1. P07205 Concept Review RP100: 100Kg Payload Robotic Platform

2. Introduction  Goal: To consolidate technologies from teams in the P07200 Project Family into a finalized product that can be used in the following configurations:

3. 7200 Project Family

4. RP10 & RP100 Core Sub-functions  Load-Platform Interface  Dynamometer Interface  Communication  Shell  Autonomy & Navigation  Electronics Pack  Software

5. Concept Generation & Selection

6. Functional Breakdown: Diagram

7. Concept Selection Scheme  Brainstorm as a group  Divided into mechanical and electrical sub-teams  Select reasonable choices  Screening  Scoring  Preliminary analysis

8. Functional Breakdown: Group Brainstorming Physical PlatformOutsideInside PlatformPayload AttachmentsBumpersShellFrameWiring platform material how to secure payloads outside layer of chassis, body Woodt-nuts 360 degree wrappingplasticpillars/columns common connectors (1 kind of con's) Aluminumclamps8 edge bumperswoodtriangular supportcolor coding - wires Steelvicesrubber stoppersaluminumnone shrink wrap (cover wires for organization) Plasticseatbeltsspring loadedcolors using internal components as supportcorrugated tubing (metal) Cheese bungee holes (for cords)shock absorbersRIT stickercircle framecorrugated tubing (plastic) side loopsnonediamond platecross shape fromZip ties dovetail groove metal bumpers (elastic)Soju girl, with sojupizza slice shapemultiple wire cable perforated metalswater bottlesacrylic shielded wires to avoid noise ratchet belttiressheet rock quick-connect side flaps (see Tian for drawing)air filledcardboard ferrite beads towing hook composite CAT5E ball hitch toggle clamps

9. Functional Breakdown: Group Brainstorming Information Management AbilityElectrical AccessoriesSensorsOverCurrent ProtectionPC104 optional hardware winchProximity Sensorsfusesremote control weight scaleLightresettable fusestethered laptop jackweightthermal fuseswireless laptop payload lifttemperature (TC)hot plugsIR sensors power screw driverstrain gaugecircuit breakersRF LCD displaysonar forkliftaccelerometers intercom systeminfra red speaker(s)A-D (for each sensor) horn(s)encoder LED array display bull horn

10. Individual Overall Concepts

19. Specialty Breakdown  Each ME/EE sub- team discarded unreasonable choices before starting the screening and scoring methods. Platform platform material Wood Aluminum Steel Plastic Cheese (unreasonable)

20. Screening Process Step 1-Research: Pros & Cons Step 2-Define Selection Criteria: Include customer needs Step 3-Datum Selection: Estimate an immediate decision Step 4-Complete Screening Matrix Step 5-Summarize Results [Ulrich, Ch 7]

21. Scoring Process Step 1-Need Identification Step 2-Weight Calculation Step 3-Reference Selection Step 4-Complete Scoring Matrix Step 5-Results Step 6-Selection Summary: Recommended Concept & JustificationRecommended Concept & Justification Improvements/Weaknesses discovered during the processImprovements/Weaknesses discovered during the process Work to be done in the future:Work to be done in the future:  Selection/Installation details  Performance  Cost [Ulrich, Ch 7]

22. General Selection Criteria  General selection criteria The following criterion is to be considered in each concept:  Cost It relates back to the amount of work required in the production of the concept. As it was specified by the customer (see Needs Assessment, 12) the robot must be easy to manufacture.  Ease of Repairing It deals with the amount of work, time and cost needed to repair the feature if broken. It relates to the need of keeping down cost and maximizing the flexibility of the robot (see Needs Assessment, 5 and 12).  Availability It is considered because it is a way to estimate how easily obtained the feature will be, which relates to the customer’s requirement of having more than one vendor per component (see Needs Assessment, 12).  Weight It serves a duel purpose because it will affect human safety and performance given fixed resources: ex. A lighter robot will be safer for people to transport. It will also consume less energy (see Needs Assessment, 1 and 6).  Wow factor It is related to the appeal of the concept as a combination of functionality and appearance (see Needs Assessment, 3 and 8)  Robustness It is a measure of durability in terms of its ability to withstand abuse (see Needs Assessment, 6).

