1. ECE 477 Final Presentation Group 7  Spring 2005

2. Outline Project overviewProject overview Block diagramBlock diagram Professional componentsProfessional components Design componentsDesign components Success criteria demonstrationsSuccess criteria demonstrations Individual contributionsIndividual contributions Project summaryProject summary Questions / discussionQuestions / discussion

3. Project Overview An autonomous vehicle designed to look for moving heat-emitting targets and engage them while patrolling a limited area and avoiding ground obstacles. + =

4. Gorgeous! Isn’t it? (The sky blue color scheme really gives it that extra something)

5. Block Diagram

6. Professional Components Constraint analysis and component selection rationaleConstraint analysis and component selection rationale Patent liability analysisPatent liability analysis Reliability and safety analysisReliability and safety analysis Ethical and environmental impact analysisEthical and environmental impact analysis

7. Constraint Analysis Major Constraints - Many peripheral devices - Many peripheral devices - 1 Airsoft Gun Motor - 4 Passive Infrared Sensors - 1 Ultrasonic sensor - 1 Servo - 2 Drive Motors - 1 LCD - Small Package Size/Weight - Small Package Size/Weight - Small Tank base (4.5” x 8”) - Mobile Battery Power Supply - Mobile Battery Power Supply - 2 7.2V NiMH Rechargeable Batteries - 4 9V Alkaline Batteries - Time of Flight Computation Requirement - Time of Flight Computation Requirement - Ultrasonic Ping flight time needed to be found - No major cost constraints - No major cost constraints

8. Component Selection Rationale Robot Base: Rogue Robotics RT-ATR - Small design easy to work with - Flexible/Expandable design for attaching many peripherals many peripherals Micro-controller: Motorola M68MOD912C32 - Contains requisite I/O for each peripheral - Capable of pulse measurement for Time of Flight - Compact module design allows for small PCB to fit on small tank base fit on small tank base

9. Component Selection Rationale Passive Infrared Sensors: Kitsrus K30 - Interfaced well with HC(S)12 - Small design/lightweight - Good Range (Approx. 120 degree range) Liquid Crystal Display: Optrex DMC20261A - Worked well with HC(S)12 SPI port - 2 x 20 Character display was good size for displaying engagement count/reload status displaying engagement count/reload status

10. Component Selection Rationale Servo Motor: JR NES-537 - Easy to interface/operate compared to stepper motor - High torque rating ( 45 oz-in ) - Very small/lightweight Ultrasonic Sensor: Devantech SRF04 - Small/lightweight - Used for short ranges (3 cm to 3 m) - Directly interfaces with HC(S)12 Paintball Gun: KTC 210910 - Fully Automatic - Electronic Trigger - Small ( 9” after cut down ) - Light weight ( less than 1 lb ) - Little or No kickback on gun fire

11. Patent Liability Analysis Results of Patent SearchResults of Patent Search –Many patents relate with our project Autonomous robot with 2 sets of rotorsAutonomous robot with 2 sets of rotors Robot operating in multiple modesRobot operating in multiple modes Autonomous robot with obstacle detectionAutonomous robot with obstacle detection –Recommended action Doctrine of equivalentsDoctrine of equivalents –“Robot performing social interactivity” Patent lawyer and/or licensingPatent lawyer and/or licensing

12. Reliability/Safety Analysis OverviewOverview –Mean Time To Failure (MTTF) analysis of crucial components –FMECA worksheet for entire schematic

13. Reliability/Safety Analysis – mean time to failure (MTTF) analysis of crucial components Freescale 9S12C32 MicrocontrollerFreescale 9S12C32 Microcontroller –failures every 10 6 hours : 1.388 –MTTF : 7.205 x 10 5 hours –Not acceptable Linear Tech LT 1374-5 Switching Regulator –failures every 10 6 hours : 2.33 –MTTF : 4.292 x 10 5 hours –Not acceptable Linear Tech LT 1376-5 Switching RegulatorLinear Tech LT 1376-5 Switching Regulator –failures every 10 6 hours : 2.33 –MTTF : 4.292 x 10 5 hours –Not acceptable 4N28 Phototransistor Output Optocoupler4N28 Phototransistor Output Optocoupler –failures every 10 6 hours : 5.4912 –MTTF : 1.8211 x 10 5 hours –Acceptable

14. Reliability/Safety Analysis - FMECA worksheet for entire schematic Chip Power Supply (Block A)Chip Power Supply (Block A) Motors Power Supply (Block B)Motors Power Supply (Block B) Microcontroller and interface headersMicrocontroller and interface headers (Block C) (Block C) PIR interfaces (Block D)PIR interfaces (Block D) LCD interface (Block E)LCD interface (Block E) H-Bridge and Servo motor interfacesH-Bridge and Servo motor interfaces (Block F) (Block F) Gun interface (Block G)Gun interface (Block G)

15. Reliability/Safety Analysis - FMECA worksheet for entire schematic Two levels of criticality:Two levels of criticality: –High : Cause injury to the user or permanent damage to the robotCause injury to the user or permanent damage to the robot Expected to have failure rate smaller than 10 -9Expected to have failure rate smaller than 10 -9 –Low : Robot does not function properly but does not cause injury or permanent damageRobot does not function properly but does not cause injury or permanent damage Expected to have failure rateExpected to have failure rate between 10 -9 and 10 -4 between 10 -9 and 10 -4

16. Ethical/Environmental Analysis Ethical AnalysisEthical Analysis - Warning Labels and Cautions in - Warning Labels and Cautions in Documentation Documentation - Remote “Kill Switch” - Remote “Kill Switch” - Durability - Durability

