2. © 2001 By Default!Slide 1 Project Cybot/OSCAR ongo01 May 30, 2002

3. © 2001 By Default!Slide 2 Introduction Project Advisor –Dr. Ralph Patterson Project Co-Leaders –Kivanc Kahya, CprE, 2 nd Semester –John Davidson, CprE, 2 nd Semester Client –Department of Electrical and Computer Engineering

4. © 2001 By Default!Slide 3 Introduction Ongoing senior design project Project includes two robots –Octagonal, Speech-Controlled, Autonomous Robot (OSCAR) –Cybot OSCAR is new and nearing completion Cybot is old and remains semi-functional

5. © 2001 By Default!Slide 4 Project Sub-Teams Motion Control –Upgrade/maintain motion control hardware End-Effector –Create an arm, wrist, and gripper assembly Sensor –Create and maintain a reliable sensing system Software –Develop control and user-interface software Power –Supply sufficient power for all sub-systems

6. © 2001 By Default!Slide 5 Project Budget Sub-teamPersonnelFinancial Motion Control 266$12.00 End-Effector582$715.13 Software275$12.00 Sensors152$107.00 Power135$56.00 Team Leaders 175$0.00 Totals1585$902.13

7. © 2001 By Default!Slide 6 Motion Control

8. © 2001 By Default!Slide 7 Members Brooks Graner (CprE –2 nd ) Sub-Team Leader Boon-Siang Cheah (CprE –2 nd ) Robert Milliken (EE – 1 st ) Chao-Hern Wong (EE – 1 st )

9. © 2001 By Default!Slide 8 Problem Statement Failure of motion control system of OSCAR –Current motor driver circuit design flaws Same design as Cybot, but larger motor loadSame design as Cybot, but larger motor load Failure of motion control system of Cybot New motor driver design for OSCAR –New H-Bridge controller –New H-Bridge design with NMOS and PMOS –Motor load issues, high frequency vibration Restore Cybot’s motion (time permitting) –Worked in the past, what went wrong?

10. © 2001 By Default!Slide 9 Design Objectives Research, Design, Implement new motor driver circuit for OSCAR –New H-Bridge controller (TPS2811) Suggested by Mr. Barry Beulow of Rockwell CollinsSuggested by Mr. Barry Beulow of Rockwell Collins Will use TPS2814 and TPS2815Will use TPS2814 and TPS2815 –Needs to work with current microcontroller (LM629) –Needs to work with current MOSFET’s Better H-Bridge design with PMOS and NMOS transistorsBetter H-Bridge design with PMOS and NMOS transistors Restore Cybot’s motion –Design is good –Possibly a bad chip

11. © 2001 By Default!Slide 10 End Product Description OSCAR will have full motion capabilities –Forward, backward, rotate left and right –Efficient, stable circuit Cybot will have motion restored

12. © 2001 By Default!Slide 11 Assumptions & Limitations Assumptions –Microcontroller design good –Software will work for new design –Will have funding for new H-Bridge controller chips Limitations –Limited budget –Part ordering takes time –Minimum PWM of LM629 is 3.9kHz –Problems setting PWM signal

13. © 2001 By Default!Slide 12 Project Risks & Concerns Time – Goal to have OSCAR functional by VEISHEA –Regular weekly meetings Part ordering –Order parts early in semester Will design work? –Intensive research –Outside assistance

14. © 2001 By Default!Slide 13 Technical Approach Motion Control System interaction Computer Computer Motion Control System Motion Control System Motor(s) Motor(s)

15. © 2001 By Default!Slide 14 Technical Approach CPU CPU CPU Interface CPU Interface Motion Controller Motion Controller Motor Driver Motor Driver Motor Motor Motion Control System Motion Detector Motion Detector

16. © 2001 By Default!Slide 15 Technical Approach Motor driver circuit and H-Bridge

