1. Project Cybot - Ongo01 December 12, 2001 Project Leaders: Sath Sivasothy Caleb Huitt Faculty Advisor: Dr. Ralph Patterson Client: Department of Electircal and Computer Engineering Acknowledgements: Dr. Lawrence Genalo

2. Presentation Outline Overview Sensors Power End-Effector Motion Control Software Interactive Learning Summary

3. Introduction OSCAR (Concept)OSCAR (Current)

4. Team Cybot History - Once a club - Robots: Zorba - No longer exists Cybot - Department Ambassador - Many demonstrations - Now failing OSCAR - Newest robot - Being designed and built

5. Organization Six subteams Sensors Power End-Effector Motion Control Software Interactive Learning (New Addition) Weekly subteam meetings Weekly team leader meetings E-mail mailing lists

6. Subteam Interaction

7. Previous Accomplishments Cybot: Complete motion control Moving arm Speech and voice recognition Many and complex demonstrations OSCAR: Complete design Motion control Sensors installed Gripper fabricated

8. Beginning of the Semester Cybot: Motion control inoperable Arm stopped working over summer Speech still works Very few demonstrations work OSCAR: Motion control nearly complete Few demonstrations Sensors usually working Arm design nearly complete Solid power system Few people know about robot

9. End Goals Cybot: Restore to previous functionality OSCAR: Robot can accomplish tasks autonomously Speech control and interaction Internet interface for remote learning Ability to demonstrate with a few minutes notice Take over Cybot’s role as ambassador Become famous (at least on campus)

10. Semester Goals Concentrate on OSCAR: Motion control stabalized Sonar sensors working New sensors installed Easier robot control: - Voice - Arrow keys New computer power supply Finish arm design Manufacture more of arm Investigate ways to get robots “heard about” Give demonstrations of robots

11. Risks and Concerns Problems with previous work Hardware breakdown Time available Personnel problems Technical knowledge Demonstrations

12. Risk Management Test early Deal with it as the problems arise Schedule properly Stay flexible in assignments Good documentation Keep Cybot as functional as possible

13. Questions

14. Sensors Team

15. Team Members: Chris Hutchinson (CprE, 2 nd ) - team leader Adam Kasper (CprE, 2 nd ) Saw Meng-Soo (CprE, 2 nd ) Waqar Habib (EE, 1 st )

16. Problem Statement Provide sensing capabilities Finish sonar system Add compass and temperature sensors Determine accuracy and limits Finalize software interface

17. Design Objectives Modular design Future expandability Low power consumption Provide accurate data

18. Assumptions and Limitations Assumptions: Only one sensing function at a time Only one active transducer at a time Limitations: Sonar effective from 1.5 to 35 feet EM interference affects compass Limited microcontroller I/O pins Limited power and space

19. Risks and Concerns Part damage Electromagnetic interference Inconsistent data

20. End Product Description Distance sensing within +/- 3% Temperature sensing within +/- 2° F Data filtering Reliable software interface

21. Technical Approach Completion of sonar system: Multiplex with programmable logic Permanently mount all components Tweek for accuracy Determine limits Transducer BasicX-24 Microcontroller

22. Technical Approach Addition of new sensors: Thermistor for temperature sensing Dinsmore 1655 Analog Compass Tweek for accuracy (ongoing)

23. Technical Approach Software Interface: Serial communication Modular / scaleable design Simple implementation Interface protocol - 1 byte ATNCommandOperand(s)

24. Completed System

25. Problems Encountered Damaged programmable logic chip Memory issues Sonar noise Transducer dissipation Inaccurate compass

26. Evaluation of Success Software interface implemented Integration of new sensors Accurate and reliable reporting of data Met financial and time budgets

27. Future Work Data accuracy Efficiently utilize sensors Additional sensors: - Video imaging - Tactile / Pressure - Infrared

28. Lessons Learned Experience with the BX-24 microcontroller Implementation of analog and digital sensors Demonstrations with large groups Things break – roll with the punches

29. Summary Sensor system is fully functional OSCAR has the power to interact Ready for further sensing capability

30. Questions

31. Demonstrations Sonar sensors Compass sensor Thermistor

32. Power Team

33. Team Members: Nicholas Sternowski (EE, 2 nd ) - team leader Kris Kunze (EE, 1 st )

34. Design Objectives Install new batteries Replace DC/AC inverter Build/Test/Install DC/DC converter

35. Assumptions and Limitations Assumptions: Batteries in good working condition Limitations: Batteries can only be run down to 50% Initial power system design not available Limited budget No experience with PCB fab

36. Risks and Concerns Short circuit Power system with charger

37. Technical Approach Cheaper is better! Utilize readily available batteries Parallel DC/DC converters

38. Technical Approach

41. Problems Encountered PCB fabrication Part order delays

42. Evaluation of Success DC/DC converter design determined PCB fabrication Parts ordered Batteries installed & functioning

