micro-hydraulic toolkit report

Defence Research and Recherche et développement Development Canada pour la défense Canada

Micro-Hydraulic Toolkit Report

Defence R&D Canada

Contract Report

DRDC Suffield CR 2008-212

December 2006

Guillaume Lambert, Collineo inc. Contract Scientific Authority: B. Beckman, DRDC Suffield

The scientific or technical validity of this Contract Report is entirely the responsibility of the contractor and the contents do not necessarily have the approval or endorsement of Defence R&D Canada.


Guillaume Lambert Collineo inc. 1375 rue Gay-Lussac, bureau A Boucherville QC J4B 7K1 Contract Number: W7702-03R975 Contract Scientific Authority: B. Beckman (403-544-5502) The scientific or technical validity of this Contract Report is entirely the responsibility of the contractor and the contents do not necessarily have the approval or endorsement of Defence R&D Canada.

DRDC Suffield CR 2008-212 December 2006

Defence R&D Canada – Suffield Contract Report

MICRO-HYDRAULIC TOOLKIT

USER MANUAL

V1.0

December 2006

Table of contents

1 - INTRODUCTION.................................................................................................................. 5

2 - TOOLKIT ARCHITECTURE AND SUBSYSTEMS DESCRIPTION.................................... 62.1 - Generic functional breakdown of any machine...........................................................................62.2 - Functional breakdown of the toolkit............................................................................................ 7

2.2.1 - Main functional breakdown tree.......................................................................................... 72.2.2 - Subsidiary functional breakdown trees............................................................................... 8

2.3 - Toolkit's physical subsystems...................................................................................................112.3.1 - Wheel drive module.......................................................................................................... 122.3.2 - Direction articulation module.............................................................................................142.3.3 - Intramotion articulation module......................................................................................... 182.3.4 - Traction variation module..................................................................................................202.3.5 - Intramotion variation module.............................................................................................232.3.6 - Propulsion hydraulic power supply module.......................................................................262.3.7 - Intramotion hydraulic power supply module......................................................................292.3.8 - Electric power accumulation module.................................................................................322.3.9 - Electronic power supply module....................................................................................... 332.3.10 - Electric power supply regulation module........................................................................ 362.3.11 - Electronic and processing module (prototype)................................................................39

3 - ASSEMBLY AND POSSIBLE KIT CONFIGURATIONS................................................... 453.1 - Individual connections...............................................................................................................45

3.1.1 - Mechanical connection standard.......................................................................................453.1.2 - Hydraulic connection standard..........................................................................................47

3.2 - Assembly techniques and hints................................................................................................ 483.3 - Assembly examples.................................................................................................................. 49

3.3.1 - Leg type 1 assembly (straight locomotion – no direction module)....................................493.3.2 - Leg type 2 assembly (with direction module)....................................................................533.3.3 - Complete toolkit assembly................................................................................................ 573.3.4 - Top surface component layout (Suggested)....................................................................60

3.4 - Known toolkit assemblies......................................................................................................... 613.4.1 - Assembly # 1 – 4 rigid wheels vehicle.............................................................................. 613.4.2 - Assembly # 2 – 4 wheels, 2 direction, 4 2-DOF legs articulated vehicle.......................... 623.4.3 - Other possible configurations........................................................................................... 63

3.5 - Operation capability examples..................................................................................................64

1458 RUE MICHAUD, DRUMMONDVILLE, QC, CANADA, J2C [email protected] 819-479-0624

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High mobility roboticsPrototypes and mechatronic systems manufacturing

Industrial and technical services

4 - SUBSYSTEM CONFIGURATION AND OPERATION INTERFACE................................. 654.1 - Communication......................................................................................................................... 654.2 - CAN and CANopen general information...................................................................................664.3 - Subsystem configuration.......................................................................................................... 68

4.3.1 - Hydraulic valve.................................................................................................................. 684.3.2 - Electric motor controller.................................................................................................... 714.3.3 - PID compensation.............................................................................................................734.3.4 - Processing node............................................................................................................... 744.3.5 - Using CANopen Magic Pro to configure subsystems....................................................... 74

4.4 - Operation interface................................................................................................................... 754.4.1 - Operation mode................................................................................................................ 754.4.2 - Process data..................................................................................................................... 764.4.3 - Using CANopen Magic Pro to operate the Toolkit............................................................ 76

5 - SUBSYSTEMS REGULATION.......................................................................................... 785.1 - Wheel drive module.................................................................................................................. 795.2 - Direction articulation module.................................................................................................... 805.3 - Intramotion articulation module.................................................................................................815.4 - Propulsion hydraulic power supply module.............................................................................. 825.5 - Intramotion hydraulic power supply module............................................................................. 83

6 - SAFETY CONSIDERATIONS............................................................................................ 846.1 - Handling....................................................................................................................................846.2 - Heavy objects fall......................................................................................................................846.3 - Subsystems in operation.......................................................................................................... 85

6.3.1 - Electrical shock................................................................................................................. 856.3.2 - Hydraulic pressure leakage cuts.......................................................................................856.3.3 - Burns due to motor heat................................................................................................... 85

6.4 - Vehicle in motion.......................................................................................................................866.4.1 - Body part cut..................................................................................................................... 866.4.2 - Security area..................................................................................................................... 876.4.3 - External power supply limitations (portable recharge system)......................................... 876.4.4 - Toolkit's legs stepping on operator's foot..........................................................................87

7 - BASIC REPAIR AND MAINTENANCE.............................................................................. 887.1 - Periodical maintenance............................................................................................................ 88

7.1.1 - Mechanical systems.......................................................................................................... 887.1.2 - Hydraulic system............................................................................................................... 887.1.3 - Electrical systems............................................................................................................. 88

7.2 - Maintenance log........................................................................................................................897.3 - Troubleshooting........................................................................................................................ 89


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8 - OPERATION IN OUTDOOR ENVIRONMENT................................................................... 908.1 - Preparation before external use............................................................................................... 90

8.1.1 - Levels and status (Priority 1) – Every mission departure..................................................908.1.2 - Physical damage (Priority 2) – Every 5 missions..............................................................908.1.3 - Assembly integrity (Priority 3) – Every 6 months.............................................................. 91

8.2 - Toolkit environmental conditions.............................................................................................. 928.3 - Environment protection............................................................................................................. 93

8.3.1 - Procedures........................................................................................................................ 938.3.2 - Oil selection.......................................................................................................................938.3.3 - Battery fluids..................................................................................................................... 93

9 - ANNEXES.......................................................................................................................... 94


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1 - INTRODUCTION

The Micro-Hydraulic Toolkit is an integrated set of modular components to create articulated vehicles for mobile robotics and teleoperation applications. Its components involve mechanical, electrical, electronic and hydraulic technologies and can be assembled in various ways to build different vehicle configurations depending on the final application.This manual is intended to the final user and covers all the topics necessary to understand, assemble, operate and maintain the toolkit.


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2 - TOOLKIT ARCHITECTURE AND SUBSYSTEMS DESCRIPTION

2.1 - Generic functional breakdown of any machine

Functional decomposition is a concept that Collineo has developed over time in an attempt to standardise and universalise the language used in machine design and their applications.

Functional decomposition allows to precisely define beforehand the role (or the function) of each and every part of a machine, starting right at the conceptual design phase, within a structured and systematic development process. This results in a more uniform final design, higher system integrability and coherent and uniform systems designation throughout all systems that we developed, thus enabling for interoperability over time.The basic of the functional decomposition concept resides in the observation that every machine have the same basic functionalities that can be recognized universally, no matter the technology used, the knowledge deployed in its design, its brand or the specificities of its design.From this time on every machine designed will only be a complete or partial combination of these 9 high level functions.

GENERIC MACHINE FUNCTIONS

1- LOCOMOTION2- INTRAMOTION1

3- POWER SUPPLY4- PROTECTION5- MANIPULATION6- TRANSFORMATION (External environment transformation)7- DECISION (Mission planning, Action)8- PERCEPTION9- COMMUNICATION

1 INTRAMOTION is a term that we have invented to express the specific function of a system of being able of internal motion. As opposed to LOCOMOTION, which describes the faculty of moving a system in its whole resulting in a absolute motion with respect to a fixed reference, INTRAMOTION reflects the relative motion of parts of a system with respect to other parts of the same system. Articulated systems are typical systems where INTRAMOTION is present. Literally, INTRAMOTION signifies “Internal movement of itself”.


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2.2 - Functional breakdown of the toolkit

The micro-hydraulic toolkit is constituted of only 3 of the 10 generic machine functions. Each of these high-level functions represents complex systems with advanced behaviour which can be broken down into numerous lower-level functions with simpler behaviour. In order to result in a high-level function, the arrangement of these lower-level functions have to follow a specific and structured architecture forming a functional breakdown tree.

