Needed ample room to mount peripherals –Has a finished body –Included a battery pack –Has a rear motor to drive forward and backward (large current spike) –Had a steering servo which was replaced

Patent Liability Analysis (Zubin) Patents foundPatents found –# 6,645,037 - Programmable toy and game –# 6,533,191 - Water projection device and method for projecting water –# 6,658,325 - Mobile Robotic with web server and digital radio link –# 6,845,297 - Method and system for remote control of mobile robot

Patent Liability Analysis (Zubin) Literal InfringementsLiteral Infringements –# 6,658,325 - Mobile Robotic with web server and digital radio link Infringements under Doctrine of EquivalentsInfringements under Doctrine of Equivalents –All others Shooting waterShooting water Keyboard ControlKeyboard Control Control MechanismControl Mechanism

Patent Liability Analysis (Zubin) Similar Commercial ProductSimilar Commercial Product -Adventure Cam

Reliability/Safety Analysis (Kwun) Reliability Analysis (MTTF Analysis)Reliability Analysis (MTTF Analysis) - Freescale MC9S12NE64 MCU – years - Vishay SUD50DN02-06 Power MOSFET for water pump – years - Vishay Si1865DL Load Switch for Power Options – years - AnaChip AP1501A Power Regulator – 773 years

FMECAFMECA - High Criticality (high potential to cause injury) 1. Microcontroller 2. Power 3. Drive Train 4. Wireless bridge and webcam - Low Criticality 1. Water Pump 2. Sensors 2. Sensors Reliability/Safety Analysis (Kwun)

Ethical/Environmental Analysis (Manoj) Warning labelsWarning labels - The 19.2V and 12V battery. - The Pan/Tilt servos - PCB Example: WARNING: Live Electrical Components. May Cause Shock! In case of problems, take product to manufacturer.Example: WARNING: Live Electrical Components. May Cause Shock! In case of problems, take product to manufacturer.

Ethical/Environmental Analysis (Manoj) Hazard due to waterHazard due to water - Secure wires against water - Seal the water tank, pump and pipe against leaks Battery rechargerBattery recharger - Design a battery recharger to plug into the shell

Ethical/Environmental Analysis (Manoj) Objects entering through the undercarriageObjects entering through the undercarriage - Fitting a plastic plate underneath the Hummer W2 Erratic circuit behavior due to low battery chargeErratic circuit behavior due to low battery charge - Install a voltage monitor Hummer W2 will collide with objects and peopleHummer W2 will collide with objects and people - Sensors will prevent collision

Ethical/Environmental Analysis (Manoj) Dangerous chemicals used in PCB fabricationDangerous chemicals used in PCB fabrication - Use chemicals like Peroxy- Sulfuric acid Disposal of the Hummer W2 can pose a problemDisposal of the Hummer W2 can pose a problem - Consumers can call Solid & Hazardous Waste Division ( )

Design Components Packaging design considerationsPackaging design considerations Schematic design considerationsSchematic design considerations PCB layout design considerationsPCB layout design considerations Software design considerationsSoftware design considerations

Packaging Design (Kwun)

Schematic Design (Chad)

Ethernet schematicEthernet schematic Taken from FreeScale recommended schematicsTaken from FreeScale recommended schematics

Schematic Design (Chad) 2 Rear Infrared Sensors2 Rear Infrared Sensors Servos for steering and pan/tiltServos for steering and pan/tilt

Schematic Design (Chad) The new Front sensorsThe new Front sensors Originally Digital SensorsOriginally Digital Sensors Now Analog SensorsNow Analog Sensors

Schematic Design (Chad) Optional LED’sOptional LED’s 2x Power Options for 5V 1A loads2x Power Options for 5V 1A loads - Never tested because time constraints

Schematic Design (Chad) 5VDC regulators from 12VDC input5VDC regulators from 12VDC input Replaced the switchesReplaced the switches

Schematic Design (Chad) 3.3VDC regulator from 12VDC input3.3VDC regulator from 12VDC input

Schematic Design (Chad) MOSFET for the WaterPumpMOSFET for the WaterPump

PCB Layout Design (Manoj)