43. Future Work Completing of DC/DC converter Provide power to sensor, end effector teams System protection

44. Lessons Learned Power supply operation Slow drain on batteries cause failure PCB fabrication Minimum order requirements are a killer

45. Summary Didn’t meet all goals Work needed identified

46. Questions

47. End-Effector Team

48. Team Members: Jet Ming Woo (EE – 2nd ) – team leader Alex Mohning (ME – ME 466 ) Alex Rodrigues (ME – ME 466) Chris Trampel (EE – 1st) Yan Chak Cheung (EE – 1st) Jim Schuster (Cpre – 1st)

49. Design Objectives Full range of movement Move at reasonable speed Lift 2 lb objects − 1 lb at full arm extension Lift 3” diameter objects Controlled by OSCAR’s central computer Modular approach

50. Assumptions and Limitations Assumptions: Sufficient funding for the fabrication of arm All motors will operate at 12 volts Limitations: Arm pivoted on top of OSCAR Use JAVA to write the program 12V available for gripper

51. Risks and Concerns Cost of development Availability of parts Power Consumption of motors

52. Risk Management Search for cheaper parts Buy parts over several semesters Look for cheaper designs Buy widely used motors at the start of the semester after designing the arm Search for parts with low power consumption

53. Technical Approach Assembly and testing of the gripper Research on existing control circuits Develop software and electronic control circuits Develop software and electronic control circuits Develop detailed drawings and schematics for the wrist Develop detailed drawings and schematics for the wrist

54. Wrist Control Circuit PC Motion Controller LM 629 Half-Bridge MOSFET Driver LT 1158 Half-Bridge DC Wrist Motor Motion Controller LM 629 Half-Bridge MOSFET Driver LT 1158 Half-Bridge PWM Quadrature Incremental Feedback

55. Gripper Control Circuit PC DC Gripper Motor 4 Phase Stepper Motor Drive UCN 5804B Dual Full Bridge Motor Driver UDN2998W Inductance to Resistance Drive Card

56. Gripper Design Stepper actuator Stepper actuator – Inexpensive – Compact – Linear drive without transmission Linkages easy to manufacture Linkages easy to manufacture Interchangeable fingers Interchangeable fingers

57. Overall Design Arm will pivot on top-center of OSCAR Arm will pivot on top-center of OSCAR Aluminum links Aluminum links Joints use modular worm gear assembly Joints use modular worm gear assembly Driven by Pittman DC motors Driven by Pittman DC motors

58. Wrist Design 360º rotation 360º rotation 270º bend at wrist joint 270º bend at wrist joint Separate motors for bend and rotation Separate motors for bend and rotation Utilizes similar components as rest of arm Utilizes similar components as rest of arm

59. Worm Drive for Bend Pittman DC motor Pittman DC motor – Reduced speed – Readily available – Reliable Worm assembly Worm assembly – Dramatic torque gains – No back drive – save power

60. Gear Drive for Twist Spur gear drive Spur gear drive – Reduced speed – Torque gains – Linear transmission

61. Problems Encountered Lost of financial sources Team members not familiar with JAVA

62. Evaluation of Success Motor installed in gripper and functional Control circuit for gripper is ready Gripper’s software is almost done Wrist design completed Wrist control circuit schematic is drawn

63. Future Work Draw layout of circuit using PCB program Build the control circuit boards for all motors Modify wrist design Machine and assemble the arm Software for the arm

64. Lessons Learned Program and test I/O card on OSCAR JAVA language H-bridge

65. Summary Gripper motor installed and functioning Wrist design is detailed and completed Wrist design is detailed and completed Future work planned for the completion of arm Future work planned for the completion of arm

66. Questions 4.00” 3.75” 8.5”

67. Demonstrations Gripper

68. Motion Control Team

69. Members: Rius Tanadi (EE – 2nd ) – team leader Brooks Graner (CprE – 1st ) Boon-Siang Cheah (CprE – 1st )

70. Problem Statement Robot movement Hardware broken/unstable Further research on new circuit implementation

71. Design Objectives Debug and maintain motion control hardware Reliable software interface

72. End Product Description OSCAR’s motion will be fully operational Improve motion control design

73. Assumptions and Limitations Original assumptions –Old software/hardware validated Limitations –Robot breaks down –Robot used for presentations

74. Risks and Concerns Short circuit Over-heating components Loss of current members

75. System Overview Subsystem block diagram Computer Motion Control Subsystem Motor(s)

76. Technical Approach CPU Motor CPU Interface Motion Controller Motor Driver Motion Detector Motion control subsystem

77. Technical Approach Motion control circuitry will be debugged and tested - Individual/component testing - Sub-system testing Reliable software interface will be created - Create GUI