23. Shell Concepts

24. Overview The shell is defined as an external casing of the robot excluding the platform. The shell’s material will therefore define its ability to protect the internal components and add to the overall appearance. The shell is defined as an external casing of the robot excluding the platform. The shell’s material will therefore define its ability to protect the internal components and add to the overall appearance.

25. Needs Addressed  SAFETY (1)  Cost (5)  Easy to manufacture (11)  Robust (6)  Wow Factor (3), (8)

26. Issues  Must be designed to provide safety to the robot.  Should not reduce accessibility of components.

27. CONCEPTS  Aluminum A readily available material which can be obtained in various sizes that would accommodate our needs. As large as 1.22x1.22m (4x4’)A readily available material which can be obtained in various sizes that would accommodate our needs. As large as 1.22x1.22m (4x4’)  Steel A common and durable building material.A common and durable building material.  Acrylic Can be used in many industrial applications because of its lightweight and insulation properties.Can be used in many industrial applications because of its lightweight and insulation properties.

28. Preliminary Analysis  Aluminum ProsPros  Lightweight  Impressive finish (polished)  Easy to machine  Can be repaired ConsCons  Expensive  Lower strength  Conductor CostCost  48x24x1/16”: $62.84  Acrylic ProsPros  Easy to machine  Lightweight  High WOW factor  Insulator ConsCons  Weak  Brittle CostCost  48x24x1/16”: $57.18  Steel ProsPros  Very Strong  Tight tolerances  Inexpensive  Reparable  Easy to weld ConsCons  Heavy  Rust prone CostCost  48x24x1/16”: $57.18

29. Final Concept Steel / Acrylic The scoring matrices showed that, according to our criteria based upon the customers needs, a steel shell would be the most advantageous material. Steel is the strongest material that we considered it is also cheaper than aluminum and plastic. Steel can also be very visually appealing.

30. Wiring Concepts

31. Overview Wiring is one of the most critical phase of equipment design. Wiring is one of the most critical phase of equipment design. It ensures equipment protection and safety. It ensures equipment protection and safety. The complete functionality of the platform depends on wiring. The complete functionality of the platform depends on wiring.

32. Needs Addressed  SAFETY (1)  Regulation (2)  Perform required tasks (3)  Modular (4)  Robust (6)  Adaptable (7)(11)  ‘Wow’ factor (8)

33. Issues  Both data and power cabling need proper designing, accommodating the required needs of all the consoles.  Withstand overload and heating till some extent.  Efficient to avoid power and data losses.

34. CONCEPTS  Color Coding and Shielded Wires Shielded wires ensure safety against data losses and color coding ensures easy understanding and general safety. This type of method and wires help in understanding wiring configurations easily, sets standards by following color coding as well as provide EMI immunity against all external interferences.Shielded wires ensure safety against data losses and color coding ensures easy understanding and general safety. This type of method and wires help in understanding wiring configurations easily, sets standards by following color coding as well as provide EMI immunity against all external interferences.  Corrugated Plastic Tubing It is a method of coating the wires with a hard flexible plastic coating. It provides durability and robustness to the complete wiring structure along with excellent flexibility.It is a method of coating the wires with a hard flexible plastic coating. It provides durability and robustness to the complete wiring structure along with excellent flexibility.

35. Preliminary Analysis  Color Coded and Shielded Wires NEC color standardsNEC color standards  Black – Negative  Red – Positive  Green - Ground ProsPros  Setup with general standards  Decipher wiring configurations  Safety  Inherent increase in marking area  EMI immunity from external sources and crosstalk from neighboring wires ConsCons  Color degradation  Expensive than unshielded wires CostCost  Approximately $4.49-$5 for a 6-ft 2 port RS-232 Serial Data with DB-9 male connectors  Corrugated Plastic Tubing ProsPros  Low Weight  Excellent Flexibility  Provides protection from abrasion, oxidation and overheating  Neat organization of wires ConsCons  Hard to remove once used CostCost  100 ft Poly Flex Tubing - $ 17.58

36. Final Concept COLOR CODED SHIELDED WIRES After thorough research with other teams and via internet, it is concluded that shielded color coded wiring design system will be adopted. This method and wiring will allow easiness in understanding wiring design configuration as well as ensure standard safety precautions. Corrugated tubing on the other hand might be considered during the future final stages of the project to add more robustness and organization to the wires because in the present stage, due to continuous trouble shooting and change in wiring designs, this method will make the process tedious.

