Ongo-01 Project OSCAR

Project Oscar Fall 2004 ZacharyKotlarek CprE 492 DavidHawley CprE 492 MichaelLarson EE 492 JustinRasmussen CprE 492 GavinRipley CprE 492 Peter Rufino EE 492 JasonSytsma EE 492 KevinCantu EE 491 Phil Derr EE 491 JawadHaider EE 491 JeffParent CprE 491 Client Department of Electrical and Computer Engineering Presentation Date January 27, 2005 Faculty Advisor Ralph Patterson III Team Members

Initial InformationHuy Project IntroductionWilliam, John Description of ActivitiesEveryone Resources and SchedulesDavid, Gus SummaryDung Project Oscar Presentation Overview

OSCAROctagonal Speech-Controlled Autonomous Robot CVSConcurrent versions system CybotThe predecessor to OSCAR drive trainThe assembly of electrically controlled motion elements, including the robot’s wheels, gears, belts, and tachometers End effectorThe assembly of electrically controlled mechanical arm and gripper EthernetA computer network communication protocol GUIGraphical user interface Linear bearingA rolling element that moves on a straight track SONARSound navigation and ranging TachometerA device for indicating speed of rotation Project Oscar List of Definitions

Project Introduction William, John

General Problem Statement To capture the interests of visitors and potential students, the department needs an exciting demonstration of the technological capabilities of its students. Last Semester’s Needs New power system Improve drive train Navigation using SONAR New robotic end effector General Solution Approach Recreate entire power delivery system Understand and improve existing software base Design a more suitable end effector Develop intelligent coordination of SONAR and drive motion Project Introduction Problem Statement

Project Introduction Operating Environment Indoors (Outdoors with ideal weather) Temperature between 32 o F – 100 o F Flat surfaces If obstacles are present, they must be at least 2.5 feet high to be detected

Project Introduction Intended Users and Uses Users Project OSCAR team members Trained demonstrators Supervised non-technical users Uses Demonstrate to campus visitors Communicate with operators and audience Autonomous navigation throughout a room or corridor Pick up and place objects Respond to spoken commands

Project Introduction Assumptions and Limitations Assumptions Operators speak English Demonstrations last under an hour Technical supervisors present during operation Limitations Software must run in Mandrake Linux SONAR range is 0.5 – 35 feet Wireless Ethernet within 328 feet Must fit through a standard 30-inch doorway Power supply must be rechargeable End effector must fit within top module

Project Introduction End Product Full drive motion capability Interaction with users via speech recognition software GUI-driven software package Wireless connection Manual motion control Speech output Room/corridor navigation Script recording and playback Externally rechargeable power supply

Project Introduction Other Deliverables End-user operation instructions Power system and recharging instructions Software user’s guide Power system specifications and schematic SONAR array specifications and schematics

Description of Activities Everyone

Command-line speech output New motor control for drive motion End effector assembly was made lighter Project website was redesigned Partial description of navigation algorithm Description of Activities Previous Accomplishments

Rebuild power delivery system Reroute wiring Install interface panels Consider power inversion and conversion methods Purchase and install new battery Create schematics and user’s manual Improve software architecture Document existing software Develop wireless control interface Test and document new software Developed a GUI Description of Activities Present Accomplishments

Create reference base for SONAR array Build façade for chassis Improve drive train Fix belt slipping Design tachometer circuitry Redesign end effector (robotic arm) Design control system Establish documentation standard Description of Activities Present Accomplishments

Description of Activities General Approach

Description of Activities Project Definition Total Weight Points: 39 Urgency Scaling Factor: 28%HighestHighMediumLowLowest Software Highest Develop control infrastructure High Develop SONAR array testing software Develop GUI for control and sensor structures EffortMedium Develop remote interface Develop scripts and macros for demonstrations Test newly-developed software Low Document existing software Document new software Lowest Priority Weight (larger = greater priority)

Description of Activities Project Definition TaskSystem priorityProject priority Characterize sonar array through testing23%6% Develop navigation algorithms for sensor array21%6% Write SOPs for sonar testing15%4% Create sonar array reference materials13%4% Document sonar testing from S048%1% Research imaging and image processing options8%2% Test newly developed software10%3% Develop SONAR array testing software21%6% Develop control infrastructure21%6% Develop remote interface15%4% Develop GUI for control and sensor structures15%4% Develop scripts and macros for demonstrations13%4% Document existing software10%3% Document new software8%2% Reroute wiring, install panels and external connections9%3% Design controllers for end effector motors11%3% Create wiring documentation9%3% Test new end effector assembly5%2% Design suspension system for drive train7%1% TOTAL 100% Yellow = percentage value forced for conformity to 100% total requirement * List has been truncated to fit in this space

Description of Activities Project Definition Tasks grouped under milestones to assign overall priority #MilestonePriority (%) 1Drive motion29 2Speech Output2 3External Façade1 4End Effector16 5Navigation38 6Suspension1 7Research1 8Demonstration / Presentation3 9Project Reporting9

Description of Activities Research Power conversion Current power inverter (DC/AC) is not rated to supply necessary power to computer. Many alternative products considered. DC ATX power supply is too expensive. DC/DC converter cannot supply computer’s demand. New DC/AC inverter is the best solution. Purchase of new inverter delayed until this semester.