17. © 2001 By Default!Slide 16 Evaluation of Project Success Full Motion Capability of OSCAR –Partially met H-Bridge design with PMOS/NMOS completeH-Bridge design with PMOS/NMOS complete H-Bridge control circuit design completeH-Bridge control circuit design complete Integration with LM629 incompleteIntegration with LM629 incomplete Cybot’s motion control restored –Partially met Motion control circuit back togetherMotion control circuit back together Software to test it doesn’t workSoftware to test it doesn’t work

18. © 2001 By Default!Slide 17 Recommendations for Future Work Layout the H-Bridge circuit on PCB –Circuit design is good, needs to be on a PCB Additional work with LM629 –Need to adjust frequency of PWM signal

19. © 2001 By Default!Slide 18 Financial Budget DescriptionQuantity Unit Price Total Poster Dues 4$3.00$12.00 TPS 2814 2 Free Sample $0.00 TPS 2815 2 Free Sample $0.00 PMOS Transistors 2 Free Sample $0.00 Total$12.00

20. © 2001 By Default!Slide 19 Personnel Budget MemberEstimatedRevisedActual Brooks Graner 757577 Boon-Siang Cheah 676761 Robert Milliken 626267 Chao-Hern Wong 626269 Totals266266274

21. © 2001 By Default!Slide 20 Lessons Learned A design once thought to be correct may be totally wrong, eg. H-Bridge Circuit using LT 1158 Don’t be afraid to start a new design from scratch Keep good documentation Professional outside resources are very helpful

22. © 2001 By Default!Slide 21 Summary OSCAR now has a partially functional motor drive circuit, and H-Bridge circuit –This circuit will need to be placed on a PCB –The LM629 circuit will need to be tested for different PWM frequencies With this semester’s design and the previous 2 goals met, OSCAR will move!

23. © 2001 By Default!Slide 22 End-Effector

24. © 2001 By Default!Slide 23 Members Yan-Chak Cheung (EE – 2 nd ) Sub-Team Leader Chris Trampel (EE – 2 nd ) Muhammed Rahim (EE – 2 nd ) Thi-Ha Soe (EE – 1 st ) Mike Nguyen (CprE – 1 st ) Matt Baird (ME – 1 st ) Tony Gartner (ME – 1 st ) Chad Harbour (ME – 1 st )

25. © 2001 By Default!Slide 24 Problem Statement OSCAR requires a robotic arm to interact with its surroundings Stresses on the structure of the arm Low power consumption Controlled by OSCAR’s central computer

26. © 2001 By Default!Slide 25 Design Objectives Design and build the control circuit Develop software for motor control Easy to use software interface Fabricate the whole arm

27. © 2001 By Default!Slide 26 End Product Description The arm will pivot on center top of OSCAR Lift 2 lb objects –1 lb at full arm extension Gripper could hold items 3” wide

28. © 2001 By Default!Slide 27 Assumptions & Limitations Assumptions: –Sufficient funding for the fabrication of arm –All motors will operate at 12 volts –Fabrication facilities available on campus Limitations: –Arm pivoted on top of Oscar –Arm must remain under 12 pounds –Arm must be designed to allow future modifications –Must use Java

29. © 2001 By Default!Slide 28 Technical Approach Research on existing control circuits Develop layout for the control circuit boards Develop software control Machine the arm

30. © 2001 By Default!Slide 29 Technical Approach Control circuit block diagram PWM Quadrature Incremental Feedback DCMotor MotionController LM 629 MotionController PC PC H-BridgeLMD18200H-BridgeLMD18200

31. © 2001 By Default!Slide 30 LMD18200 Schematic Diagram

32. © 2001 By Default!Slide 31 LMD18200 Board Layout

33. © 2001 By Default!Slide 32 Structural Design and Fabrication o Framework o Motors o Gears o Bearings o Gripper o General Parts

34. © 2001 By Default!Slide 33

35. © 2001 By Default!Slide 34 Fabrication Budget 60% Savings Direct from Factory

36. © 2001 By Default!Slide 35 Possible Mechanical Improvements o Shock Absorption o Adjustment of Support Wheels o Modification of the Gripper o Possible Clutch System o Detachable arm to allow for quick change to buzz saw for battle-bot mode.

