Octagonal Speech-Controlled Autonomous Robot ONGO-01 Project OSCAR Octagonal Speech-Controlled Autonomous Robot ONGO-01

Project OSCAR Fall 2005 Client: Iowa State University Department of Electrical and Computer Engineering Faculty Advisor: Ralph E. Patterson III Presentation Date: December 6, 2005 EE Team Members Kevin Cantu EE 492 Jawad Haider EE 492 Robert Dunkin EE 491 Nicholas Hoch EE 491 CprE Team Members Jeff Parent CprE 492 Peter Gaughan CprE 491 Andrew Levisay CprE 491 Mike Mikulecky CprE 491 ME Team Members Lynn Tweed ME 466 Michael Snodgrass ME 466 David Brownmiller ME 466

Project OSCAR Presentation Overview Initial Information Jeff Project Introduction Jeff Description of Activities Tachometer Jawad & Bob Software Mike & Peter End-effector construction Dave & Michael End-effector electronics Nick Documentation: Wiki Andy Resources, Schedules , Summary Kevin Closing Jeff

Project OSCAR List of Definitions OSCAR Octagonal Speech-Controlled Autonomous Robot BasicX-24 Microcontroller used to interface with SONAR system CVS Concurrent versions system Cybot The predecessor to OSCAR Drive train The assembly of electrically controlled motion elements, including the robot’s wheels, gears, belts, and tachometers End effector The electrically controlled mechanical arm and gripper GUI Graphical user interface I/O Input and output to a device PEEL Programmable Electrically Erasable Logic SONAR Sound navigation and ranging Tachometer A device for indicating speed of rotation Wiki An internet based content management system for many users

Project Introduction Jeff Parent

Project Introduction Problem Statement General Problem Develop a robot and perform demonstrations to generate interest in the field and in the department. General Solution Approach An ongoing project was started to design a modular, autonomous robot which incorporates speech control, sonar sensors, and an end effector to interact with its surroundings and audience.

Project Introduction Operating Environment Indoors Flat surfaces, no downward stairs or drop-offs Obstacles must be 2.5 feet high

Project Introduction Intended Users and Uses Project OSCAR team members Supervised non-technical users Use: Demonstration to raise interest in the field and the department Autonomous navigation of a hallway Ability to pick up and place objects via the end effector Ability to speak Manual movement via wireless control software Control via spoken commands

Project Introduction Assumptions and Limitations Demonstrations last less than one hour Technical supervisors present during operation Operators speak English and are familiar with control software Remote PC for robot control has the appropriate software and hardware Limitations Software must run in Mandrake Linux Speech commands are issued less than 15 feet away Sonar range is 15 inches – 35 feet Wireless Ethernet within 328 feet Must fit through a standard 30-inch doorway End effector must fit within top module

Project Introduction End Product & Deliverables A robot with working systems Power Drive Sensors Software End effector Documentation

Jawad Haider Bob Dunkin Tachometer Jawad Haider Bob Dunkin

Tachometer Electromechanical Design Problem Interface of Motor Controller and Optical Encoder Optical encoder outputs digital pulse train Motor controller needs analog 5V with direction Solution Build a Wheel Tachometer circuit and interface the motor and encoder

Tachometer Electromechanical Design Optical encoder digital output Optical Encoder Needed analog signal

Tachometer Proposed Design

Tachometer Parts Used and Schematic Switch: ADG419 Frequency-to-voltage converters: LM2907 and/or AD650KN Phase decoder: LS7184 LSI sheet/LS7184 USD sheet Op-amps: LM324 Charge pumps (providing negative voltage): ADM660 Adjustable voltage regulator: LM117

Tachometer Accomplishments Tested the phase decoder We look at the UP/DN output Signal flips between +5V and 0V with the change in the direction of shaft motion Signal level stays there until direction changes again

Charge Pump Voltage Regulators Tachometer Testing Two capacitors of 10uF are used for charge storage The voltage inversion operation is obtained using ADM 660 Voltage Regulators Two types of voltage regulators are used (5V and 12V)

Tachometer Frequency to Voltage LM 2907 Unknown chip malfunction AD 650KN MATLAB analysis Ripple voltage too high Used for higher frequency motors Range (100Hz—1MHz)

Tachometer Average and Ripple Voltage

Need to put more research into chips Tachometer Future Need to put more research into chips TC 9402 chips seems more feasible up to 100Hz Design new circuit, with new chips Create and test circuit components

Mike Mikulecky Peter Gaughan Software Mike Mikulecky Peter Gaughan

Software Past Accomplishments Design process Software controls hardware Software extends in all directions to all levels Main software system

Software Software Languages All ported to Linux Java Pearl C#

Software Current Problems Code Voice recognition Documentation of code Computer hardware Inconsistent power supply performance Defective power button Motherboard battery dead

Add support for debugging Software Java Improve Java code Reorganize Add support for debugging

Rapid evaluation of ideas Wireless motion control via Xbox controller Software Prototyping Rapid evaluation of ideas Wireless motion control via Xbox controller Prototyping framework