37. Wiring Design Estimate

38. Over-Current Protection

39. Overview  Protection circuitry is required to ensure that electrical components are protected during malfunction  Battery cell protection, as well as component protection primarily encompass over-current protection.

40. Concerns  Large peak current (67.8A)  Battery details currently unknown  Exact electronic characteristics (threshold) values unknown for modules  Inner environment characteristics of RP unknown

41. Concept #1  Resettable Fuse ProsPros  Acts as an over temperature detector  Manual resetting/replacement not required  Does not require operation awareness  Easy integration ConsCons  Low “trip” currents in high temperature  Requires extensive environment research

42. Resettable Fuse

43. Concept #2  Hot Plug Controller ProsPros  Customizable “trip” current  Manual resetting/replacement not required  Does not require operation awareness  Kill switch feature available ConsCons  Complex implementation

44. Hot Plug Controller

45. Preliminary Analysis

48. Improved Concept  Initial concept only consisted of a standard fuse  Did not take into account start-up characteristics

49. User Interface (hardware)

50. Overview  Translate user actions into electrical control signal which controls the robot movement  Be able to input and store coordinates and translate that into control signals that can autonomously displace the robot to the desire coordinates

51. Concerns (selection criteria)  Size and weight of user interface  User friendly  Number of features it can have  Maximum signal range   Adaptability to add-ons and features   Programming language with PC104

52. Concept #1  Tethered Laptop ProsPros  Adaptable to future programs and control modules  Full featured  Complex functionality  inexpensive ConsCons  Limited distance  Not ergonomic

53. Concept #2  Wireless Remote ProsPros  Light weight  User friendly  Long operating range ConsCons  Expensive transceiver modules  Limited functionality

54. Preliminary Analysis

55. Safety Sensor

56. Overview  Prevent the robot from running into pedestrians  Prevent damage to the robot by sensing obstacles within its path

57. Concerns (selection criteria)  Ability to detect both humans and obstacles  Response time  Range and coverage area  Power consumption

58. Concept #1  Ultrasonic Sensors ProsPros  Easy to implement  Inexpensive  Wide focus angle ConsCons  Range is not adjustable  Low response time

59. Concept #2  IR proximity sensors ProsPros  Adjustable range  Easy to implement  Inexpensive ConsCons  Slow response time  Narrow focus

60. Preliminary Analysis

62. Conclusion More engineering analysis and cost comparison is needed to optimize safety and cost concerns Option of using both concepts on robot is will also be considered

63. Conclusion Software concepts decision will be determined after an optimal solution for the user interface unit is tested and determined Using a wireless keyboard as the communication interface could also be feasible. Cost less and more feature than remote Wireless capability Lighter weight than a laptop

64. Framing Concepts

65. Overview The Frame is an extremely important part of any vehicular design. The Frame is an extremely important part of any vehicular design. It is what all other components will be mounted to. It is what all other components will be mounted to. The frame must be designed to accommodate all mechanical components and electrical components. The frame must be designed to accommodate all mechanical components and electrical components.

66. Needs Addressed  The Platform is Economical (5)  Perform required tasks (3)  Modular (4)  Robust (6)  Adaptable (7)(11)  ‘Wow’ factor (8)

67. Issues  Both strength and functionality are required in the designing.  Will support the required payload of 100kg. Accommodate all modules and electronics  Efficient design to reduce weight and material (cost).

68. CONCEPTS  Sheet Metal Sheet metal can be formed in to shapes that can be used to support loads ex. file cabinets.Sheet metal can be formed in to shapes that can be used to support loads ex. file cabinets.  Tubular Tubes can form structures when welded together as in car frames.Tubes can form structures when welded together as in car frames.