37. © 2001 By Default!Slide 36 Project Risks & Concerns Cost of development Buy widely used parts at the beginning of the semester Power Consumption of motors Takes long time to machine the arm

38. © 2001 By Default!Slide 37 Evaluation of Project Success The project is said to be successful 70% of completion –Modified the wrist design – Met –Location of less expensive motors – Met –Design of gripper control software – Met –Basic components ordered and machining – Met –Complete fabrication of control boards – Partially met –Design of arm control software – Not met –Assemble and test arm components and control systems – Not met

39. © 2001 By Default!Slide 38 Recommendations for Future Work Assemble and test the whole arm Design software to control the arm Documentation of the arm Install a small camera and pressure sensors on the gripper

40. © 2001 By Default!Slide 39 Financial Budget DescriptionQuantity Unit Cost Total Cost Poster8$3.00$24.00 Drive motors 4$471.13 Motor control circuit components About $20.00 per motor $100.00 Software development $0.00$0.00 Aluminum 2 Bars $50.00$100.00 Machine shop costs 100 hours $0.00/hr$0.00 Total$695.13

41. © 2001 By Default!Slide 40 Personnel Budget MemberEstimatedActual Yan-Chak Cheung 10484 Chris Trampel 6356 Muhammed Rahim 5543.5 Thi-Ha Soe 5556 Mike Nguyen 7656 Matt Baird 7468.5 Tony Gartner 7048 Chad Harbour 8548 Total582456

42. © 2001 By Default!Slide 41 Lessons Learned Learned how to use the Eagle layout program Learned how to debug a circuit when it has problems Order parts early Find backup vendor when ordering parts Request sample parts or donation

43. © 2001 By Default!Slide 42 Summary Low cost design Control circuit layout is done Most of the parts of the arm are fabricated Gripper can be controlled by OSCAR’s central computer

44. © 2001 By Default!Slide 43 Demonstration Gripper Control Software

45. © 2001 By Default!Slide 44 Sensors

46. © 2001 By Default!Slide 45 Members Waqar Habib (EE –2 nd ) Sub-Team Leader John Stacy (CprE –1 st ) Sze-Yiing Tan (CprE – 1 st )

47. © 2001 By Default!Slide 46 Problem Statement Image processing – complete the ground work for adding computer vision sensor Compass – Improve the accuracy Sonar Array – Repair faulty sonar sensors and have all working

48. © 2001 By Default!Slide 47 Design Objectives Accurate, convenient and reliable sensing Modular design Future expandability Software interface through serial Com Port Collect information for software sub-team

49. © 2001 By Default!Slide 48 End Product Description Modular design Temperature and direction sensing ability Computer imaging ability Eight individual distance measuring sensors Simple computer interface through Serial Com Port

50. © 2001 By Default!Slide 49 Assumptions & Limitations Assumptions –One sensor works at a time with the existing set of sensors –With the additional video sensor, OSCAR can process the images from camera and data from other sensors at the same time Limitations –Students do not have the proper background for the image processing – Steep Learning Curve –System is highly unstable and stops working very often –Limited space for the sensor system

51. © 2001 By Default!Slide 50 Project Risks & Concerns Part Damages - Weekly system check up Unfamiliarity with Image Processing –Extensive research –Faculty assistance

52. © 2001 By Default!Slide 51 Computer Imaging –Two different, but overlapping areas Computer VisionComputer Vision Image ProcessingImage Processing Technical Approach

53. © 2001 By Default!Slide 52 Technical Approach Computer Vision –Images are acquired and examined by the computer –Computer makes the intelligent decisions

54. © 2001 By Default!Slide 53 Technical Approach Image Processing steps Input Image Input Image Preprocessing Preprocessing Data Reduction Data Reduction Feature Analysis Feature Analysis

55. © 2001 By Default!Slide 54 Technical Approach CPUCPU Computer imaging System Camera Camera Frame grabber Frame grabber End Effectors End Effectors Motion Control Motion Control Image Processing Image Processing

56. © 2001 By Default!Slide 55 Evaluation of Project Success Hindrances in the research work Significant amount of ground work has been done for the computer imaging. Failed compass design Sensor system has still got some problems in communicating with the computer.

