Testing Readiness Review
March 3, 2014
Ben Azlein, Chris Bennett, Kara
Bongiovanni, Eric Brenner, Lea Harris,
Austin Kootz, Stephanie Oij, Jason Schelz
Customer: Barbara Streiffert, JPL
PAB Advisor: Dr. Nabity
Project Overview
Test Readiness
Schedule
Budget
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Project Overview Test Readiness Schedule Budget
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Project Overview Test Readiness Schedule Budget
The goal of DARE is to design and build a Child
Rover (CR) that is capable of deploying,
communicating, and docking with the
previously designed TREADS Mother Rover
(MR), while also being able to ascend and
descend slopes between 30o and 70o. These
slopes will replicate a sandstone surface found
when exploring canyon walls, craters, and
caverns on Earth.
4 3/3/2014 ASEN 4028: TRR References: 3
Project Overview Test Readiness Schedule Budget
After deploying from the MR and travelling a maximum of 20m across flat ground, the CR will ascend and/or descend a slope of 30o to 70o, then return to the MR
The CR will travel up to 20m on level terrain
The CR will communicate with the MR and the Ground Station (GS)
The CR will capture color images
The CR will be capable of docking and deploying with the TREADS MR
The CR will determine its position relative to the MR to within ±1m and its elevation angle to within ±5o
5 3/3/2014 ASEN 4028: TRR References: 3, 4
Project Overview Test Readiness Schedule Budget
Legend
Blue = Critical to Project
6 3/3/2014 ASEN 4028: TRR
Project Overview Test Readiness Schedule Budget
Fan Assembly Electronics
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Project Overview Test Readiness Schedule Budget
Drivetrain
Wheels/Cogs
Motors
Rubber Skirt
Chassis
Suction Fan
RoboVero
Microcontroller/
FireSTORM COM
Motor Controllers Electronic Battery
Fan Battery
Encoders
Caspa FS Camera
Ground
Station
CR Ascends
then Descends
CR Descends
then Ascends CR Approaches
Slope
8
MR CR
CR Returns
to MR
NOTE: Images not to scale.
20 meters
3/3/2014 ASEN 4028: TRR
Legend
GS to CR
MR to CR
GS to MR
Descending slopes
30 – 70o Rover takes a
picture
3/3/2014 ASEN 4028: TRR 9
Suction Fan Status Update
Suction fan shall provide 955 Pa pressure differential over
a 0.1 m2 area. Fan assembly tested: ~3000 Pa
pressure differential possible Seal design shall maintain an inlet volumetric flow rate of
63 cfm while at required pressure differential.
Drivetrain Status Update
Chassis shall support loads caused by suction fan and
motors. 1. Chassis supports fan load
2. Motors match expected torque
at acceptance
3. Planning to complete
drivetrain assembly test ~3/7
Motors shall be able to provide a continuous torque of 4.3
Nm and a burst torque of 5.1 Nm.
Wheels shall remain in contact with the surface.
Software Status Update
The software shall allow the user to operate the pressure
fan, locomotion, and capture images. 1. Software allows user to
command the RoboVero
microcontroller and Faulhaber
motor controllers
2. Software provides meaningful
feedback to the user
The software shall provide meaningful feedback to the
user of position, status, images, and history.
The software parses information from GS to MR to CR, as
well as GS to CR.