2.2.1 - Main functional breakdown tree

The main functional breakdown tree of the toolkit is as follows :

LOCOMOTION : Directional wheeled platform| PROPULSION

| TRACTION (x4) : Hydraulic wheel drive| POWER SUPPLY : Hydraulic power supply

| DIRECTION| POWER SUPPLY : Electric power supply

INTRAMOTION : Limbs| ATICULATION (x8) : Hydraulic rotative articulation| TRANSMISSION #1 (x8) : Long structural beam| TRANSMISSION #2 (x8) : Short structural beam| POWER SUPPLY #1 : Electric power supply| POWER SUPPLY #2 : Hydraulic power supply

POWER SUPPLY : Electric power supplyCOMMUNICATION : CANopen network


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2.2.2 - Subsidiary functional breakdown trees

Subsidiary functional breakdown trees of the toolkit are as follows :

LOCOMOTION / PROPULSION / TRACTION : Hydraulic wheel drive| ARTICULATION #1 : Wheel rotation

| FASTENING : Wheel aluminium hub| TRANSMISSION : Wheel aluminium rim| JOINT : Sealed ball bearing| ACTUATION

| MOTORISATION : Hydraulic gearmotor| REDUCTION : Harmonic drive| VARIATION #1 : Proportional directional hydraulic valve| VARIATION #2 : Valve electronic drive

| SENSATION : Inductive quadrature encoder| REGULATION : PID compensation| PROTECTION: Low friction lip seal

| ARTICULATION #2 : Wheel tire

LOCOMOTION / PROPULSION / POWER SUPPLY : Hydraulic power supply| GENERATION

| CONVERSION : Hydraulic gearpump| MOTORISATION : DC brushed permanent magnet motor| ACTIVATION : Power relay| ACCUMULATION : Vented Hydraulic tank

| FASTENING : Aluminium frame| SENSATION : Hydraulic pressure sensor| REGULATION : Pressure sensor threshold| FILTRATION : Return line filter (low pressure) | ACCUMULATION : Pressurized bellows accumulator (optional)| TRANSMISSION #1 : Hydraulic pump manifold| TRANSMISSION #2 : Hydraulic valve manifold


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INTRAMOTION / POWER SUPPLY #1 : Electric power supply| CONVERSION : Battery charger (24V)

| ACCUMULATION : Battery (24V)

| FASTENING : Aluminium frame

| SELECTION : Power relay to select power source

| PROTECTION : Fuse (100A)| ACTIVATION : Power switch

INTRAMOTION / POWER SUPPLY #2 : Hydraulic power supply| GENERATION

| CONVERSION : Hydraulic gearpump| MOTORISATION : DC brushed permanent magnet motor| ACTIVATION : Power relay

| FASTENING : Aluminium frame| SENSATION : Hydraulic pressure sensor| REGULATION : Pressure sensor threshold| FILTRATION : Return line filter (low pressure)| ACCUMULATION : Pressurized bellows accumulator (optional)| TRANSMISSION #1 : Hydraulic pump manifold| TRANSMISSION #2 : Hydraulic valve manifold

POWER SUPPLY : Electric power supply| CONVERSION #1 : AC-DC converter (24V)

| CONVERSION #2 : DC-DC converter (12V)

| CONVERSION #3 : DC-DC converter (5V)| FILTRATION : LC filter| PROTECTION : E-switch

Note : some minor functions have been intentionally omitted for further clarity


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2.3 - Toolkit's physical subsystems

The micro-hydraulic toolkit is composed of several subsystems. Each subsystem is a physical assembly of different functions that have been gathered together for modularity and interoperability purposes. Physical subsystems cannot always be integrally identified with specific high-level functions since they have to obey to physical and technological constraints. However, the construction of the toolkit subsystems mostly follows the toolkit functional breakdown and only a few functions have been relocated.


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2.3.1 - Wheel drive module

Multiplicity : 4

Main functional components :

Functional path TechnologyLOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / FASTENING

Wheel aluminium hub

LOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / TRANSMISSION

Wheel aluminium rim

LOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / JOINT Ball bearingLOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / ACTUATION / MOTORISATION

Hydraulic gearmotor

LOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / ACTUATION / REDUCTION

Harmonic drive (50:1)

LOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / SENSATION

Inductive quadrature encoder

LOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / PROTECTION

Low friction lip seal

LOCOMOTION / PROPULSION / TRACTION / ARTICULATION #2 Wheel tire

Physiology :

Operation :Rotation range : unlimited


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PORT 1-2-3-4

Speed range : 0.5 ~ 5 km/h (estimated, TBC )Torque range : 0 ~ 25 Nm max.(estimated, TBC )

Connectivity :

Port 1Description : Wheel hub connection Type : MechanicalTechnology : Bolted connection Number : 4Characteristics : Bolt : M6x50mm SHCS plated

Nut : M6 platedWasher : M6 plated AFNOR

Port 2Description : Hydraulic work ports Type : HydraulicTechnology : O-ring boss Number : 2Characteristics : Thread : 9/16 SAE

Port 3Description : Hydraulic drain ports Type : HydraulicTechnology : Flexible low pressure hose Number : 1Characteristics : Diameter ¼ in.

Port 4Description : Wheel sensors connection Type : ElectricTechnology : Plug/socket connection Number : 4Characteristics :

Pin Function Description1 DC supply (12V) Sensors power supply2 DC ground Sensors ground3 Digital output (NPN) First sensor measurement output4 Digital output (NPN) Second sensor measurement output


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2.3.2 - Direction articulation module

Multiplicity : 2


Functional path TechnologyLOCOMOTION / DIRECTION / ARTICULATION / FASTENING Aluminium housingLOCOMOTION / DIRECTION / ARTICULATION / TRANSMISSION #1 Hardened aluminium shaft with

internal oil conduitsLOCOMOTION / DIRECTION / ARTICULATION / TRANSMISSION #2 Aluminium radial beamLOCOMOTION / DIRECTION / ARTICULATION / TRANSMISSION #3 Aluminium axial beamLOCOMOTION / DIRECTION / ARTICULATION / JOINT Sealed ball bearingLOCOMOTION / DIRECTION / ARTICULATION / ACTUATION / MOTORISATION

Permanent magnet brushless DC motor

LOCOMOTION / DIRECTION / ARTICULATION / ACTUATION / REDUCTION #1

Planetary gear assembly (23:1)

LOCOMOTION / DIRECTION / ARTICULATION / ACTUATION / REDUCTION #2

Worm gear assembly (30:1)

LOCOMOTION / DIRECTION / ARTICULATION / ACTUATION / SENSATION

Hall effect sensors

LOCOMOTION / DIRECTION / ARTICULATION / SENSATION Wirewound potentiometer

Physiology :


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A- DOUBE INTEGRATED SWIVEL JOINT VERSION

B- INDIVIDUAL SWIVEL JOINT VERSION


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PORT 1-A

PORT 3

PORT 2-4

PORT 5-6-7

PORT 1-B

PORT 5-6-7

PORT 3

PORT 2-4

PORT 1-A

PORT 1-B (Side)

Operation :Rotation range : -90 ~ 90 degSpeed range : 0 ~ 7 rpm (estimated, TBC)Torque range : Individual swivel config. : 0 ~ 17 Nm (estimated, TBC) Double swivel config. : 0 ~ 10 Nm (estimated, TBC)

Connectivity :

Port 1Description : Articulation housing connection Type : MechanicalTechnology : Bolted connection Number : 8Characteristics : Bolt : M4x20mm Hex head

Washer : M4 plated AFNOR

Port 2Description : Articulation output connection (to wheel drive) Type : MechanicalTechnology : Bolted connection Number : 4Characteristics : Bolt : M6x25mm SHCS

Washer : M4 AFNOR plated

Port 3Description : Traction hydraulic work ports - valve side Type : HydraulicTechnology : JIC fittings Number : 2Characteristics : 9/16 threads, Thermoplastic flexible hose 5/16

Port 4Description : Traction hydraulic work ports - wheel side Type : HydraulicTechnology : O-ring face compression sealing Number : 2Characteristics : 5mm I.D. O ring, - Internal rigid tubing O.D. ¼ in.