Software Design (Zubin) Two partsTwo parts –Microcontroller –PC Interface MicrocontrollerMicrocontroller –Polling loop –Interfaced to PC via UDP (over Ethernet/wireless) –Using the OpenTCP stack –Used (TIM) Simple PWM for servo motors, ATD for sensors –Fits in 64KB flash of MC9S12NE64

Software Design (Zubin) Init Check for Ethernet packet Check sensors, set flags Control PWM for motors, turret Drive train motor control

Software Design (Zubin) Inter device communicationInter device communication –UDP packets –3 bytes data (not including Ethernet/UDP frame size) –Movement, Turret position, Shoot (0,0,0) –One packet sent every 500 ms 500 ms

Software Design (Zubin) PC InterfacePC Interface –Written in Visual Studio.NET with C# –Communicates with Microcontroller via UDP packets –Controls the motors and water cannon –Displays the video from webcam

Software Design (Zubin)

Success Criteria Demonstrations 1.Ability to control vehicle drive train (forward/ reverse/ speed/ turn) - demo demo 2.Ability to position turret (rotation / elevation) - demo demo 3.Ability to fire water cannon - demo demo 4.Ability to avoid collisions - demo demo 5.Ability to receive/decode UDP stream over Ethernet/wireless to control vehicle, turret and cannon

Individual Contributions Team Leader - Chad CarrieTeam Leader - Chad Carrie Member 2 - Zubin RupawalaMember 2 - Zubin Rupawala Member 3 - Manoj JacobMember 3 - Manoj Jacob Member 4 - Kwun Fung YunMember 4 - Kwun Fung Yun

Team Leader – Chad Carrie Ordered most of the partsOrdered most of the parts Constraint Analysis PaperConstraint Analysis Paper Schematic Design PaperSchematic Design Paper Populated the PCBPopulated the PCB Helped with the PCB LayoutHelped with the PCB Layout Package ConstructionPackage Construction Repaired after damagingRepaired after damaging

Member 2 – Zubin Rupawala Designed entire software logicDesigned entire software logic Designed the control interface with visual studio.NET (GUI) with C#Designed the control interface with visual studio.NET (GUI) with C# Implemented the UDP decode subsystemImplemented the UDP decode subsystem Programmed the ATD and TIM modules for sensors and servo motors with help of Manoj and KwunProgrammed the ATD and TIM modules for sensors and servo motors with help of Manoj and Kwun Patent LiabilityPatent Liability Helped with actual constructionHelped with actual construction Debugged and Tested systemDebugged and Tested system

Member 3 – Manoj Jacob Research on parts requiredResearch on parts required Tested the theory of operationTested the theory of operation Helped with Schematic designHelped with Schematic design PCB designPCB design Ethical and Environmental AnalysisEthical and Environmental Analysis Helped with Package ConstructionHelped with Package Construction

Member 4 – Kwun Fung Yau Designed the user control interface with Visual Studio.NET in C#Designed the user control interface with Visual Studio.NET in C# Programmed the keyboard and mouse movement logicProgrammed the keyboard and mouse movement logic Programmed the ATD modules for sensorsProgrammed the ATD modules for sensors Help with debuggingHelp with debugging Packaging DesignPackaging Design Reliability and safety analysisReliability and safety analysis Helped with hardware integrationHelped with hardware integration Order partsOrder parts Debugged and Tested systemDebugged and Tested system

Project Summary Important lessons learnedImportant lessons learned –Zip ties and hot glue and proto-boards are essential for prototyping –Ground/power traces should be extra thick –DC motors and current spikes –For prototyping, local sources should be used for parts acquisition –Don’t use ready-made parts (“intelligent” h-bridge, pan/tilt)

Project Summary Important lessons learntImportant lessons learnt –Headers are invaluable –Code-warrior/debugging skills –Team work and time-management skills

Project Summary Second iteration enhancementsSecond iteration enhancements –Build own H-bridge –Use custom parts (no reverse engineering) –Use better turret (pan/tilt) –Use only one battery –Add more functionality

Questions / Discussion