Project Overview Test Readiness Schedule Budget
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Legend
Make
Done
In-Progress
Future Work
Procure
On-hand
On order
Future Purchase
Project Overview Test Readiness Schedule Budget
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Project Overview Test Readiness Schedule Budget
Navigation
Communication
Mission Validation
Acceptance Tests Integration Tests System Test
Final Validation Fan Assembly Fan
Drivetrain
Motors
Motor Controller
Electronics/ Software
Robovero (Microcontroller)
CASPA FS
(Camera)
FireSTORM
(COM)
Battery Discharge
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LEGEND
Planned
Completed
In Process
Critical
LEGEND
Planned
Completed
In Process
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Results
Expected Can receive signals and return
digital output
Actual Passed
Impact
Verifies board is functional and
ready for programming and
integration
Results
Expected Match supplier specifications
Actual Passed
Impact
Verifies the motors can be
controlled and provide necessary
torque
Results
Expected Fan can maintain 955 Pa on
prototype base
Actual 1400 Pa
Impact Verifies fan design
Validates design concept
Results
Expected Determine battery discharge profile
Actual In progress
Impact Verifies sufficient power for mission
duration
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LEGEND
Planned
Completed
In Process
Results
Expected Fan can maintain 955 Pa on actual
base
Actual ~3000 Pa
Impact Verifies fan/seal design
Validates design concept
3/3/2014 ASEN 4028: TRR 15
Test Overview
Purpose
Ensure drivetrain assembly can
deliver expected torque without
deforming
Equipment Motors, motor controllers,
power supply, torque gauge,
Method Static torque measurements
Expected
Results
Continuous torque of 4.1 Nm and
burst torque of 5.3 Nm
Impact Verifies meet drivetrain
requirement
LEGEND
Planned
Completed
In Process
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User
gsmain
GS computer
Port
Communication
MR computer
Port
Communication
mrmain
MR computer
Port
Communication
CR FireSTORM COM
Firestorm Library
RoboVero
RoboVero Library
robomain
Encoder1
Encoder2
Camera
Motorcontroller1
Motorcontroller2
Fan
Legend
Software
Hardware
Firmware
Project Overview Test Readiness Schedule Budget
CR RoboVero
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Legend
Software
Hardware
Firmware
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Test Overview
Purpose Command fan and receive fan status
Equipment Fan, Power Conditioning Circuit,
RoboVero, FireSTORM, GS
Method Ensuring code output corresponds to
physical state of fan
Expected Results Fan turns on and off, fan status is
accurately provided upon request
Impact Fan can be controlled and system is
ready for next level integration
Legend
Software
Hardware
Firmware
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Legend
Software
Hardware
Firmware
Test Overview
Purpose Capturing images upon user
command
Equipment GS, RoboVero, FireSTORM,
Caspa FS
Method Command camera and
validate image on GS
Expected
Results
Camera captures and
communicates image to GS
Impact
Camera can capture and
communicate images for
science
Test Overview
Purpose Obtain Distance Traveled
Equipment Encoder, GS, RoboVero
Method Manually roll wheels over
measured distance
Expected
Results
Distanced traveled and
software output matched
within ± 1 m
Impact CR is capable of meeting
navigation requirement
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Legend
Software
Hardware
Firmware
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Legend
Software
Hardware
Firmware
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Legend
Software
Hardware
Firmware
Test Overview
Purpose Command and Status update of Motors
Equipment GS, FireSTORM, RoboVero, Faulhaber, Motors
Method Send command or status check
Expected Results Motors rotate intended linear distance, status is clearly
received by GS
Impact CR is capable of traveling
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Legend
Software
Hardware
Firmware
3/3/2014 ASEN 4028: TRR 24
Legend
Done
In-Progress
Future Work
Software Environment Configuration
Communication with GS to FireSTORM
Wi-Fi Communication GS to FireSTORM
Command_motor
Read_motor
Command_camera
Command_fan
Read_fan
Read_encoders
Wi-Fi Communication GS to MR to FireSTORM
System Integration Test
Project Overview Test Readiness Schedule Budget
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LEGEND
Planned
Completed
In Process
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Test Overview
Purpose Ensure GS can communicate
with CR
Equipment RoboVero, FireSTORM, GS
Method Place CR up to 20m away from
GS and send commands
Expected
Results
Exact distance at which CR
can maintain communication
Impact Validate communication
objective
Test Overview
Purpose Ensure navigation is within