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Port 5Description : Direction motor power connection Type : ElectricTechnology : Plug/socket connection Number : 3Characteristics :

Pin Function Description1 DC analog input Motor winding 12 DC analog input Motor winding 23 DC analog input Motor winding 3

Port 6Description : Direction motor sensors connection Type : ElectricTechnology : Plug/socket connection Number : 5Characteristics :

Pin Function Description1 DC supply (5V) Hall sensors power supply2 DC ground Hall sensors ground3 Digital output (NPN) Hall sensors output 14 Digital output (NPN) Hall sensors output 25 Digital output (NPN) Hall sensors output 3

Port 7Description : Direction sensor connection Type : ElectricTechnology : Plug/socket connection Number : 3Characteristics :

Pin Function Description1 DC supply (12V) Potentiometer power supply2 DC ground Potentiometer ground3 DC analog output Potentiometer measurement output


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2.3.3 - Intramotion articulation module

Multiplicity : 8


Functional path TechnologyINTRAMOTION / ARTICULATION / FASTENING Aluminium frameINTRAMOTION / ARTICULATION / TRANSMISSION Aluminium circular flangeINTRAMOTION / ARTICULATION / JOINT Ball bearingINTRAMOTION / ARTICULATION / ACTUATION / MOTORISATION Double vane hydraulic rotary

actuatorINTRAMOTION / ARTICULATION / SENSATION Wirewound potentiometer

Physiology :

Operation :Rotation range : 0 ~ 100 degSpeed range : 0 ~ 100 °/s (estimated, TBC)Torque range : 0 ~ 500 Nm (estimated, TBC)


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PORT 4PORT 2

PORT 1 PORT 3

Connectivity :

Port 1Description : Articulation frame connection Type : MechanicalTechnology : Bolted connection + shear sleeve 7x10mm Number : 8Characteristics : Bolt : M6x25mm Hex head


Port 2Description : Articulation flange connection Type : MechanicalTechnology : Bolted connection + shear sleeve 7x10mm Number : 8Characteristics : Bolt : M6x25mm Hex head


Port 3Description : Hydraulic rotary actuator ports Type : HydraulicTechnology : JIC fittings Number : 2Characteristics : 9/16 threads, Thermoplastic flexible hose 5/16

Port 4Description : Articulation sensor connection Type : ElectricTechnology : Plug/socket connection Number : 3Characteristics :



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2.3.4 - Traction variation module

Multiplicity : 4


Functional path TechnologyLOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / ACTUATION / VARIATION #1

Proportional directional hydraulic valve

LOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / ACTUATION / VARIATION #2

Valve electronic drive

LOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / ACTUATION / TRANSMISSION

Hydraulic manifold

Physiology :


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SHOWN IN GROUP OF 2 FOR ASSEMBLY PURPOSES

PORT 1

PORT 3

PORT 2

PORT 4

PORT 5

Operation :Voltage range : 21 ~ 30 VCurrent range : 0 ~ 540 mAPressure range : 0 ~315 bar (port P, A and B), 0 ~160 bar (port T)

Connectivity :

Port 1Description : Manifold bottom connection Type : MechanicalTechnology : Bolted connection Number : 4Characteristics : Bolt : M6x25mm Hex head


Port 2Description : Hydraulic supply port Type : HydraulicTechnology : JIC fittings Number : 2Characteristics : 9/16 threads, Thermoplastic flexible hose 5/16

Port 3Description : Hydraulic return port Type : HydraulicTechnology : JIC fittings Number : 3Characteristics : 9/16 threads, Low pressure (300 PSI) rubber flexible hose 3/8

Port 4Description : Hydraulic work ports Type : HydraulicTechnology : JIC fittings Number : 2Characteristics : 9/16 threads, Thermoplastic flexible hose 5/16

Port 5Description : Valve electric connection Type : Electric


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Port 5Technology : Plug/socket connection Number : 4Characteristics :

Pin Function Description1 DC supply (24V) Valve power supply2 DC ground Valve power ground3 DC analog input Valve command signal4 DC analog common Valve command reference


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2.3.5 - Intramotion variation module

Multiplicity : 8


Functional path TechnologyINTRAMOTION / ARTICULATION / ACTUATION / VARIATION #1 Proportional directional hydraulic

valveINTRAMOTION / ARTICULATION / ACTUATION / VARIATION #2 Valve electronic driveINTRAMOTION / ARTICULATION / ACTUATION / TRANSMISSION Hydraulic manifold

Physiology :


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SHOWN IN GROUP OF 2 FOR ASSEMBLY PURPOSES

PORT 1

PORT 3

PORT 2

PORT 4

PORT 5

Operation :Voltage range : 21 ~ 30 VCurrent range : 0 ~ 540 mAPressure range : 0 ~315 bar (port P, A and B), 0 ~160 bar (port T)

Connectivity :

Port 1Description : Manifold bottom connection Type : MechanicalTechnology : Bolted connection Number : 4Characteristics : Bolt : M6x25mm Hex head




Port 4Description : Hydraulic work ports Type : HydraulicTechnology : JIC fittings Number : 2Characteristics : 9/16 threads, Thermoplastic flexible hose 5/16

Port 5Description : Valve electric connection Type : ElectricTechnology : Plug/socket connection Number : 4


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Port 5Characteristics :



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2.3.6 - Propulsion hydraulic power supply module

Multiplicity : 1


Functional path TechnologyLOCOMOTION / PROPULSION / POWER SUPPLY / GENERATION Hydraulic generation unitLOCOMOTION / PROPULSION / POWER SUPPLY / FASTENING Aluminium frameLOCOMOTION / PROPULSION / POWER SUPPLY / SENSATION Propulsion hydraulic pressure

sensorLOCOMOTION / PROPULSION / POWER SUPPLY / FILTRATION Low pressure return line filterLOCOMOTION / PROPULSION / POWER SUPPLY / ACCUMULATION Pressurized bellows accumulator

(optional)LOCOMOTION / PROPULSION / POWER SUPPLY / TRANSMISSION #1 Hydraulic pump manifold

Physiology :

Operation :


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PORT 2PORT 1

PORT 6

Digital pressure sensor/indicator

NOTE - PORT 4 - DRAIN LINE PASSED THROUGH TANK VENT

Low pressure filter

PORT 3

PORT 4

PORT 5

Voltage range : 0 ~24 VCurrent range : refer to product specificationsFlow range : 0 ~8.6 L/minPressure range : refer to product specifications

Connectivity :

Port 1Description : Frame connection Type : MechanicalTechnology : Bolted connection + shear sleeve 7x10mm Number : 4Characteristics : Bolt : M6x25mm Hex head




Port 4Description : Hydraulic drain port Type : HydraulicTechnology : Hole Number : 1Characteristics : Tank vent

Port 5Description : Pump motor connection Type : ElectricTechnology : Bolted connection Number : 2


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Pin Function Description1 DC analog input Motor positive terminal2 DC ground Motor negative terminal

Port 6Description : Pressure sensor connection Type : ElectricTechnology : Plug/socket connection Number : 4Characteristics :

Pin Function Description1 DC supply (24V) Sensor power supply2 DC analog output Sensor measurement output3 DC ground Sensor ground4 Digital output (PNP) Sensor switch output


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2.3.7 - Intramotion hydraulic power supply module

Multiplicity : 1


Functional path TechnologyINTRAMOTION / POWER SUPPLY / GENERATION Hydraulic generation unitINTRAMOTION / POWER SUPPLY / FASTENING Aluminium frameINTRAMOTION / POWER SUPPLY / SENSATION Propulsion hydraulic pressure

sensorINTRAMOTION / POWER SUPPLY / FILTRATION Low pressure return line filterINTRAMOTION / POWER SUPPLY / ACCUMULATION Pressurized bellows accumulator

(optional)INTRAMOTION / POWER SUPPLY / TRANSMISSION #1 Hydraulic pump manifold

Physiology :


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PORT 3

PORT 2

NO DRAIN LINE NEEDED FOR THIS POWER SUPPLY UNIT

Low pressure filter

PORT 1

PORT 6

PORT 5

Accumulator

Operation :Voltage range : 0 ~24 VCurrent range : refer to product specificationsFlow range : 0 ~4.35 L/minPressure range : refer to product specifications

Connectivity :

Port 1Description : Frame connection Type : MechanicalTechnology : Bolted connection + shear sleeve 7x10mm Number : 4Characteristics : Bolt : M6x25mm Hex head




Port 5Description : Pump motor connection Type : ElectricTechnology : Bolted connection Number : 2Characteristics :

Pin Function Description1 DC analog input Motor positive terminal2 DC ground Motor negative terminal


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Port 6Description : Pressure sensor connection Type : ElectricTechnology : Plug/socket connection Number : 4Characteristics :

Pin Function Description1 DC supply (24V) Sensor power supply2 DC analog output Sensor measurement output3 DC ground Sensor ground4 Digital output (PNP) Sensor switch output


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2.3.8 - Electric power accumulation module

Multiplicity : 2


Functional path TechnologyLOCOMOTION / POWER SUPPLY / ACCUMULATION

INTRAMOTION / POWER SUPPLY #1 / ACCUMULATIONAcid-gel batteries

LOCOMOTION / POWER SUPPLY / FASTENING

INTRAMOTION / POWER SUPPLY #1 / FASTENINGAluminium frame

Physiology :