Software Perl Prototyping language Flexible and fast Modular

Software Miscellaneous New brain for OSCAR No change in voice synthesis

Continue modularization of Java Software Future Continue modularization of Java Finish and extend prototyping framework Use framework to test motion algorithms Integrate better voice synthesis

End Effector Mechanical David Brownmiller Michael Snodgrass

End Effector Previous Design 2 1 3 4 Design was only 50% Complete Slide mechanism had binding issues Gears and motors were not modeled to scale Structural issues on wrist rotational motor

End Effector Current Design 1 2 Remodel Gears and Motors Design rotational joint to eliminate stress on the rotation motor A completed arm with slide and base rotation for spring 06 Selected materials for structural integrity and aesthetics

End Effector Current Status Acquisition of materials Physical manufacture of the arm Manufacturing limitations on campus Machine shop in Nevada

End Effector Control Nick Hoch

End Effector Control Overview Functionality Computer control for five motors in the new end effector H-bridges for power Controlled by microcontroller(s) Communication with the PC Goals To fully design the system To build the system without significant design revisions

End Effector Control Original Technology Selection BasicX-24 top level Multiplexers LM629 motorcontrollers (1 per motor) H-bridges (1 per motor)

End Effector Control Questions Too complex Serial PC <-> BasicX Serial BasicX <-> LM629 Skills requred: Java, Basic, LM629 codes, hardware programming

End Effector Control Possible Improvements USB connection (PC <-> microprocessor) Fewer parts (possibly only 1 microcontroller + 5 H-bridges) More software, less hardware (faster implementation) C instead of BASIC as a primary language (students have experience)

End Effector Control Possible Solutions LabVIEW board and software previously discarded because of PC and Linux issues PIC like the PIC18F4550 USB capable Specialized PIC or a DSP chip like the dsPIC30F4011 6 PWM outputs 1 optical encoder input FPGA with programmed logic to replace entire circuit.

Documentation Andy Levisay

Documentation Previous Problems Incomplete No central repository Decision process not documented Design and testing not well documented

Documentation Solution: The OSCAR Wiki Well organized Carries from semester to semester Easy sharing of documents and pictures Also provides a place for making announcements and meeting times Useful in document collaboration

Documentation The OSCAR Wiki

Documentation The OSCAR Wiki

Documentation Documentation Activities Software Tachometer testing Sonar maintenance End Effector

Documentation Future Activities Dedicated server for the WIKI Adding more back data to the WIKI

Resources and Summary Kevin Cantu

Resources and Schedules: Fall 2005 Material Requirements End effector Structural materials, machining – donated Motors – salvaged Electronics – $99.90 Workstation PC - donated Software Operating system – free OSCAR PC – $10 Documentation Wiki – free, donated Wiki PC – $10 Projected semester cost: ~$700 Actual semester cost: $119.90

Resources and Schedules: Fall 2005 Personnel Effort Requirements Visitor demonstrations End effector control circuit design Tachometer implementation Software Documentation project Senior Design reporting Projected total hours: 1013 Actual hours: 622

Resources and Schedules: Fall 2005 Financial Requirements Projected cost of materials: $700 Actual cost of materials: $119.90 Projected cost of labor at $10.50 per hour: $10,636.50 Actual cost of labor: $6,131.00 Fall 2005 Projected Total: $11,336.50 Fall 2005 Actual Total: $6,650.90 Previous Semesters Spring 2005: $6,000-9,000 Fall 2004: $9,000-13,000 Spring 2004: $12,000 Fall 2003: $15,000 Spring 2002: $10,000-16,000 Fall 2001: $11,000-17,000 Estimated Overall Total, Spring 2001- Fall 2006: $115 thousand

Resources and Schedules: Fall 2005 Project Schedule

Project OSCAR: Summary Lessons Learned What went well New team member orientation to complex system What did not go well Implementing tachometer design Initial team progress: late start this semester What technical knowledge was gained Electronic, mechatronic and control systems Linux software development

Project OSCAR: Summary Lessons Learned What non-technical knowledge was gained Project management experience Documentation methods, skills, and importance Presentation skills Interdisciplinary engineering interaction What would be done differently Better teaching of new team members Better completed and organized documentation

Project OSCAR: Summary Risks and Risk Management Anticipated potential risks Part ordering delays Documentation problems Personal injury Loss of a member Anticipated risks encountered

Project OSCAR: Summary Risks and Risk Management Unanticipated risks encountered Long term loss of faculty advisor Software malfunction Lost knowledge Resultant changes in risk management More sophisticated documentation Emphasis on shared knowledge

Closing Jeff Parent

Project OSCAR: Summary Closing Still in overall implementation stage – autonomy is incomplete Continued demonstrations have been effective in developing team member abilities Future should involve Finalizing OSCAR system Satisfying department needs through further robot development projects

Questions? http://seniord.ee.iastate.edu/ongo01 Project OSCAR Questions? http://seniord.ee.iastate.edu/ongo01