57. © 2001 By Default!Slide 56 Recommendations for Future Work Research and purchase of imaging equipment Physical circuit design for the computer imaging sensor Perform regular system check New Compass design

58. © 2001 By Default!Slide 57 Financial Budget No hardware or equipment was purchased this semester No hardware or equipment was purchased this semester DescriptionQuantity Unit Price Total Poster Dues 3$4.00$12.00 Total$12.00

59. © 2001 By Default!Slide 58 Lessons Learned Learned aspects of video imaging through research Regular system testing Demonstrations with large groups

60. © 2001 By Default!Slide 59 Personnel Budget MemberEstimatedRevisedActual Waqar Habib 797972 John Stacy 525250 Tan Sze Yiing 515150 Totals182182172

61. © 2001 By Default!Slide 60 Summary Reliable and consistent sensory system –Provide enough data to make autonomous and educationed decisions Variety of different sensing capabilities to operate safely and successfully –Image processing sensor –8 sonar sensors –Temperature sensor –Navigational compass Ready for future sensing capability

62. © 2001 By Default!Slide 61 Demo Edge Detection –A large change in image brightness over a short spatial distance indicates the presence of an edge Online Demo1

63. © 2001 By Default!Slide 62 Software

64. © 2001 By Default!Slide 63 Members Sastra Winarta (CprE –2 nd ) Sub-Team Leader Tom Allen (CprE –1 st ) Julianto Leonardo (CprE – 1 st ) Joseph Lahart (CprE – 1 st )

65. © 2001 By Default!Slide 64 Problem Statement Create powerful software solutions –Full control of OSCAR –Interact with other subsystems Control of gripper and arm is required Integration of sensor and motion is required Finalize voice control Develop demonstrations

66. © 2001 By Default!Slide 65 Design Objectives Create sensor API Develop end-effector drivers Improve voice control Improve motion control software Create demonstrations showing new abilities Document all system software

67. © 2001 By Default!Slide 66 End Product Description Control of OSCAR through voice commands Control of OSCAR’s gripper and arm Increase functionality of OSCAR’s motion control Able to obtain and process sensor information The system software will be fully documented

68. © 2001 By Default!Slide 67 Assumptions & Limitations Assumptions: –The motion control,sensor and end-effector interfaces are not changing –The sound card on OSCAR will be operational –Windows 98 will provide the necessary hardware support Limitations: –Voice control accuracy depends on ambient noise levels –Previous code in Java

69. © 2001 By Default!Slide 68 Project Risks & Concerns Team members do not have Java programming experience Hardware may break down Existing software is not be properly documented

70. © 2001 By Default!Slide 69 Technical Approach End-effector driver design based on motion control design Communication with sensors will take place over a serial port connection Use of sensors subsystem pre-existing communication protocol Voice control will be improved and integrated with OSCAR’s capabilities

71. © 2001 By Default!Slide 70 Technical Approach Input Flowchart Voice Command Voice Recognition Onboard Computer - Java Low Level Driver SensorSensor Keyboard and Mouse BASICXBASICX

72. © 2001 By Default!Slide 71 Evaluation of Project Success All code located and partially documented Sensor interface developed Voice control improved by integration with OSCAR’s other systems Motion control software and GUI functionality improved Gripper software control working

73. © 2001 By Default!Slide 72 Recommendations for Future Work Implement CVS Generate API documentation using Javadoc Complete arm control code Improve voice control to use OSCAR’s new capabilities Develop new demonstrations Upgrade OS and software –Windows OS or Linux –Java SDK –IBM ViaVoice

74. © 2001 By Default!Slide 73 Financial Budget DescriptionQuantityUnit PriceTotal Poster Dues4$3.00$12.00 CPU1$0.00 Motherboard1$87.00 Heat Sink and Fan1$8.00 SDRAM2$60$120 Total$227.00