17. Ethical/Environmental Analysis Environmental AnalysisEnvironmental Analysis - Product Manufacture - Product Manufacture - Surface Mount Technology - Surface Mount Technology - Material Substitution - Material Substitution - Reuse/Recycle - Reuse/Recycle - Normal Use - Normal Use - Disposal - Disposal - PCBs - PCBs - Batteries - Batteries - Base - Base

18. Design Components Packaging design considerationsPackaging design considerations Schematic design considerationsSchematic design considerations PCB layout design considerationsPCB layout design considerations Software design considerationsSoftware design considerations

19. Packaging Design Many components squeezed into small space including 9 separate PCB’s. - Main Board - Main Board - 4 PIR PCB’s - 4 PIR PCB’s - 1 Ultrasonic PCB - 1 Ultrasonic PCB - 1 H-Bridge PCB - 1 H-Bridge PCB - 1 RF switch PCB - 1 RF switch PCB - 1 LCD PCB - 1 LCD PCB Key Packaging Decisions -Low battery weight -Readable LCD positioning -Hidden PIR in gun

20. Schematic Design Voltage regulatorsVoltage regulators LCD interfaceLCD interface PIR interfacePIR interface Ultrasonic sensor interfaceUltrasonic sensor interface Servo interfaceServo interface H-Bridge and drive motors interfaceH-Bridge and drive motors interface Gun trigger interfaceGun trigger interface MCUMCU

21. Schematic/Theory of Operation – Final Schematic

22. PCB Layout Design 12 mil traces – Standard12 mil traces – Standard 50 mil traces – Power/Ground50 mil traces – Power/Ground Footprints created: headers, LT1374-5 (regulator), surface mount diodeFootprints created: headers, LT1374-5 (regulator), surface mount diode Decoupling capacitorsDecoupling capacitors Routing is…

23. the root of all EVIL!

24. Before

25. After

26. Software Design AssemblyAssembly Metrowerks CodeWarriorMetrowerks CodeWarrior Polling LoopPolling Loop ModulesModules - GROVER - Servo - GROVER - Servo - Ultrasonic - AirSoft - Ultrasonic - AirSoft - H-Bridge - H-Bridge - PIR - PIR - LCD - LCD

27. Target Detected? Display Ammo Status / Engagements Poll PIR Sensors Poll Ultrasonic Sensor Obstruction Detected? Turn Motors ON FWD 1 3 *2 Turn 90 o Right Turn Motors OFF Stop Turret Fire Weapon / Update Ammo Set Engagement Flag Engagement Flag Set? Increment Engagement Count on LCD Pause for 10 Seconds Clear Engagement Flag / Reset Turret Turret Sensor Triggered? Turn Maxed? Step Turret Right 15 o Step Turret Left 15 o Reset Turret Initialization Reset Turret Clear LCD Start Which PIR Sensor? Yes Turn Motors OFF Yes No Reset Variables No * Note: PIR Sensors 1 and 3 have priority over 2. See ‘Center Sweep’ Turn Grover 90 o in Direction of Turn Ammo = 0? NoYes Stop Program Flow

28. Success Criteria Demonstrations An ability to avoid collisions with inanimate objectsAn ability to avoid collisions with inanimate objects

29. Success Criteria Demonstrations An ability to detect a heat-emitting targetAn ability to detect a heat-emitting target An ability to turn weapon to face targetAn ability to turn weapon to face target An ability to fire the weaponAn ability to fire the weapon

30. Success Criteria Demonstrations An ability to determine and display the number of engagementsAn ability to determine and display the number of engagements

31. Individual Contributions Team Leader – Joel StubbsTeam Leader – Joel Stubbs Team Member 2 – Stan MillerTeam Member 2 – Stan Miller Team Member 3 – Andrew ParcelTeam Member 3 – Andrew Parcel Team Member 4 – Edwin TjandranegaraTeam Member 4 – Edwin Tjandranegara

32. Team Leader – Joel Stubbs Researched, developed, and tested initial software prototyping and communication for Ultrasonics module and ServoResearched, developed, and tested initial software prototyping and communication for Ultrasonics module and Servo Developed and tested gun opto-isolator interface circuitDeveloped and tested gun opto-isolator interface circuit Put together main PCBPut together main PCB Contributed key packaging ideas & Packaged portion of designContributed key packaging ideas & Packaged portion of design Organized team/Helped Motivate MeetingsOrganized team/Helped Motivate Meetings

33. Member 2 – Stan Miller Gun and servo-turret packagingGun and servo-turret packaging Tank motor, weapon sensor, and battery mountingTank motor, weapon sensor, and battery mounting PCB design and layoutPCB design and layout Patient liability analysisPatient liability analysis Final packagingFinal packaging

34. Member 3 – Andrew Parcel GROVER Software DesignGROVER Software Design Environmental/Ethical ConstraintsEnvironmental/Ethical Constraints PrototypingPrototyping Initial InterfacingInitial Interfacing WebmasterWebmaster

35. Member 4 – Edwin Tjandranegara LCD and SPI software design and interfaceLCD and SPI software design and interface Power supplies and circuit designPower supplies and circuit design Schematic designSchematic design Reliability and Safety analysisReliability and Safety analysis Co-webmasterCo-webmaster H-bridge, RF remote and PIR sensors interfaceH-bridge, RF remote and PIR sensors interface

36. Project Summary Important lessons learnedImportant lessons learned –Mark power/ground consistently –Don’t order too many expensive parts –Check part specifications –Keep a timeline and stick to it

37. Project Summary Second iteration enhancementsSecond iteration enhancements –All parts surface mount –Bigger…better…base! –Fiberglass shell –Secondary control through internet –Remotely fire gun with key fob –Fit more to main PCB

38. Questions / Discussion