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Valence U1 Batteries

ALTERNATE MOUNTING OF BATTERIES – REMOVE HYDRAULICS AND USE FRAME AS BATTERY HOLDER

Standard Acid-Gel batteries Hydraulic power unit Frame

USE NYLON STRAPS IN SLOTS TO HOLD BATTERIES

2.3.9 - Electronic power supply module

Multiplicity : 1


Functional path TechnologyPOWER SUPPLY / GENERATION #1 DC-DC converterPOWER SUPPLY / GENERATION #2 DC-DC converterPOWER SUPPLY / FILTRATION LC filterPOWER SUPPLY / PROTECTION Plastic enclosure

Physiology :

Operation :Voltage input range : 21 ~ 30 VCurrent input range : 0 ~ 20 A


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Electronic power supply module

SHOWN ASSEMBLED ON TOOLKIT UPPER PLATFORM

PORT 1

PORT 2-3-4

Connectivity :

Port 1Description : Batteries connection Type : ElectricTechnology : Plug/socket connection (Molex Mini-Fit Sr.) Number : 4Characteristics :

Pin Function Description1 DC analog input Locomotion electronic power supply2 DC ground Locomotion electronic power ground3 DC analog input Intramotion electronic power supply4 DC ground Intramotion electronic power ground

Port 2Description : Electronic filtered 24V power supply Type : ElectricTechnology : Plug/socket connection (Molex Mini-Fit Jr.) Number : 12Characteristics :

Pin Function Description1 not used2 DC ground Ground3 DC ground Ground4 DC ground Ground5 DC ground Ground6 DC ground Ground7 not used8 DC analog output 24V filtered power supply (1A max)9 DC analog output 24V filtered power supply (1A max)

10 DC analog output 24V filtered power supply (5A max)11 DC analog output 24V filtered power supply (5A max)12 DC analog output 24V filtered power supply (5A max)


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Port 3Description : Electronic 12V power supply Type : ElectricTechnology : Plug/socket connection (Molex Mini-Fit Jr.) Number : 10Characteristics :

Pin Function Description1 DC ground Ground2 DC ground Ground3 DC ground Ground4 DC ground Ground5 DC ground Ground6 DC analog output 12V power supply (1A max)7 DC analog output 12V power supply (1A max)8 DC analog output 12V power supply (1A max)9 DC analog output 12V power supply (1A max)

10 DC analog output 12V power supply (1A max)





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2.3.10 - Electric power supply regulation module

Multiplicity : 2


Functional path TechnologyLOCOMOTION / POWER SUPPLY / SELECTION

INTRAMOTION / POWER SUPPLY #1 / SELECTIONPower relay

LOCOMOTION / PROPULSION / POWER SUPPLY / GENERATION / ACTIVATION

INTRAMOTION / POWER SUPPLY #2 / GENERATION / ACTIVATION

Power relay

LOCOMOTION / POWER SUPPLY / FASTENING

INTRAMOTION / POWER SUPPLY / FASTENINGAluminium frame

LOCOMOTION / POWER SUPPLY / PROTECTION

INTRAMOTION / POWER SUPPLY / PROTECTIONPlastic enclosure

Physiology :


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Operation :Voltage range : 21 ~ 30 VCurrent range : 0 ~ 100 A

Connectivity :

Port 1Description : Battery and hydraulic pump connection Type : ElectricTechnology : Screw terminal (AWG 4) Number : 4Characteristics :

Pin Function Description1 DC analog Battery positive terminal2 DC ground Battery negative terminal3 DC analog output Pump motor positive terminal4 DC ground Pump motor negative terminal

Port 2Description : Charger and converter connection Type : ElectricTechnology : Screw terminal (AWG 10) Number : 6Characteristics :

Pin Function Description1 DC analog input AC/DC converter positive terminal2 DC ground AC/DC converter negative terminal3 DC analog input Battery charger positive terminal4 DC ground Battery charger negative terminal5 DC analog output Electronic power supply6 DC ground Electronic power ground


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Port 3Description : E-stop connection Type : ElectricTechnology : Wire connection Number : 2Characteristics :

Port 4Description : Pressure sensor digital output connection Type : ElectricTechnology : Plug/socket connection Number : 1Characteristics :


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2.3.11 - Electronic and processing module (prototype)

Multiplicity : 1


Functional path TechnologyPROCESSING WildFire single board computerCONDITIONNING Electronic interface boardTRANSMISSION Electronic connexion boardPROTECTION Aluminium enclosureLOCOMOTION / PROPULSION / TRACTION / ARTICULATION #1 / REGULATION (x1)

PID compensation

LOCOMOTION / DIRECTION / ARTICULATION / ACTUATION / VARIATION (x1)

Advanced unipolar PWM drive for brushless motor

LOCOMOTION / DIRECTION / ARTICULATION / REGULATION (x1) PID compensationINTRAMOTION / ARTICULATION / REGULATION (x2) PID compensation

Physiology :


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Operation :Voltage input range : 12 and 24 VCommunication : CANopen network

Connectivity :


Pin Function Description1 not used2 DC ground Ground3 DC ground Ground4 DC ground Ground5 DC ground Ground6 DC ground Ground7 not used8 DC analog output 24V filtered power supply (1A max)9 DC analog output 24V filtered power supply (1A max)

10 DC analog output 24V filtered power supply (5A max)11 DC analog output 24V filtered power supply (5A max)12 DC analog output 24V filtered power supply (5A max)

Port 2Description : Electronic 12V power supply Type : ElectricTechnology : Plug/socket connection (Molex Mini-Fit Jr.) Number : 10


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Port 3Description : E-stop connection Type : ElectricTechnology : Wire connection Number : 2Characteristics :

Port 4, 6Description : Connection to Locomotion and Intramotion

electric power supply regulation modulesType : Electric

Technology : Plug/socket connection Number : 4Characteristics :

Pin Function Description1 Digital input E-stop signal2 Digital input (NPN) Logic enable signal3 Digital input (PNP) Pressure sensor digital output4 DC ground Electronic ground


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Port 5, 7Description : Connection to Propulsion and Intramotion

hydraulic pressure sensorsType : Electric

Technology : Plug/socket connection Number : 4Characteristics :

Pin Function Description1 DC supply (24V) Sensor power supply2 DC ground Sensor ground3 DC analog output Sensor measurement output4 Digital output (PNP) Sensor switch output

Port 8, 10, 12Description : Hydraulic valve electric connection Type : ElectricTechnology : Plug/socket connection Number : 4Characteristics :


Port 9, 11Description : Articulation sensor connection Type : ElectricTechnology : Plug/socket connection Number : 3Characteristics :



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Port 13Description : Wheel sensors connection Type : ElectricTechnology : Plug/socket connection Number : 4Characteristics :

Pin Function Description1 DC supply (12V) Sensors power supply2 DC ground Sensors ground3 Digital output (NPN) First sensor measurement output4 Digital output (NPN) Second sensor measurement output

Port 14Description : Direction motor power connection Type : ElectricTechnology : Plug/socket connection Number : 3Characteristics :

Pin Function Description1 DC analog input Motor winding 12 DC analog input Motor winding 23 DC analog input Motor winding 3

Port 15Description : Direction sensors connection Type : ElectricTechnology : Plug/socket connection Number : 8


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Pin Function Description1 DC supply (5V) Hall sensors power supply2 DC ground Hall sensors ground3 Digital output (NPN) Hall sensors output 14 Digital output (NPN) Hall sensors output 25 Digital output (NPN) Hall sensors output 36 DC supply (12V) Potentiometer power supply7 DC ground Potentiometer ground8 DC analog output Potentiometer measurement output

Port 16Description : CAN communication connection Type : ElectricTechnology : Plug/socket connection (DB9) Number : 3Characteristics :

Pin Function Description7 DC digital CAN High2 DC digital CAN Low

3, 6 DC ground CAN ground


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3 - ASSEMBLY AND POSSIBLE KIT CONFIGURATIONS

3.1 - Individual connections

3.1.1 - Mechanical connection standard

To ensure minimal weight of the toolkit, we have chosen to use smaller bolts and support the loads with smaller, lighter shear bushings. This also enabled to standardize most of the toolkit's nuts and bolts throughout the toolkit, even where higher loads were to be carried.


