1. Mars Rover By: Colin Shea Dan Dunn Eric Spiller Eric Spiller Advisors: Dr. Huggins, Dr. Malinowski

2. Outline Project SummaryProject Summary Review of Previous WorkReview of Previous Work Division of LaborDivision of Labor Project DescriptionProject Description Data SheetData Sheet Equipment and PartsEquipment and Parts Design ChangesDesign Changes ScheduleSchedule Progress UpdateProgress Update

3. Project Summary The main objective is to design the Rover for long battery life that must last 7 days without recharging. The Rover will use PC104 to control the interface among the user and the Rover and high level software. It will also use the MicroPac 535 microprocessor to control low level software such as the motors for motion, the sonar system, and the battery level. The user will be able to enter a specific distance, move the Rover using the keypad, or rotate the Rover to get a preferred direction.

4. Previous Work 20022002 Rob Shockency and Randall SatterthwaiteRob Shockency and Randall Satterthwaite Robotic Platform DesignRobotic Platform Design EMAC 8051 and a CPLDEMAC 8051 and a CPLD Design GoalsDesign Goals 1. Create Cheaper version of Telerobotics 2001 1. Create Cheaper version of Telerobotics 2001 2. Upgradeable and expandable in the future 2. Upgradeable and expandable in the future

5. Division of Labor Dan DunnColin SheaEric Spiller Assembly CodeJava/ServerHardware - Motor Speed - Image Capture- DC Motors - Wheel Sensors- Rover Controls- Platform Construction - Battery Charge Level- Serial Communication- H-bridge/Motor Driver - Serial Communication- Battery Charger - Acoustics Sensors

6. Functional Description Wait mode –Wait mode – All systems are powered, except the motors. The CPU monitors the wireless card for network activity The last image captured from the camera is displayed to the user. Web page accessible to user Battery Status is monitored Sleep mode –Sleep mode – The sub-systems are powered down except for the CPU and the wireless network card.The sub-systems are powered down except for the CPU and the wireless network card. CPU runs in a reduced power mode.CPU runs in a reduced power mode. Web page accessibleWeb page accessible Battery Status is monitored.Battery Status is monitored. Rover remains in sleep mode until signaled by the user.Rover remains in sleep mode until signaled by the user.

7. Functional Description Low battery mode –Low battery mode – Battery drops below 10% of charge Email sent to Dr. Malinowski requesting a charge Rover shuts down all components. Charge mode –Charge mode – Rover continues to charge until power button is pressed Stays in this mode until battery level reaches 100% User mode –User mode – All Systems poweredAll Systems powered Distance and Direction ControlDistance and Direction Control Web Page accessible to userWeb Page accessible to user Image capture and displayImage capture and display Battery Status is MonitoredBattery Status is Monitored

8. Functional Description

9. System Block Diagram

10. Software Flow Chart High Level SoftwareHigh Level Software Rover ControlRover Control

11. Software Flow Chart High Level SoftwareHigh Level Software Image Retrieval/DisplayImage Retrieval/Display

12. Software Flow Chart Low Level SoftwareLow Level Software Motor ControlMotor Control

13. Software Flow Chart Low Level SoftwareLow Level Software Object DetectionObject Detection

14. Software Flow Chart Low Level SoftwareLow Level Software Battery Voltage LevelBattery Voltage Level

15. Data Sheet Specifications Turning accuracy - ± 5° for an individual turn command Turning resolution - 15° Driving accuracy - ± 5cm and ± 2° for a 100cm command Camera capture speed – 5 frames/sec @ 324x288 resolution for a 10BaseT connection Weight – ~28lbs Battery life – 7 days without a recharge Top speed – 10cm/s Acoustic sensors – Time between transmit signals – 1 second Farthest object detection – 200cm Closest object detection – 50cm

16. Data Sheet Motors – Model number – GM9X12 Gearing – 1:65.5 Max current – 4.56A Voltage – 12V Wheel Sensors – Output – TTL Pulses per revolution of shaft – 512 Voltage required – 5V Battery charge level accuracy - ± 5% Wireless protocol – 802.11b Dimensions – 31.4cm x 46.4cm x 21cm (L x W x H) Battery – 2 X 12V @ 7.2Ah Wheels – 5cm x 16cm (Width x Diameter)

17. Data Sheet PC104 – Max Current, during bootup – 1.5A Normal operating current –.8A Sleep mode current –.026A Processor – National Semiconductor Geode Processor @ 300MHz RAM – 128MB Video – Onboard Video card PCMCIA module – Current -.07A Wireless Card – Linksys WPC11 Max Current -.3A Current in Sleep mode -.02A Hard Drive – IBM Travelstar 2.5 inch IDE hard drive, 10GB Max Current -.94A (Spin-up Current) Current in Sleep Mode -.02A Camera – Logitech USB Webcam Max Current -.1A

18. Power Calculations Power Consumption for Sleep Mode: PC104 computer.026A PC104 PCMCIA module.07A IDE Laptop Hard drive.015A PCMCIA Wireless Card.009A EMAC.045A + _____ + _____ Total.165A 24hrs * 7days = 168hrs 168hrs *.165A = 27.72 Ah @ 5V 27.72Ah * 5V = 138.6Wh Using 2 - 12 Volt, 7.2Ah batteries: 12V * 7.2Ah * 3 = 259.2 Wh available