required accuracy
Equipment RoboVero, Encoders,
FireSTORM, GS
Method Compare software results with
physical
Expected
Results
Position known within ±1 m and
± 5o
Impact Verify navigation meets
requirements
LEGEND
Planned
Completed
In Process
Purpose Validate CR is able to complete simulated mission
To investigate the capability of the complete rover system
Assure all systems are compatible with each other
All requirements validated except R.5.4, R.11, R.16 Test surface is not large enough to meet range
requirements R.11 and R.16
R.5.4 will be met in communication component testing
Expected Results Performance map of capabilities to compare to
objectives
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Project Overview Test Readiness Schedule Budget
Shorten mission distance to make testing
feasible
Two methods will be used to account for the
reduced mission length
1. Perform mission at 10 m circuit test length
Extrapolate to 80 m length
2. Perform 80 m mission in consecutive 2.5 m
segments
Add data segments to form data set for complete
80m mission
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Project Overview Test Readiness Schedule Budget
3/3/2014 ASEN 4028: TRR 29
30𝑜
50𝑜 70𝑜
2.5 m Level Platform
Rover takes
a photo and
transmit
Project Overview Test Readiness Schedule Budget
RECUV lab
Vicon optical positioning system
Infrared imaging
Precise position data
Indoor facility
Controlled environmental conditions
Safety Concerns
Battery electric shock to people and components
Improper set up of testing ramp
Particles ejected at high velocity from exhaust
Improper handling of the CR
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Project Overview Test Readiness Schedule Budget
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Project Overview Test Readiness Schedule Budget
3/3/2014 ASEN 4028: TRR 32
= Assembly
= Test = Software = Procurement
Legend
= Baseline
Project Overview Test Readiness Schedule Budget
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Project Overview Test Readiness Schedule Budget
3/3/2014 ASEN 4028: TRR 34
Project Overview Test Readiness Schedule Budget
CDR Proposed
Budget ($) TRR Expenses ($)
3202.11 4059.78
Primary extra expenses: Spare Chassis Spare Batteries Spare Machining Metal Power Conditioning Board
Remaining Budget: $840.22
Parts Expected Cost ($)
Current expenditure 4059.78
Misc. Nuts and Bolts 100.00
TOTAL 4,159.78
[1] STARR Project Team. “Spring Project Review: STARR: Sample Targeting and Retrieval Rover.” University of Colorado. April 2012.
[2] TREADS Project Team. “Spring Project Review: RADS: Rover Acquisition & Deployment System.” University of Colorado. 23 April 2013.
[3] DARE Project Team. “Project Definition Document: DARE: Descending/Ascending Rover for Exploration.” University of Colorado. September 2013.
[4] DARE Project Team. “Conceptual Design Document: DARE: Descending/Ascending Rover for Exploration.” University of Colorado. 30 September 2013.
[5] DARE Project Team. “PDR”. University of Colorado. 10/2/13.
[6] Murray, Michael et al. “STARR Critical Design Review.” 05 Dec. 2011. University of Colorado at Boulder AES. 12 Oct. 2013.
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37 3/3/2014 ASEN 4028: TRR
38 3/3/2014 ASEN 4028: TRR 4 References: 1,2
Developed:
• 3rd generation CR
• Sample
identification
based on color
• CR sample
collection and
retrieval
2008 - 2009 2009 - 2010 2010 - 2011 2011 - 2012
Developed:
• 1st generation
Mother Rover (MR)
• Optical navigation
system
Purchased:
• 2 COTS Child
Rover (CR)
Developed:
• 1st generation CR
• 2nd generation MR
• 2D ultrasonic
“cricket”
navigation system
• CR imaging
system
Developed:
• 3rd generation MR
• Deployable MR
ramp
• Enhanced relay
COM system
• 2nd generation CR
• CR rocker-bogie
suspension
2012 - 2013
Developed:
• 4rd generation MR
• Sample storage
• Multiple CR storage
• Retractable ramp
• Driving
• LEDs for
deployment and
retrieval of CRs
The legacy Mother Rover (MR) and Child Rover (CR) developed for JPL by CU.
3/3/2014 ASEN 4028: TRR 39
robomain
parse
Status or
Command
Motor,
Encoder,
or Fan
Fan,
Camera,
or Motor?
read_motor
read_encoder
read_fan
command_camera command_fan
command_motor
Status
Command
Fan Camera
Motor
Fan
Encoder
Motor
Project Overview Schedule Manufacturing Budget
3/3/2014 ASEN 4028: TRR 40
Project Overview Schedule Manufacturing Budget
User
gsmain
GS computer
Port
Communication
FireSTORM COM
Firestorm Library
RoboVero
RoboVero Library
robomain
Legend
Software
Hardware
Firmware
parse Status or
Command
Command
Status
command_motor
RoboVero
RoboVero Library
Motor1 Motor2
read_motor
RoboVero
RoboVero Library
Motor1
Motor2
Motorcontroller1
Faulhaber Library
Motorcontroller2
Faulhaber Library Motorcontroller1
Faulhaber Library
Motorcontroller2
Faulhaber Library
3/3/2014 ASEN 4028: TRR 41
R.1) The CR shall fit within the TREADS MR docking bay.