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Standard 6mm and 10 mm shear bushing

bolting system

M6 Hexagonal bolts- Variable Length -

10mm O.D. X 6mm I.D. Bushing system

- Variable Length -M6 Washer – Small

diameter « AFNOR » Type

M6 Nut


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B - Connection modules Circular bolting pattern

A - Connection modules LARGE rectangular bolting pattern

Standard MECHANICAL bolting patterns

3 types only (A-B-C)

C - Connection modules SMALL rectangular bolting

pattern

3.1.2 - Hydraulic connection standard

All replaceable hydraulic ports have been standardized to 9/16 SAE thread for screwing into aluminium, Including pressure and return lines, and 9/16 JIC ends for the hose connection side. The JIC Standard can be assembled and disassembled many times easily without any leakage problems.Return lines use 9/16 SAE thread at the fittings and 3/8 in I.D. Flexible low pressure hoses and adequate porting.Pressure lines use 9/16 SAE thread at the fittings and 5/16 in I.D. Flexible high pressure thermoplastic hoses and shows adequate adequate porting where required.A colour code was also respected in that all hoses have a specific type and colour to simplify the user's work.

– Pressure lines – Black

– Return lines – Blue

– Drain lines – Transparent


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HYDRAULIC PRESSURE LINE (black)

HYDRAULIC RETURN LINE (blue)

3.2 - Assembly techniques and hints

– Insert ALL bolts first, without tightening them. Tighten in a star pattern only last

– Don't struggle. When you have to put extra force to unscrew or move something, check first if it's not blocked in any way.

– ALWAYS use the proper tools. Otherwise you end up stripping or damaging your equipment.

– Prepare your tools and material before starting assembly. Bins (plastic or cardboard) and bags to keep small parts organized is a must

– Tight cables and hoses with the proper keys

– In some cases, doing a preliminary assembly helps understand the structure and the functioning of the device. Once this is done, we can proceed with the final assembly of the device

– Always make sure the assembly surface on the worktable is cleaned from dirt and dust. This is important for all assembly but is MANDATORY for hydraulics

– Clean assembly surfaces, hands and surroundings of mounting surfaces of components to prevent contamination inside mechanical sub-assemblies or hydraulic devices

– Use lint-free rags for cleaning

REMINDER OF THE MOST IMPORTANT RULES

- DONT STRUGGLE with the parts- WORK IN A CLEAN ENVIRONMENT all the time


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3.3 - Assembly examples

3.3.1 - Leg type 1 assembly (straight locomotion – no direction module)

1. Prepare for assembly a wheel drive unit, a long ”Extension section” and a connecting flange “Wheel drive conversion”

2. Screw in the 2 JIC fittings. Put the two 5mm O rings in place between the flanges. Screw in the flange to the wheel drive body using 4 x M6 x 35mm SHCS bolts

3. Install the hoses for the leg on the fittings – Tighten properly4. Use M6 Hex bolts inserted from the top to bolt the long extension sections to the

connecting flange, using nuts on the outside to tighten it5. Install the Shoulder connection facing outward (the back flat surface aligned with

the hollowed side of the tubing)


49



32 41

5

Direction of inserting the

M6 bolts


M6 bolts

6. Bolt an articulation module with 4 bolts only (for now) to the shoulder connection module

7. Pre-assemble the upper leg section module as shown, using 2 shoulder connection modules and a short extension module

8. Assemble the upper leg section to the other flange of the already installed articulation module on the lower leg section. The actuator must point outwards. Assemble a second articulation module facing inwards on the other articulation module's flange.

9. Assemble hydraulic hoses on the knee actuator. Pass the hoses to the upper part of the leg


50



76 98

10. Pre-assemble a double-circuit manifold assembly with a shoulder internal modular mounting plate. Install the modular mounting plate into the shoulder recess. Leave the modular plate unscrewed

11. Connect hoses to the manifold unit12. When the hoses are connected and tightened, only then, bolt the base connecting

plate to the bottom of the shoulder recess


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12

10 11

1. Bolt the two manifolds together and make sure the two o rings are in place and well placed before tightening the manifolds together

2. Bolt the assembled manifold unit to the modular shoulder manifold connecting plate

3. Assemble the NG3 valves on the manifolds. Verify if the o rings of the bottom surface of the valve are well in place


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1

3Wandfluh Valve NG3

Separate circuits by plugging the two blocks side by side

2

Shoulder modular connection plate

3.3.2 - Leg type 2 assembly (with direction module)

DIRECTION MODULE ASSEMBLY

1. Assemble the direction module with the leg connection bracket. Also prepare the manifold connector plate with the Swagelock fittings and Cable grips.

2. Connect rigid hydraulic tubing to the fittings of the manifold connector plate. It might be useful at that moment to unscrew the top part of the rigid tubing to tighten the lower part first.

3. Align parts and insert M6 SHCS bolts as indicated. Tight top part of the rigid hydraulic tubing when everything is assembled in place


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21 3


M6 bolts

Fittings and connectors

first

leg connection

bracket

1. Install hydraulic hoses on the leg as per the same instructions of leg Type 1. 2. Install hoses and electronic wiring on the direction module last. Leave the hoses

and wires dangling for later connection with valves and drives located on the top surface of the toolkit


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21

FINISHED ASSEMBLY OF THE TYPE 2 LEG (WITH DIRECTION MODULES)

1. Regroup 4 LONG leg extensions and 4 tube adaptation plates. Assemble 2 subgroups as shown. Leave the top corner and bottom bolt hole empty. These will be bolted WITH the main body frames later. Do not tight the bolts fully at this point

2. Fix the 2 central body sub-assemblies to the main body frames. Use long M6 bolts to connect the assemblies at the TOP and BOTTOM corners. The bolt must pass through the Main body AND the adaptation plate AND the Extension flange. Do not tight the bolts fully at this point

3. Install the battery plate4. Install the second main body frames and tighten all bolts properly


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1 2

3 4

Top corner bolt hole

Bottom corner bolt

hole

Battery plate

5. Install batteries and use nylon straps passed through slots in the battery plate to hold the batteries in the vertical and the horizontal axis

6. Install top cover plate over the batteries. Depending on your toolkit assembly configuration, you might want to install the top plate later when all hydraulics are bolted to it


56



5 6

3.3.3 - Complete toolkit assembly


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2

1

Prepare the 4 legs, making sure you have 2 x Type 1 legs and 2 x Type 2 legs and that both sets have right handed assemblies and 2 x left handed assemblies

Install the 4 legs, on each corner of the body. Make sureyou take into account the full rotationnal range of the Articulation modules before bolting the legs in their final position.

It is usefull for this operation to place the body on a high drum to enable the legs dangling on the sides


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3

4

Install the batteries in the central body, of this not done yet

Install the electrical cablingfrom the legs, through the body at that point

Install the top plate to determine where you will pass the hydraulic hoses coming from the legs and the electrical wires


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5

6

Remove the top plate and mount hydraulic material on it, separately.

Put back the top plate with it's hydraulics when the assembly is complete

Install the power units in a preliminary fashion to determine the final hose positions.

When this is done, fix the power units at connect the hoses from the legs to the top Manifolds

3.3.4 - Top surface component layout (Suggested)


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FORWARD

Top CONNECTION manifolds- 5 output types (2x) – For oil supply- 4 output types (2x) – For oil return

4 top articulation module's valves and

subplates

3.4 - Known toolkit assemblies

3.4.1 - Assembly # 1 – 4 rigid wheels vehicle

Weight : Approx. 70lbsTotal DOF : 4


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3.4.2 - Assembly # 2 – 4 wheels, 2 direction, 4 2-DOF legs articulated vehicle

Weight : 350 lbsTotal DOF : 14


62



3.4.3 - Other possible configurations


63



CENTER OF BODY SWIVEL

6 WHEELS 6 ARTICULATED LEGS

3.5 - Operation capability examples


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4 - SUBSYSTEM CONFIGURATION AND OPERATION INTERFACE

4.1 - Communication

There are two main purposes for the user to communicate with the toolkit's subsystems. The first purpose is to enable the user to configure the toolkit's subsystems when this option is available through a communication media. The second purpose is to provide a means to interface the toolkit's subsystems together as well as with the user during operation.To serve the different communication needs for toolkit configuration and operation two communication media are available : RS232 serial communication

CANopen communication over CAN field-bus network


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4.2 - CAN and CANopen general information

CAN

CAN (Controller Area Network) is a serial bus system which provides :➢ A multi-master hierarchy, which allows building intelligent and redundant systems. If

one network node is defect the network is still able to operate. ➢ Broadcast communication. A sender of information transmits to all devices on the bus.

All receiving devices read the message and then decide if it is relevant to them. This guarantees data integrity as all devices in the system use the same information.

➢ Sophisticated error detecting mechanisms and re-transmission of faulty messages. This also guarantees data integrity.

CAN open

CANopen is a CAN-base higher layer protocol.The CANopen communication model specifies the different communication objects and services and the available modes of message transmission triggering. The communication model supports the transmission of synchronous and asynchronous messages.With respect to their functionality, four types of messages (objects) are distinguished [DS301 V4.02] : Administrative Messages (Layer Management, Network Management and Identifier

Distribution Messages) perform the setting up of layer specific parameters (Layer Management services), the initialisation, configuration and supervision of the network.