69. CONCEPTS  Columns Columns are used in various applications as load supportsColumns are used in various applications as load supports  Perforated Metal Many frames for shelves use perforated metal.Many frames for shelves use perforated metal.

70. CONCEPTS  Internal Components The internal components could be used to support the platformThe internal components could be used to support the platform

71. Pros and Cons  Sheet Metal ProsPros  Inexpensive  High wow factor (when done correctly) ConsCons  Fabrication time  Requires special equipment

72. Pros and Cons  Tubular ProsPros  Inexpensive ConsCons  Welding Requirements

73. Pros and Cons  Columns ProsPros  High load rating  Easy to manufacture ConsCons  Alignment Issues  Needs to be combined with other structures

74. Pros and Cons  Perforated Metal ProsPros  Versatile  Reusable ConsCons  Requires hardware (attachments)

75. Pros and Cons  Internal Components as Supports ProsPros  Inexpensive  Requires least amount of hardware ConsCons  May create damaging stresses on components  Possibility of heating issues

76. Preliminary Analysis  Frame Size Estimate RectangularRectangular  1.14x.784m (45x27in) Doorways.864m (34in)Doorways.864m (34in) Motor Module Flange.223m (9in)Motor Module Flange.223m (9in) Component Clearance: battery.14x.17x.18m (5.5x6.5x7in)Component Clearance: battery.14x.17x.18m (5.5x6.5x7in) TriangularTriangular .784m (27in) equilateral

77. Preliminary Analysis  Loads and Forces 4-wheelMassForceSafety factorEstimated force Assumptions Payload100 kg981 N1.51471.5 Nstatic load Frame13.2 kg129.49 N1 square box 1.4x1.4x0.5m, 1.5 kg/m Batteriesto be included static load Electronicsto be included static load Total1600.99 N 3-wheel Payload30 kg294.3 N1.5441.45 Nstatic load Frame9.9 kg97.11 N1 triangular prism 1.4x1.4x0.5m, 1.5 kg/m Batteriesto be included static load Electronicsto be included static load Total538.57 N

78. Preliminary Analysis  Cost Estimates DescriptionSupplierDimensions/DescriptionCost Part Number Perforated Aluminum Tubular StructureMcMaster-Carr 1 1/2 " square and have 0.328" dia. bolt holes on 1 1/2 " centers. $43.64 / 8'8809T31 Connectors for the above see catalog pg 1520 on McMaster- Carrhttp://www.mcmaster.com/ Square Structural Tubing (Steel)McMaster-Carr 1 1/4" x 1 1/4" with wall thickness.06"$21.49 / 6'6527K14 Round Structural Tubing (Aluminum)McMaster-CarrOD 1 1/4 with wall thickness.065"$42.33 / 6'89955K65

79. Preliminary Analysis  Future Costs and Considerations ShippingShipping WeldingWelding HardwareHardware Lead TimeLead Time

80. Payload Attachment Concepts

81. Overview Securing the payload is important for safety and appearance. Securing the payload is important for safety and appearance. The payload should not come off the platform during platform operation. The payload should not come off the platform during platform operation. The platform should look organized when the attachment device is not in use. The platform should look organized when the attachment device is not in use.

82. Needs Addressed  SAFETY (1)  Perform required tasks (3)  Economical (5)  Robust (6)  Appealing (8)  Easy to manufacture (11)

83. Issues  The securing devices must be easily concealed in the platform.  They must therefore be light and small to not overload the platform.  It is desirable to have the mounting holes be multi-functional for multiple mounting devices.

84. CONCEPTS  Tee nuts These can be secured by a bolt to a slot, meaning they can be moved to any location along the slot.These can be secured by a bolt to a slot, meaning they can be moved to any location along the slot.  Toggle clamps These are a quick and simple way to tightly secure the payload; just turn a lever.These are a quick and simple way to tightly secure the payload; just turn a lever.