75. © 2001 By Default!Slide 74 Personnel Budget MemberEstimatedActual Sastra Winarta 7081 Tom Allen 7059 Julianto Leonardo 6555 Joseph Lahart 7048 Totals275243

76. © 2001 By Default!Slide 75 Lessons Learned Java programming language IBM ViaVoice technology Serial port communication using Java I/O card control using Java

77. © 2001 By Default!Slide 76 Summary Various ways to control OSCAR’s movements Control of OSCAR’s gripper Control of OSCAR’s sensors OSCAR interacts with users in demonstration

78. © 2001 By Default!Slide 77 Demonstrations Motion Control’s GUI Voice Control Gripper’s Control Sensors

79. © 2001 By Default!Slide 78 Power

80. © 2001 By Default!Slide 79 Members Kris Kunze (EE –2 nd ) Sub-Team Leader Todd Carlson (EE –1 st )

81. © 2001 By Default!Slide 80 Problem Statement Power Supply to Computer –DC/AC inverter –Standard PC power supply Conserve power for Sensor, and End Effector teams

82. © 2001 By Default!Slide 81 Design Objectives Build/test/install a new PC power supply Remove DC/AC inverter System Protection

83. © 2001 By Default!Slide 82 End Product Description DC/DC converter –Losses aboard the robot will be minimized Fault prevention Maintain current electrical system

84. © 2001 By Default!Slide 83 Assumptions & Limitations Assumptions: Batteries will be properly charged Limitations: Batteries can only be run down to 50% Initial power system design not available Limited budget No experience building a Printed Circuit Board

85. © 2001 By Default!Slide 84 Project Risks & Concerns Short circuit –Components of other sub-team –Protecting each sub-system individually –Soldering PCB Part ordering –Ordered parts early in semester Will design work?

86. © 2001 By Default!Slide 85 Technical Approach Save money Assure quality and reliability Remove DC/AC inverter

87. © 2001 By Default!Slide 86 Evaluation of Project Success Receive correct parts –In April we received the last of the parts needed to complete the power supplies Build/Test/Install Power Supplies – –Power Supplies are Built – –Tested for voltage stability – –Are installed and working System Protection –Wires were rerouted –Power cables were run through plastic conduit –Battery post protectors were added

88. © 2001 By Default!Slide 87 Recommendations for Future Work Build and install permanent supply for sensors Explore methods to connect batteries that do not contribute to battery drainage Wiring diagram for base

89. © 2001 By Default!Slide 88 Financial Budget DescriptionQuantity Unit Price Total Poster Dues 2$3.00$6.00 Wires, Bridges, and Fuses 1$10.00$10.00 Power Supply Parts $40.00 Total$56.00

90. © 2001 By Default!Slide 89 Personnel Budget MemberEstimatedActual Kris Kunze 7571 Todd Carlson 6058 Totals135126

91. © 2001 By Default!Slide 90 Lessons Learned Soldering Printed Circuit Boards Circuit protection –upgrading the wiring system Ordering and receiving parts –Some parts were lost after they arrived at the department. –Wrong parts were ordered last semester

92. © 2001 By Default!Slide 91 Summary System protection for OSCAR Power Supplies Work Power saved ≈ 15% Voltage3.3V5V12V-12V-5V No-Load Test3.29V4.97V12.10V-11.69V-5.01V Voltage3.3V5V12V-12V-5V Load Test3.27V4.89V12.02V -12.15V-4.97V Motherboard Monitor 3.369V4.792V11.813V n/a

93. © 2001 By Default!Slide 92 Project Summary Accomplishments –New motion control circuit designed and tested –High-end onboard computer –Speech recognition demonstrated successfully –End-effector and sensor software interface created –Improved power distribution wiring –Significant documentation work completed –New power supply for onboard computer

94. © 2001 By Default!Slide 93 Project Summary Setbacks –Fabrication of arm not completed –Motion control circuit not installed on OSCAR –Sonar array operates sporadically

95. © 2001 By Default!Slide 94 Questions ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?