Service Data Messages (SDO) read from entries or writes to entries of the Object Dictionary. The SDO transport protocol allows transmitting objects of any size.

Process Data Messages (PDO) perform real-time data transmission.

Pre-defined Messages (Synchronisation, Time Stamp, Emergency Messages) provide node synchronisation, time stamping and emergency notification or failure reporting.

Object Dictionary

The Object Dictionary describes the complete functionality of a device by way of communication objects (entries). It is an interface that acts like a buffer between the CANopen communication stack and the application programs of the device. All communication objects of a device (application process data and configuration parameters) are described in its Object Dictionary in a standardized way. References


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Official organisation specifying the CAN and CANopen standards :http://www.can-cia.org/Comprehensive course material on CAN and CANopen :http://www.esacademy.com/myacademy/


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http://www.can-cia.org/

http://www.esacademy.com/myacademy/

4.3 - Subsystem configuration

Configuration of subsystems enables the user to select among different modes of operation the one that will suit the user application. Configuration through a communication medium intervenes mostly in advanced subsystems allowing a high degree of modularity and versatility, such as mechatronic subsystems, smart sensors and drives or modular electronic components. It also requires an interface (most of the time a PC based software, but not necessarily) to provide the user with an easy way to interact with the subsystem parameters. The use and the type of communication medium to configure a subsystem totally depends on the technology and the product being used.Most of the toolkit's subsystem, when configurable, are configured manually by the user through mechanical or electric components (different bolt patterns, switches, potentiometers, etc...). However a few subsystems in the toolkit which require more advanced functionality are configurable through a communication medium.This section deals only with subsystems configuration through a communication medium. Refer to other section in this manual or product data sheets for manual configuration of other subsystems.Configuration of the toolkit's subsystems is made through either serial or CANopen communication media depending on each subsystem and the product being used. There is no real standard for device configuration through serial communication. The serial protocol used for configuration is developed by each manufacturer and is specific to each product or family of products. On the other hand, the CANopen protocol defines a generic framework for device configuration over a CAN field-bus network. This is done by the means of SDO (Service Data Objects) messages that can access entries of the device OD (Object Dictionary).

4.3.1 - Hydraulic valve

Function : VARIATIONTechnology : Proportional directional hydraulic valve with integrated electronicProduct : NG3-Mini with DSV, WandfluhFunction instances : LOCOMOTION / PROPULSION / TRACTION (x4) / ARTICULATION #1 / ACTUATION / VARIATION

INTRAMOTION / ARTICULATION (x8) / ACTUATION / VARIATION #1

ConfigurationCommunication : RS232Interface : Paso DSV 1.1.03, WandfluhOperation : see DSV user manual


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a) General considerations

Mode of operationAll valves used on the toolkit feature 2 solenoids and one 0 ~ 10 VDC analog input. The appropriate mode of operation for these types of valves is “Preset unipolar (2-sol)”.Using such a configuration both solenoids are controlled through one analog input using two consecutive ranges :• 0% to 50% (0 ~ 5 V) for solenoid B

• 50% to 100% (5 ~ 10 V) for solenoid A

The effective range of the analog input can be adapted with scaling factors to meet different application requirements.

Digital I/OThere are no digital I/O available on any valves of the toolkit. However care should be taken to enable the digital input (set to 1) at the configuration stage in order for the valve to be operational.

Valve parametersValve parameters greatly influence valve performance as well as control accuracy. Care should be taken to tune them properly in order to get the optimal performance of the valve.Minimum and maximum solenoid currents are available to compensate for the spool mechanical and electrical deadband and saturation. These parameters should be set in order to obtain the most proportional law between analog command and spool valve opening and avoid non-linear behaviour at both extremities of spool displacement. These parameters slightly vary from valve to valve, so they should be fine tuned for each solenoid and for each valve as they influence greatly the proportionality and the quality of the valve response.Dither parameters (frequency and amplitude) are used to configure the dither signal superimposed on the PWM signal that command the solenoids. Dither signal is a low amplitude low frequency signal used in spool valve technology to overcome stricktion and inertia. Dither signal results in a faster and more accurate response of the valve. Tuning dither parameters might be a complex task in the sense that their optimal values depends on various parameters that cannot be identified very easily (friction, oil quality, supply pressure, spool inertia, ...). The tuning process that the manufacturer recommend is to start with the typical default setting for proportional directional spool valves and experimentally try different parameter settings during operation until valve reaches optimal performance.


69



The typical default setting for proportional directional spool valves is : frequency = 90 ~ 100 Hz

amplitude = 100 mA

The deadband parameter should be used to implement a deadband on the input command around the “null spool position” command to avoid noise sensitivity due to analog signals resulting in chaotic commands around null spool position. Considering the mode of operation of the toolkit's valves - “Preset unipolar (2-sol)” with 0 ~ 10 VDC analog input- the “null spool position” command corresponds to a 5V analog input. The deadband which is expressed in percentile of the input command is applied on both sides of the “null spool position” command for both solenoids. The value of the deadband parameter should be chosen in accordance to the level of noise on the analog input and the desired control sensitivity.

Ramp parametersRamps parameters allow to set command ramps by approaching new received command via a linear ramp and then avoiding abrupt command jumps. Command ramping result in a smother operation of the valve and allow to control the hydraulic flow in a more continuous way. This feature is relevant for high inertia systems to protect some components against abrupt variations of the hydraulic flow resulting in a pressure rise that might be harmful or even destructive.

b) Configuration of function instances

Each function instance (device) has been configured by the means of Paso software, with the following default parameter settings :

Parameter Menu Recommended value

Units

Mode of operation Configuration / Mode of operation unipolar (2-sol) NASignal type Configuration / Scaling preset value 0-10 VDC NAUsed input Configuration / Scaling preset value Analnp1 [V] NAInversion Configuration / Scaling preset value no NACablebreak detection Configuration / Scaling preset value no NAScaling Configuration / Scaling preset value TBD %Offset Configuration / Scaling preset value TBD VDigital inputs Configuration / Digital I/O 1 NADigital outputs Configuration / Digital I/O X NADirect solenoid operation Parameters / Valve unchecked TBC NA


70




Units

lminA Parameters / Valve 100 mAlmaxA Parameters / Valve 500 mAlminB Parameters / Valve 100 mAlmaxB Parameters / Valve 500 mAFrequency Parameters / Valve 100 HzLevel Parameters / Valve 100 mADeadband Parameters / Valve 10 %Ramp A up Parameters / Ramps 0 sRamp A down Parameters / Ramps 0 sRamp B up Parameters / Ramps 0 sRamp B down Parameters / Ramps 0 s

4.3.2 - Electric motor controller

Function : VARIATIONTechnology : Advanced unipolar PWM drive for brushless motorProduct : Harmonica 5/60, ElmoFunction instances : LOCOMOTION / DIRECTION / ARTICULATION (x2) / ACTUATION / VARIATION

ConfigurationCommunication : RS232Interface : Composer 2.16, ElmoOperation : see Composer user manual


Harmonica controllers feature basic control functions for brushless motors such as electronic commutation and current variation, as well as advanced closed loop control functions with diverse feedback options.All the motor controllers on the toolkit use the basic control functions only. Closed loop control functions have been implemented by the means of other devices.


71



Therefore, the appropriate mode of operation for these devices is the Current Mode.


Each function instance (device) has been configured by the means of Composer software, with the following default parameter settings :


Units

Motor type New Application / System Data Base Rotating Brushless

N/A

Continuous Stall Current New Application / System Data Base 2.5 AMaximum Mechanical Speed

New Application / System Data Base 6000 RPM

Current Main Commutation Feedback

New Application / Commutation Feedback Parameters

Digital Hall N/A

Number of Pairs of Poles New Application / Commutation Feedback Parameters

3 N/A

Application Continuous Current

New Application / System Definitions and Limits

2.5 A

Application Peak Current New Application / System Definitions and Limits

5 A

Speed New Application / System Definitions and Limits

6000 RPM

Stop Deceleration New Application / System Definitions and Limits

default (>1000000000)

cnt/s²

Low Reference for Position


default (>1000000000)

cnt

High Reference for Position


default (>1000000000)

cnt

Input #i New Application / Logic Input Ignore (all) N/AOutput #i New Application / Logic Input default N/AStep 1 New Application / Custom checked N/AStep 2 New Application / Custom checked N/AStep 3 New Application / Custom unchecked N/AStep 4 New Application / Custom unchecked N/AStep 5 New Application / Custom unchecked N/A


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4.3.3 - PID compensation

Function : REGULATIONTechnology : PID + feed-forward compensation with anti wind-up effectProduct : CollineoFunction instances : LOCOMOTION / PROPULSION / TRACTION (x4) / ARTICULATION #1 / REGULATION