85. Concepts  Tie-Down Straps These are lightweight and easy to use and storeThese are lightweight and easy to use and store  Bungee holes around edge Bungee cords are easy to use, and mounting them in specific holes would add strengthBungee cords are easy to use, and mounting them in specific holes would add strength

86. Concepts  Platform materials with holes More holes than the previous idea, easier because purchased with holesMore holes than the previous idea, easier because purchased with holes  Platform materials with threaded holes Advantageous to a simple grid because anchors could be applied to the holesAdvantageous to a simple grid because anchors could be applied to the holes

87. CONCEPTS  Drop-Down Gates Gates would be easily storable, and would fence the whole platformGates would be easily storable, and would fence the whole platform  Side Flaps Flaps would easily expand the surface area of the platform, and be easily storableFlaps would easily expand the surface area of the platform, and be easily storable

88. Preliminary Analysis  Tee nuts ProsPros  Versatile  Looks impressive ConsCons  Difficult to manufacture  Not economical  Toggle clamps ProsPros  Easy to assemble  Looks impressive ConsCons  Difficult to manufacture  Expensive

89. Preliminary Analysis  Tie-Down Straps ProsPros  No assembly  Clean in appearance ConsCons  Not as strong as some methods  Expensive  Bungee holes around edge ProsPros  Easy to use  Economical ConsCons  Not a strong hold on payload  Difficult to manufacture

90. Preliminary Analysis  Drilled holes (grid) ProsPros  No assembly  Economical ConsCons  Not impressive in appearance  Not a strong hold on payload  Drilled and tapped holes ProsPros  Added visual appeal  More secure hold on payload ConsCons  Not easy to use  Not durable

91. Preliminary Analysis  Drop-Down Gates ProsPros  Impressive in appearance ConsCons  Not easy to manufacture  Not light  Side Flaps ProsPros  Impressive in appearance ConsCons  Not robust  Not much restraining force on load

92. Bumper Concepts

93. Overview Bumpers are an import feature as a backup system to proximity sensors. Bumpers are an import feature as a backup system to proximity sensors. It ensures building and equipment protection. It ensures building and equipment protection.

94. Needs Addressed  SAFETY (1)  Cost (5)  Easy to manufacture (11)  Robust (6)  Wow Factor (3), (8)

95. Issues  Must be designed to provide safety to the robot it’s self as well as its surrounding environment.  Should be removable to maintain a modular robot.  Should not reduce accessibility of components.

96. CONCEPTS  360-Degree Wrapping A bumper would have 360- degree coverage around the robot ie. (bumper car)A bumper would have 360- degree coverage around the robot ie. (bumper car)  Stoppers Specifically localized shock- absorbing material.Specifically localized shock- absorbing material.  None RP100 will have no bumper.RP100 will have no bumper.

97. Preliminary Analysis  360-Degree Wrapping ProsPros  Complete coverage  Inexpensive  Easy to attach ConsCons  Comprimises accessibility CostCost  4.25x.5”: $8.22/2’  Stoppers ProsPros  Easy to replace  Minimal space required Cons  Low WOW factor  Partial protection CostCost  ½” circular stopper: $11.91/pk of 64  None ProsPros  Very Inexpensive  Will allow time to develop non- backup sys. ConsCons  No protection CostCost  N/A

98. Final Concept None / 360-Degree After the filtering of our concepts through the concept selection scoring process we have concluded that no bumper would be the first choice. However it is believed that the 360-degree bumper should be developed for safety reasons.

99. Final concept Create a Drilled and Tapped Grid Through Pugh charts, we deduced that these two options met more of our criteria with a higher score than any others. The grid without threads was versatile in anchoring the load, and the threads added to our payload- securing options. We looked for bungee cords for this design, and found two options on MSC Direct. One was essentially four cords bundled in the middle (hooks are made of fiberglass and nylon), costing $14.65 per cord, and the other was a rubber bungee cord, 5/16 inches wide with metal S-hooks, costing $4.01 per cord.

100. Final Concept Perforated Tubular Hybrid After research and the concept selection process, it is concluded that a hybrid frame design system will be adopted. This will allow the strengths of each frame to be combined.

101. Shell Concepts

102. Overview The shell is defined as an external casing of the robot excluding the platform. The shell’s material will therefore define its ability to protect the internal components and add to the overall appearance. The shell is defined as an external casing of the robot excluding the platform. The shell’s material will therefore define its ability to protect the internal components and add to the overall appearance.