R.1.1) The CR shall have an area no greater than 0.457 m x 0.457 m
R.1.2) The CR mass shall not exceed 8 kg.
R.5) The CR shall communicate with the MR.
R.5.1) The CR shall transmit images to the MR.
R.5.2) The CR shall receive commands from the MR.
R.5.3) The CR shall transmit telemetry data to the MR.
R.5.5) The CR shall be capable of transferring 10kbps
R.16.1) The CR shall communicate with the MR while within the maximum range of 40 m
from the MR
R.6) The CR shall perform navigation.
R.6.3) The CR shall know the distance travelled before the ascent or descent.
R.13.1) The CR shall know its relative position to the MR to within ±1 m.
R.13.2) The CR shall know its elevation angle to within ±5o.
R.17.1) While within a 1m radius from the MR ramp, the CR shall know its relative
position to within 25 cm.
R.7) The CR shall capture color images.
R.7.1) The image shall have a resolution of at least 160x120 pixels.
R.10) After ascending or descending a slope the CR shall return to within 1 m of the MR.
R.12) The CR shall communicate with the GS.
R.12.1) The CR shall receive commands from the GS.
R.14) The CR shall travel a maximum of 20m from the MR prior to descent or ascent.
R.15) The CR shall descend or ascend a slope.
R.15.1) The CR shall descend a slope of 30o for 20 m.
R.15.2) The CR shall descend a slope of 50o for 20 m.
R.15.3) The CR shall descend a slope of 70o for 10 m.
R.15.4) The CR shall ascend a slope of 30o for 20 m.
R.15.5) The CR shall ascend a slope of 50o for 20 m.
R.15.6) The CR shall ascend a slope of 70o for 10 m.
Legend
Blue = Critical to Project
References: 3, 4, 5
*Refer to backup slides 59-61
for tiered requirements
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Minimum Level of Success R.1) The CR shall fit within the TREADS MR docking bay.
R.1.1) The CR shall have an area no greater than 0.457 m x 0.457 m
R.1.2) The CR mass shall not exceed 8 kg.
R.2) The CR shall travel a maximum of 5 m from the MR prior to descent or ascent.
R.3) The CR shall descend or ascend a slope.
R.3.1) The CR shall descend a slope of 30o for 5 m.
R.3.2) The CR shall descend a slope of 50o for 5 m.
R.3.3) The CR shall ascend a slope of 30o for 5 m.
R.3.4) The CR shall ascend a slope of 50o for 5 m.
R.4) After ascending or descending a slope the CR shall return to within 2 m of the MR.
R.5) The CR shall communicate with the MR.
R.5.1) The CR shall transmit images to the MR.
R.5.2) The CR shall receive commands from the MR.
R.5.3) The CR shall transmit telemetry data to the MR.
R.5.4) The CR shall communicate with the MR while within the maximum range of 10 m
from the MR
R.5.5) The CR shall be capable of transferring 10 kbps
R.6) The CR shall perform navigation.
R.6.1) The CR shall know its relative position to the MR to within ±2 m.
R.6.2) The CR shall know its elevation angle to within ±10o.
R.6.3) The CR shall know the distance travelled before the ascent or descent.
R.7) The CR shall capture color images.
R.7.1) The image shall have a resolution of at least 160x120 pixels.
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2nd Level of Success R.8) The CR shall travel a maximum of 10 m from the MR prior to descent or ascent.
R.9) The CR shall descend or ascend a slope.
R.9.1) The CR shall descend a slope of 30o for 10 m.
R.9.2) The CR shall descend a slope of 50o for 10 m.
R.9.3) The CR shall descend a slope of 70o for 5 m.
R.9.4) The CR shall ascend a slope of 30o for 10 m.
R.9.5) The CR shall ascend a slope of 50o for 10 m.