LOCOMOTION / PROPULSION / POWER SUPPLY / REGULATION

LOCOMOTION / DIRECTION / ARTICULATION (x2) / REGULATION

INTRAMOTION / ARTICULATION (x8) / REGULATION

ConfigurationCommunication : CANopenInterface : PCANopen Magic ProOperation : see PCANopen Magic Pro user manual


PID compensation parameters are defined in the Object Dictionary of the processing node where they are implemented. For every instance of PID compensation function an entry is created in the OD with the following pattern :

Parameter OD entry subindex

Type Range Default Units Access

Feed-forward gain 0x01 REAL32 unlimited 1 implicit* R/WProportional gain 0x02 REAL32 unlimited 0 implicit R/WIntegral gain 0x03 REAL32 unlimited 0 implicit R/WDerivative gain 0x04 REAL32 unlimited 0 implicit R/WMinimum command 0x05 REAL32 unlimited -100 implicit R/WMaximum command 0x06 REAL32 unlimited 100 implicit R/W

* Implicit means that the units are specified by the user. The parameter is then accessed in accordance to the user-specified units


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Parameter settings for each function instance has to be performed by the user depending on the application. Refer to the CANopen network configuration file in annex to identify the Object Dictionary entry relative to a function instance.

4.3.4 - Processing node

Save, update, reset configuration parameters (Not implemented yet)

4.3.5 - Using CANopen Magic Pro to configure subsystems

CANopen Magic Pro is a PC-based software enabling to monitor, configure and analyse a CANopen communication network. CANopem Magic Pro also features minimal interaction capabilities with CANopen nodes over a network.

Some of the toolkit devices featuring a CANopen interface can be configured through their Object Dictionary using the CANopen protocol. If configuration parameters are registered in the device Object Dictionary, they can be accessed and edited over the network by the means of SDO messages (write and read permissions should be granted by the device). CANopen Magic Pro allows the user to generate and transmit such messages to CANopen nodes over the network. Please refer to sections on "node selection", "SDO upload" and "SDO download" the in the CANopen Magic Pro user manual for further information on how to use SDO messages.SDO configuration, as well as any other information about the Toolkit's CANopen nodes, is available in the CANopen network configuration file attached in annex. This file should be loaded by the user when starting CANopen Magic Pro in order to retrieve all the information on the Toolkit CANopen devices. Refer to the section on "Network description" in the CANopen Magic Pro user manual for further information on this matter.Please not that in order to access the Object Dictionary of a CANopen node, the operation mode of the node must be either in Pre-Operational or Operational state. Otherwise any SDO messages transmitted to the node would be ignored.


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4.4 - Operation interface

During toolkit operation the user requires a communication interface to interact with the toolkit's subsystems such as specifying operation mode, transmitting commands to actuators and receiving sensors information. To meet this requirement the toolkit's operation interface has been centralised through CANopen communication over the toolkit's CAN field-bus network being composed of the two processing units (LOCOMOTION and INTRAMOTION) which host all the toolkit's functions that need to be addressed by the user.

4.4.1 - Operation mode

The NMT messages defined in the CANopen protocol allows the user to specify the application state of CANopen nodes, and so on the status of the functions hosted by the nodes. This way the user can directly interact with different toolkit's subsystems and specify their mode of operation resulting in a more flexible control of the machine.The CANopen protocol defines the following standard node states for any application : Initialisation

Pre-Operational

Operational

Stopped

Reset Communication

Reset Application

By operating the CANopen node states trough NMT messages the user is able to specify the toolkit's subsystems mode of operation, such as enabling, disabling, initialisation or configuration of subsystems.The following table describes the mode of operation of CANopen services as well as application services (meaning toolkit's functions hosted by processing nodes) with respect to note state.

Node state CANopen servicesNMT SDO PDO

Application services

Object Dictionary

accessInitialisation CONF

↓INIT

CONF↓

INIT

CONF↓

INIT

CONF INIT


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Node state CANopen servicesNMT SDO PDO

Application services

Object Dictionary

accessPre-Operational ON ON OFF CONF YES

Operational ON ON INIT↓

ON

INIT↓

ON

YES

Stopped ON OFF OFF OFF NO

Reset Communication CONF↓

INIT

CONF↓

INIT

CONF↓

INIT

OFF NO

Reset Application CONF↓

INIT

CONF↓

INIT

CONF↓

INIT

CONF INIT

4.4.2 - Process data

The CANopen protocol provides a standardised and efficient way to transmit real-time process data between different devices over a CAN field-bus network by the means of PDO (Process Data Objects) messages.As configuration parameters, process data also lies in the Object Dictionary of the CANopen node since the OD acts as a buffer between the CANopen communication stack and the application functions. This means that SDO messages could be used by the user to access the process data as well. However this would be a less efficient way than using PDO messages since SDO messages can access single entries at a time while PDO messages can address multiple entries simultaneously. PDO messages also have a higher priority level.The structure and content of PDO messages for each node is detailed in the CANopen network configuration file attached in annex.

4.4.3 - Using CANopen Magic Pro to operate the Toolkit

CANopen Magic Pro offers the user with a simple interface to set the operation mode of each node on the network as well as configure and transmit PDO messages to those nodes. Since all interfaces with the toolkit subsystems have been centralised through CANopen communication, the user can totally interact with the toolkit using CANopen Magic Pro interface. The "Network management" window panel enables to set the


76



operation mode for a single or multiple nodes, while the "Process Data display" window panel allows PDO data transmission and visualisation. Refer to CANopen Magic Pro user manual for further information on these features.PDO configuration, as well as any other information about the toolkit's CANopen nodes, is available in the CANopen network configuration file attached in annex. This file should be loaded by the user when starting CANopen Magic Pro in order to retrieve all the information on the toolkit CANopen devices. Refer to the section on "Network description" in the CANopen Magic Pro user manual for further information on this matter.


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5 - SUBSYSTEMS REGULATION

Before operating the toolkit, the user should get a good understanding of its functional architecture and the interactions between the different functions composing it.Most of the toolkit subsystems feature ACTUATION functions as well as SENSATION functions which provide means for external functions to directly interact with the system, such as generating an action or assessing the states of the system.In addition to these primary functions, a REGULATION function is also often associated and serves as an interface between the SENSATION function and the ACTUATION function inside the same subsystem. The REGULATION function provides some basic operation autonomy at the subsystem level with the implementation of simple behaviours. The presence of such a function inside a subsystem allows to manage most of the operation of a subsystem at a low level and therefore drastically reduces the task load at higher supervision levels.On the toolkit, the following subsystems have a REGULATION function implemented :

LOCOMOTION / PROPULSION / TRACTION (x4)

LOCOMOTION / PROPULSION / POWER SUPPLY

LOCOMOTION / DIRECTION / ARTICULATION (x2)

INTRAMOTION / ARTICULATION (x8)

INTRAMOTION / POWER SUPPLY #2

Most of the REGULATION functions allow two ways for operating the subsystem, depending on the application :

➢ direct operation, where the behaviour of the subsystem is directly controlled by an external function enabling a direct interface with the ACTUATION and SENSATION functions (open-loop system)

➢ regulated operation, where the behaviour of the subsystem is internally regulated to follow the command of an external function (closed-loop system)

In order to properly operate each subsystem and enhance its optimal performance, the configuration of each REGULATION function has to be performed by the end user depending on the final toolkit configuration and application operational constraints.

For each of the toolkit's main subsystems, a concise perspective of their architecture is presented below.


78



5.1 - Wheel drive module


79



5.2 - Direction articulation module


80



5.3 - Intramotion articulation module


81



5.4 - Propulsion hydraulic power supply module


82



5.5 - Intramotion hydraulic power supply module


83



6 - SAFETY CONSIDERATIONS

6.1 - Handling

The toolkit is a heavy piece of equipment. It weights 350 lbs. Moving it when it is not powered will require some assistance of mechanical needs. We do not recommend for individuals or even in teams of many, moving it. If however there would be some needs to even just push it around, always make sure you are assisted and be careful to avoid back injuries during handling.

6.2 - Heavy objects fall

When the toolkit is standing in upright position, it may fall on the side due to unpredictable behaviour. Because of its large weight it can cause severe injuries to people standing next to it.


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Danger when falling

6.3 - Subsystems in operation

6.3.1 - Electrical shock

Even if this is a minor threat, be careful of keeping the electrical connections covered and isolated at all times to prevent contact with hands or body.

6.3.2 - Hydraulic pressure leakage cuts

This event is rare, but if there is a hole or puncture in a hydraulic hose, the pressurized fluid is acting like a very powerful fluid cutter jet. ANY PROBLEMS YOU SEE CONCERNING ANY LEAK, Stop the toolkit and activate the EMERGENCY KILL SWITCH before doing any further investigation.