Description of Activities Research

Available solutions Integrated motion control package (LM62xN, HCTL-20xx) EXPENSIVE Computer-based control (Java or LabVIEW) Have to create software algorithm (takes time) Pentium II with Linux Create own circuit Speed:Frequency-to-voltage converter Direction:Phase decoder

Description of Activities Design Tachometer Interface

Description of Activities Design Tachometer Interface Phase Decoder LS7184 – LSI Computer Systems Frequency of CLOCK is proportional to frequency of inputs UP/DN is constant value

Description of Activities Design Tachometer Interface 2:1 Analog Multiplexer switch AD8170AN – Analog Devices SELECT chooses between IN0 and IN1, sends it to Vout

Description of Activities Design Tachometer Interface Frequency–to–Voltage conversion LM2907N-8 – National Semiconductor VccVcc

Description of Activities Design Power system Power demand identified Safety measures implemented Schematic developed

Description of Activities Design Previous code updated and extended Layers of abstraction added to the previous design Wireless adapter added Operating system upgraded to Mandrake v.10.1 Network communication protocol designed Software Architecture

Description of Activities Design End effecter Previous design was unacceptable Design Constraints SizeTotal Cost-Reuse old system components Retractable‘Buildable’ Design Features Retracting/Pivoting Shoulder Elbow Joint Wrist Pivot Locking Wrist

Description of Activities Implementation Power system Schematic followed Moving objects avoided Wires secured to chassis

Description of Activities Implementation Power system End user accesses battery through interface panel Battery charger modified

Description of Activities Implementation Drivetrain Modification Existing Drivetrain exhibited wheel ‘slop’ and belt rubbing Cause was found to be poor bushing system Loose bearing allowed wheel to slide and translate Solution: a press fit polymer bearing to eliminate all unwanted motion

Description of Activities Implementation A simple and cost-effective look for OSCAR Cam Lock system prevents theft and damage of OSCAR’s internals Façade and Lock System

Description of Activities Implementation GUI and wireless adapters Functionality is divided into four main sections Movement Controls Speech Sensor display Scripts

Description of Activities Project Documentation Technical appendices added to standard project documents Technical drawings Electrical specifications Technical methods used User’s Manual CVS repository utilized Filing cabinet reorganized Paper copies of all documentation filed CD hard backup of files left with Dr. Patterson Project tracking template

Description of Activities Testing and Modification SONAR testing Verify the operation of the model 6500 SONAR modules Measure the time required for the ECHO signal

Description of Activities Future Required Activities TaskStudent TypeSemester Implement tachometer unit circuit boardsEESpring 2005 Implement end effector assemblyMESpring 2005 Design control circuits for end effector motorsEESpring 2005 Fix SONAR arrayEE/CprESpring 2005 Characterize SONAR arrayEESpring 2005 Implement speech-recognition feature (HW and SW)CprESpring 2005 Implement control circuits for end effector motorsEEFall 2005 Build top-level façade for end effector deck(any)Fall 2005 Implement control software for end effectorCprEFall 2005 Implement navigational software algorithmCprEFall 2005 Current feature set to be fully implemented before developing new features Remote and auto drive motion Remote and auto end effector Auto navigation and object avoidance Speech command input

Resources and Schedules David, Gus

Resources and Schedules Personnel Efforts Additional resource requirements Visitor demonstrations Project planning and tracking Troubleshooting SONAR array

Resources and Schedules Financial Requirement

Donated Resources Power system materials Various gauges of wire Wire ties and labels Wireless Ethernet card (x2) 27GB hard drive Resources and Schedules Financial Requirement

Resources and Schedules Project Schedule Ambitious schedule Tasks collected into groups Milestones are group deadlines First demonstrationOct 19 Class presentationNov 18 Industrial reviewDec 7

Blue bar – original task timeline Black bar – completion status (%) Brown bar – rescheduled timeline Red bar – uncompleted task Resources and Schedules Gantt Chart Legend

Resources and Schedules Speech and Façade

Resources and Schedules Drive Motion

Resources and Schedules Speech and Façade

Resources and Schedules End Effector

Resources and Schedules Navigation

Resources and Schedules Suspension and Imaging

Resources and Schedules Deliverables

Summary Dung

What went well Acquiring materials Software development Design of the end effector Demonstrations What did not go well Unanticipated hardware flaws (SONAR array) What technical knowledge was gained Operation of frequency-to-analog converters, digital-to-analog converters, and BasicX microcontrollers Writing and rewriting sections of the code base Use of Microsoft Project, AutoCAD, SolidWorks Summary Lessons Learned

What non-technical knowledge was gained Proper documentation methods Effort coordination What would be done differently if you could do it over again Plan development time for sensor troubleshooting Accurately determine end product status before planning project Summary Lessons Learned

Anticipated potential risks Ordered parts do not arrive on time Solution: Allow extra time for delivery Failure to complete assigned tasks Solution: Get help from other team members Cost of development exceeds expectation Solution: Delay purchase or seek alternate solution Failure to attend a meeting Solution: Take notes and inform absent members Anticipated risks encountered Failure to complete assigned tasks Failure to attend a meeting Summary Risks and Risk Management

Unanticipated risks encountered Failure of the sensor system Solution: Test all hardware to find defect Wheel tachometers do not use expected interface Solution: Design an interface circuit for the optical encoders Code interface could not send any commands to move the robot Solution: Restructure old software using new Java classes Resultant change in risk management Review documentation of past semesters to accurately anticipate risks associated with existing implementation Summary Risks and Risk Management

Summary Closing Summary Bring project back on track with purpose and scope Create useable paper trail for future team members Substantial, lasting progress to be made in next year of project