19. Power Calculations Power Consumption for User Mode: PC104 computer.8A PC104 PCMCIA module.07A IDE Laptop Hard drive.4A PCMCIA Wireless Card.285A EMAC.045A Camera.1A 2 Polaroid Ultrasonic 6500.2066A + ______ + ______ Total1.9066A

20. Power Calculations The motors chosen by the Robotic Platform Design project were Pittman GM9236, which pull 2A per motor. Total with motors1.9066A + 2A * 2 = 5.91A If we assume that user is connected 1.3% (or 2.1 hrs out of a week) of the time, then power consumption is as follows: 36.5Ah * 5V = 182.48Wh required [(4A * 12V + 1.9066A * 5V) * 1.3% + (.165A *5V)* 98.7%]*168hrs=259.2Wh required

21. Parts and Price List Equipment List for Mars Rover PartQtyWebsiteManufacturerLocation of VendorPart #Price 10 Gb1 www.pricewatch.comIBM www.basoncompu ter.com$80.00 128 Mb RAM1 www.pricewatch.comInfineon www.18004memo ry.com LG1064U/064/G 3VAC$14.20 PC/MCIA Wireless Card1 www.pricewatch.comLogictech www.legendmicro. comDL1150$69.00 USB Webcam1 www.pricewatch.comLogictechwww.enpc.com961137-0403$16.00 PC104 300MHz w/ USB1 www.square1in dustries.comNational Semi www.square1indu stries.comCM-588$399.00 Dual PC/MCIA Adaptor1 www.square1in dustries.com National Semi www.square1indu stries.com NC-893 $94.00 Pittman DC Motor #92362 Bradley Owned Pittman www.pittmannet.c om $672.20

22. Design Changes Replaced Linux based operating system with Windows based operating system Video Card was incompatible with Linux although manufacturer stated the card was compatible Video Card was incompatible with Linux although manufacturer stated the card was compatible Linux operating system was not stable on PC-104 board Linux operating system was not stable on PC-104 board

23. Design Changes Flash Memory Card and PCMCIA Hard drive replaced by Laptop Hard drive Flash Memory Card was not capable of booting the PC-104 at start-up Flash Memory Card was not capable of booting the PC-104 at start-up PCMCIA Hard drive was not visible by computer until system completed start-up sequence PCMCIA Hard drive was not visible by computer until system completed start-up sequence Laptop Hard drive booted easier and still remained low power Laptop Hard drive booted easier and still remained low power

24. Laboratory WeekProject Milestones 19-Jan-03Assemble PC104 and interface with previous Robotic Platform Design project. 26-Jan-03Create boot software for Linux. Install drivers for all components in Linux. 2-Feb-03Develop and test motor control software on Micropac 535. Develop software to interpret wheel sensor bit streams. 9-Feb-03Continue working on software development for motor control and feedback loop. 16-Feb-03Develop software to capture image from camera and send to user. Continue working on software development for motor control and feedback loop. Work on web server development. 23-Feb-03Create Java applet for user interface. 2-Mar-03Continue with Java applet Work on software to estimate battery charge level. 9-Mar-03Finish working on software to estimate battery charge level 16-Mar-03Spring Break 23-Mar-03Develop software to operate acoustic sensors 30-Mar-03Finish Java applet. 6-Apr-03Testing of individual components and overall system. 13-Apr-03Testing of individual components and overall system. 20-Apr-03Preparation for presentation and final report 27-Apr-03Presentation

25. Progress Flow Chart Green = Developed Red = Partially Developed

26. Progress Update Second Semester DateProgress Description 1/19/03 to 1/25/03 Installed Linux Red Hat 8.0 onto an older Pentium 166 computer. Waited to get the PC104 board and modules. 1/26/03 to 2/1/03 Attempted to install Linux on the PC104 board using the PCMCIA hard drive as the main hard drive. Linux never recognized the drive, so we decided to use a 2.5 inch IDE hard drive. 2/2/03 to 2/8/03 Attempted to install Linux on the 2.5 inch hard drive. Linux would install and boot, but not run. After many hours of installing and adjusting configurations for Linux, we discovered that Linux was incompatible with Geode processors. We decided to use Windows 2000 instead, because of stability and compatibility. 2/9/03 to 2/15/03 After establishing a stable platform to work with, we began to add the peripherals and necessary software. Setup servers at http://webrover.bradley.edu and at http://webrover.bradley.edu:8080 2/16/03 to 2/22/03 Tested serial communication between a windows based computer and the Micropac 535. Tested H-bridge design with Pittman DC motor. 2/23/03 to 3/01/03 Continued testing serial communication between a windows based computer and the Micropac 535. Tested PWM signal from MicroPac 535 to generate signal for H-bride operation. Tested H-bridge design mounted on circuit boards with 30V Pittman DC motor and later with PWM signal from MicroPac 535. 3/02/03 to 3/08/03Reconstruct Rover and Presentation 3/09/03 to 3/15/03Continued constructing Rover, established moving routines, and developed user interface. 3/23/03 to 3/29/03Continued testing Rover 3/30/03 to 4/5/03Tested mobility of the Rover

27. Questions and Answers