R.9.6) The CR shall ascend a slope of 70o for 5 m.
R.10) After ascending or descending a slope the CR shall return to within 1 m of the MR.
R.11) The CR shall communicate with the MR.
R.11.1) The CR shall communicate with the MR while within the maximum range of 20 m
from the MR
R.12) The CR shall communicate with the GS.
R.12.1) The CR shall receive commands from the GS.
R.13) The CR shall perform navigation.
R.13.1) The CR shall know its relative position to the MR to within ±1 m.
R.13.2) The CR shall know its elevation angle to within ±5o.
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Optimal Level of Success R.14) The CR shall travel a maximum of 20 m from the MR prior to descent or ascent.
R.15) The CR shall descend or ascend a slope.
R.15.1) The CR shall descend a slope of 30o for 20 m.
R.15.2) The CR shall descend a slope of 50o for 20 m.
R.15.3) The CR shall descend a slope of 70o for 10 m.
R.15.4) The CR shall ascend a slope of 30o for 20 m.
R.15.5) The CR shall ascend a slope of 50o for 20 m.
R.15.6) The CR shall ascend a slope of 70o for 10 m.
R.16) The CR shall communicate with the MR.
R.16.1) The CR shall communicate with the MR while within the maximum range of 40 m
from the MR
R.17) The CR shall perform navigation.
R.17.1) While within a 1 m radius from the MR ramp, the CR shall know its relative
position to within 25 cm.
Initial specification verification
Replicated previous experiment to get new
measurements for purchased vacuum assembly
3/3/2014 ASEN 4028: TRR 45
Test Needed Measured
Volume Flow 63 cfm 58.7 cfm
Pressure Differential 955 Pa 1350-1450 Pa
Volume Flow Test Pressure Differential Test
3/3/2014 ASEN 4028: TRR 46
DARE Rover
Drivetrain
Front Drive
Motor System
Motor
Gearbox
Encoder
Controller
L-bracket Al 6061
Front Wheel Assy
Front Wheel Al 6061
Tread
Cog Lock
Cog Tube Al 6061
Cog
Front Shaft 316L St.
Chain
Rear Drive
L-bracket Al 6061
Rear Shaft 316L St.
Rear Wheel Assy
Rear Wheel Al 6061
Bearings x2
Cog Tube Al 6061
Cog
Cog Lock
Tread
Fan Assembly
Fan
Chassis
Fan Mounts Al 6061
Foam Core
Edge Trim
Skirt
Rubber
Bristles
Silicone Caulking
Skirt Mount Plexi-glass
Silicone Caulking
Electronics
FireSTORM
Caspa FS
RoboVero
EPS
Fan Battery Circuit
Fan Battery
Power Circuit
Electronics Battery Assembly
Electronics Battery
Power Conditioning Circuit
Board Mounts
Standoff Plate Delrin
Standoffs
Baseplate Plexiglass Motor Controllers
Software
Software Development Environment
Install drivers
Install Client Libraries
Install git
Communication with Electronics
RoboVero
Caspa FS
Motorcontrollers
FireSTORM
GS to CR
GS to MR to CR
Data Receiving and Handling
Mission Class
Status Class
History Class
Guidance User Interface main.cpp
CDR Components CDR
Cost ($)
Electronics Boards:
RoboVero, Overo,
Caspa 387.25
Testing Materials:
Wood, Poly, Nails,
Screws 241.74
Vacuum Motor 140.00
Vacuum Battery 71.93
Chassis 186.77
Motor, Motor
Controller, Gearbox 1868.40
Wheel Tread 36.80
Metal for Machining 104.92
Suction Components 23.32
Other Mechanical
Components 140.98
TOTAL 3202.11
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TRR Components TRR
Cost ($)
Printing 19.08
Electronics Boards 408.13
Vac Motor 140.00
Chassis 186.77
Wheel Tread 36.80
Metal for Machining 102.76
Suction Components 28.87
Motor, Motor Controller, Gearbox 1864.45
Power Supplies 423.27
Testing Materials 131.81
Spare Metal 190.07
Spare Chassis 187.22
Spare Power Supplies 184.50
Other Mechanical Components 156.05
TOTAL 4059.78
Project Overview Test Readiness Schedule Budget