78. Evaluation of Success Robots - Debug OSCAR (partially met) - GUI interface (met) Budget

79. Additional Work Test the remaining components Trace motion control design Aid end-effector team Research on circuit implementations

80. Lessons Learned Debug - Isolation of variables - Component validation Interact with people

81. Summary OSCAR debug is still in progress Clean up all the design flaws Research for a better design

82. Questions

83. Software Team

84. Team Members: Caleb Huitt (CprE, 2 nd ) - team leader Muhammad Saad Safiullah (CprE, 2 nd ) Anthony Bozeman (CprE, 2 nd ) Sastra Winarta (CprE, 1 st ) John Wyman (CprE, volunteer)

85. Problem Statement Provide easy SW motion control Provide voice control Use sensor information Develop demonstrations

86. Design Objectives Modular design Easily Expandable Separates drivers from logic Allows component testing Accessable interfaces Consistent techniques

87. Assumptions and Limitations Assumptions: Operators have basic computer skills Subteam members have basic programming skills Software developed for properly functioning hardware Limitations: Current documentation is incomplete Much time needed to learn subsystem Hardware breakdowns limit software testing

88. Risks and Concerns Hardware insufficient/inconsistent Members without needed experience Interoperability problems

89. Risk Management Investigate hardware early Detail necessary & optional purchases Provide explanatory papers Provide research tasks Iterative design approach

90. End Product Description Verify motion control driver code Allow arrow keys to control motion Implement voice control Expand sensor software Integrate sensor software Develop new demonstrations

91. Technical Approach Three-tier software design Modular Extensible Programming languages based on needs C for drivers Java for higher levels Use previously developed solutions

92. Technical Approach Software Three-Tier Approach: Second Tier (Application Logic) Third Tier (User Interface Logic) First Tier (Direct Control Software)

93. Technical Approach Motion control drivers tested/debugged Use JDK for IBM’s ViaVoice Sensors: Communication over serial port Protocol defined by Sensors subteam Arm driver design based on motion control’s

94. Problems Encountered Motion Control subteam debugging Sound card problems Previous sensors software unusable Java programming problems Volunteer stopped after 1/2 semester

95. Evaluation of Success Motion control software debugged Arrow key motion software working Sensors software interface rewritten Voice control software working Goals not completely met Many problems overcome

96. Future Work Software for end-effector Speech synthesis Integrate sensors data Develop more demonstrations Work on autonomous navigation

97. Lessons Learned Motion control implementation Java programming language IBM’s ViaVoice technology Serial port communication Software keystroke detection

98. Summary Didn’t meet all goals Overcame a variety of problems Have much work to do in the future

99. Questions

100. Demonstrations Arrow key control of motion Voice control proof-of-concept

101. Interactive Learning Team

102. Team Members: Kivanc Kahya (CprE, 1 st ) - team leader John Davidson (CprE, 1 st )

103. Design Objectives Initiate educational system using OSCAR Develop robotics education curriculum Initiate Internet-based remote control system Add additional functionality (if required) Consider using LEGO® Mindstorms robots

104. Assumptions and Limitations Assumptions: OSCAR will soon be fully functional Required technologies are available Client will be found Limitations: Client’s current technology infrastructure Number of students using the system simultaneously Funding

105. Risks and Concerns Integration of additional hardware/software Qualified robotics teacher for client Too many interested clients Client may lack necessary technology Complicated programming interface Lack of experience in design team

106. Risk Management Assistance from Toying with Technology Well defined software design process Peer reviews Detailed software test procedures

107. Technical Approach Technology Internet-based remote control system Inter-communication between multiple robots Educational Materials Structured exercises Robotics workshops Sponsorship of robotics competitions

108. Problems Encountered Excessive time spent on initial documentation Delayed contact responses

109. Evaluation of Success Team poster completed Gathered significant information Objectives accomplished

110. Future Work Conceptual design Software system requirements Develop robotics curriculum Search for funding Develop demonstrations

111. Lessons Learned Initiating a project without clear understanding of the problem is difficult

112. Summary Interactive learning project initiated Compiled information sufficient to initiate development Met all semester goals

113. Questions

114. Financial Budget

115. Effort Budget

116. Semester Accomplishments Thermal/compass/distance sensors Motion control GUI Wrist design DC/DC converter design Strategic planning Voice Control Successful Demonstrations

117. Future Goals Implement DC/DC converter Manufacture remainder of arm Achieve compass/sensor accuracy Implement sensors software Implement end-effector software Continue and improve demonstrations

118. Overall Summary Completed documentation Effective team communication Overcame unexpected problems Stayed well under budget Semester was a success

119. Final Questions