103. Needs Addressed  SAFETY (1)  Cost (5)  Easy to manufacture (11)  Robust (6)  Wow Factor (3), (8)

104. Issues  Must be designed to provide safety to the robot.  Should not reduce accessibility of components.

105. CONCEPTS  Aluminum A readily available material which can be obtained in various sizes that would accommodate our needs. As large as 1.22x1.22m (4x4’)A readily available material which can be obtained in various sizes that would accommodate our needs. As large as 1.22x1.22m (4x4’)  Steel A common and durable building material.A common and durable building material.  Acrylic Can be used in many industrial applications because of its lightweight and insulation properties.Can be used in many industrial applications because of its lightweight and insulation properties.

106. Preliminary Analysis  Aluminum ProsPros  Lightweight  Impressive finish (polished)  Easy to machine  Can be repaired ConsCons  Expensive  Lower strength  Conductor CostCost  48x24x1/16”: $62.84  Acrylic ProsPros  Easy to machine  Lightweight  High WOW factor  Insulator ConsCons  Weak  Brittle CostCost  48x24x1/16”: $57.18  Steel ProsPros  Very Strong  Tight tolerances  Inexpensive  Reparable  Easy to weld ConsCons  Heavy  Rust prone CostCost  48x24x1/16”: $57.18

107. Final Concept Steel / Acrylic The scoring matrices showed that, according to our criteria based upon the customers needs, a steel shell would be the most advantageous material. Steel is the strongest material that we considered it is also cheaper than aluminum and plastic. Steel can also be very visually appealing.

108. Shell Concepts

109. Overview The shell is defined as an external casing of the robot excluding the platform. The shell’s material will therefore define its ability to protect the internal components and add to the overall appearance. The shell is defined as an external casing of the robot excluding the platform. The shell’s material will therefore define its ability to protect the internal components and add to the overall appearance.

110. Needs Addressed  SAFETY (1)  Cost (5)  Easy to manufacture (11)  Robust (6)  Wow Factor (3), (8)

111. Issues  Must be designed to provide safety to the robot.  Should not reduce accessibility of components.

112. CONCEPTS  Aluminum A readily available material which can be obtained in various sizes that would accommodate our needs. As large as 1.22x1.22m (4x4’)A readily available material which can be obtained in various sizes that would accommodate our needs. As large as 1.22x1.22m (4x4’)  Steel A common and durable building material.A common and durable building material.  Acrylic Can be used in many industrial applications because of its lightweight and insulation properties.Can be used in many industrial applications because of its lightweight and insulation properties.

113. Preliminary Analysis  Aluminum ProsPros  Lightweight  Impressive finish (polished)  Easy to machine  Can be repaired ConsCons  Expensive  Lower strength  Conductor CostCost  48x24x1/16”: $62.84  Acrylic ProsPros  Easy to machine  Lightweight  High WOW factor  Insulator ConsCons  Weak  Brittle CostCost  48x24x1/16”: $57.18  Steel ProsPros  Very Strong  Tight tolerances  Inexpensive  Reparable  Easy to weld ConsCons  Heavy  Rust prone CostCost  48x24x1/16”: $57.18

114. Final Concept Steel / Acrylic The scoring matrices showed that, according to our criteria based upon the customers needs, a steel shell would be the most advantageous material. Steel is the strongest material that we considered it is also cheaper than aluminum and plastic. Steel can also be very visually appealing.

115. Combined Concept

116. Attachment With Slot Nuts Showing Platform With T-Nut Grooves

117. Attachment With Slot Nuts Cont. Close Up T-Nut Inserted In Groove

118. Useful Accessories For T-Nut Setup – Toggle Clamps Using A Toggle Clamp On Platform Source: McMaster.com (clamp model)

119. Useful Accessories For T-Nut Setup – Eyebolts And Guide Rails Using An Eyebolt And Guide Rails On The Payload Platform Source: McMaster.com (Eyebolt model)

120. Overall Platform Preliminary Concept

121. Project Weaknesses/Future Improvements  Solidify Target Specifications  Improve platform looks  Establish a Testing scheme  Take advantage of EDGE  Share detailed information with other teams