6.3.3 - Burns due to motor heat

The pump's motor can get very hot. It is a short duty cycle motor that can't dissipate it's heat fast. Be careful careful of NOT TOUCHING it until 30-40 minutes AFTER every operation.


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Pump motor – Can get VERY HOT

6.4 - Vehicle in motion

6.4.1 - Body part cut

The toolkit has many degrees of freedom and many moving parts. Furthermore, its eight hydraulic actuators are VERY POWERFULL. When working around the toolkit, make sure the EMERGENCY KILL SWITCH is activated and POWER is off at all times. A suddenly moving leg can easily cut a complete hand or a finger if they are trapped between the leg and the toolkit's body.


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POWER SWITCH

EMMERGENCY KILL SWITCH

6.4.2 - Security area

As with all moving vehicles, precautions must be observed when working around it. Maintain a minimum security radius of 3 meters around the robot where NO ONE can move into when the toolkit is in operation.

6.4.3 - External power supply limitations (portable recharge system)

When operating on the external power unit, a cable is plugged into the toolkit. If the cable is extended to it's lengths limits, the cable itself can become stretched or twisted around a foot or a leg and become dangerous for the peoples around it.

6.4.4 - Toolkit's legs stepping on operator's foot

The toolkit can actually “walk” with it's legs and can also roll aver foots. Be careful to wear STEEL CAPPED shoes at all times when working around the toolkit to prevent foot injuries.


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7 - BASIC REPAIR AND MAINTENANCE

The toolkit has been designed so minimal maintenance and repair need to be performed by the final user. If one of the parts gets damaged, it is strongly recommended to send the material back to Collineo for repair or adjustment.

7.1 - Periodical maintenance

7.1.1 - Mechanical systems

Harmonic drive in traction modules➢ First maintenance : change oil bath once after 100 hours of operation (after initial

wearing out).➢ Next maintenance : change oil bath every 6 months of use.

Contact manufacturer for oil specifications.

7.1.2 - Hydraulic system

Hydraulic system➢ Change oil every 6 months of use.

➢ First oil flush (after pumps and motors wear out)

➢ Change hydraulic filters every time oil is changed

Contact manufacturer for oil specifications.

7.1.3 - Electrical systems

Electric batteriesIt is expected that battery performance drops after a period of use, depending on its usage. After 300 hours of operation, batteries should be replaced or if significant performance drop is noticed.

Electric fusesCheck fuses every 6 months and replace if necessary.


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7.2 - Maintenance log

We strongly recommend maintaining a comprehensive SINGLE record of EVERY MAINTAINANCE AND INSPECTION executed on the toolkit. The record should mention the date of the event, the name of the person performing it, and a detailed list of the work performed.

This log will eventually serve as an important information source for generating data on the toolkit's reliability and individual component's life analysis.

7.3 - Troubleshooting

Any problem that is not a maintenance issue should be reported immediately to Collineo for appropriate actions and recommendations.


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8 - OPERATION IN OUTDOOR ENVIRONMENT

8.1 - Preparation before external use

8.1.1 - Levels and status (Priority 1) – Every mission departure

✔ Battery charge check. Make sure batteries are charged at least 80% of capacity before every mission.

✔ When using Li-ion batteries, drain batteries before charging them, or use Valence's battery regulation system

✔ Oil levels - Fill oil levels if required following each mission to make sure the machine is always ready for the next mission

✔ Tire pressure – Maintain pressure stated on tire by tire manufacturer

8.1.2 - Physical damage (Priority 2) – Every 5 missions

Visual inspection of the toolkit subsystems :✔ Container leakage. Check all oil tanks for external leaks, especially around the tank's

connecting side to the hydraulic power unit manifold✔ Battery container leakage

✔ Hydraulic hoses fittings leakage

✔ Watertight protection for enclosures

– Propulsion module rear covers. These covers protect the internal parts of the wheel drives. Make sure the rubber seal and cover plate are in good condition in order to ensure proper sealing.NOTE : The wheel hub covers are usually not installed during development periods, since access to parts inside the wheel hub is necessary for modules assembly. However, when a suitable assembly combination has been achieved, the wheel hub covers should be installed before operating outside.

– Direction module motor enclosure. Check if the motor housing on the steering module is not damaged as it can lead to dust or water infiltration.

✔ Mechanical seals. Check all wheel drives and articulation modules for external leakages– Propulsion module wheel seals (4 sets)

– Direction module bearing seals (2 sets)

– Wires passage connectors (cable grips) – Check they are properly tightened

✔ Oil level plugs on propulsion module gearbox (2 per wheel). Contact manufacturer for oil specifications.


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✔ Cables abrasion and cuts. Check all electric cables and hydraulic hoses for cuts, pinching marks and abrasions because they can lead to the toolkit's malfunction and leaks.

8.1.3 - Assembly integrity (Priority 3) – Every 6 months

✔ Check structures bolting

– Missing bolts and nuts

– Wrong bolting (if repaired or maintained by third party)

✔ Check for clinging noises

– Loose nuts

– Cracks in frames

✔ Check for structures permanent deformation and cracks in each welding beam

✔ Electric wiring and battery connections

✔ Corrosion marks


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8.2 - Toolkit environmental conditions

Operating temperature : - 20°C to 35°C (needs warm-up sequence at -20°C)Storage temperature : - 40°C to 50°CImpacts : 2 km/h impact on wheel drives

All hydraulic connections are industrial standards design to fully withstand dust and rain when properly closed and tightened.Legs components of the toolkit can resists light rain mist and minimal dust. Top modules of the toolkit must be protected for more demanding external uses.Propulsion and direction modules can be immersed separately in 20 cm of water, when the covers and seals are properly installed in place and well bolted. The articulation modules, however, are only IP67 protected (cannot be immersed).


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8.3 - Environment protection

8.3.1 - Procedures

When oil spill happens, contact your environment representative to asses the contamination. Basically, all external operations involving repair of hydraulics or even accident spillages should have the contamination spot identified, marked and the contaminated soil removed.

8.3.2 - Oil selection

The toolkit is provided with standard mineral oil. This oil is suitable for in house testing and outside operations. However, we recommend a biodegradable oil for more extensive operational use of the toolkit.

8.3.3 - Battery fluids

The toolkit is provided with common Gel-Acid batteries. However, we recommend upgrading batteries to Li-ion batteries for more extensive operational use of the toolkit. Both battery types should be treated with care and any battery damage resulting in fluid spillage should be responded with appropriate environmental cleaning measures.


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9 - ANNEXES


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TOOLKIT CANOPEN NETWORK DESCRIPTION FILE (prototype processing node only)

<?xml version="1.0" encoding="UTF-8"?><cxl version="1.00" author="COLLINEO" date="19-Mar-2006"> <objectdictionary> <entry> <index>0x6000</index> <name>Application Configuration Parameters</name> <subentry>

<subindex>0x01</subindex> <name>Update configuration flag</name> <type>BOOLEAN</type>

</subentry> <subentry>

<subindex>0x02</subindex> <name>Save configuration flag</name> <type>BOOLEAN</type>


<subindex>0x03</subindex> <name>Reset configuration flag</name> <type>BOOLEAN</type>


<subindex>0x04</subindex> <name>Verbose configuration flag</name> <type>BOOLEAN</type>

</subentry> </entry> <entry> <index>0x6100</index> <name>Articulation 1 Measurement Variables (TPDO1)</name> <subentry>

<subindex>0x01</subindex> <name>Measured position</name> <type>INTEGER16</type>


<subindex>0x02</subindex>

<name>Measured velocity</name> <type>INTEGER16</type>


<subindex>0x03</subindex> <name>Position error</name> <type>INTEGER16</type>


<subindex>0x04</subindex> <name>Actuator command</name> <type>INTEGER16</type>

</subentry> </entry> <entry> <index>0x6200</index> <name>Articulation 1 Control Variables (RPDO1)</name> <subentry>

<subindex>0x01</subindex> <name>Desired position</name> <type>INTEGER16</type> </subentry>

<subentry> <subindex>0x02</subindex> <name>Reserved</name> <type>UNSIGNED8</type>

</subentry> </entry> <entry> <index>0x6101</index> <name>Articulation 2 Measurement Variables (TPDO2)</name> <subentry>





95



<name>Measured velocity</name> <type>INTEGER16</type>





</subentry> </entry> <entry> <index>0x6201</index> <name>Articulation 2 Control Variables (RPDO2)</name> <subentry>



</subentry> </entry> <entry> <index>0x6102</index> <name>Direction Measurement Variables (TPDO3)</name> <subentry>



<subindex>0x02</subindex> <name>Measured velocity</name> <type>INTEGER16</type>





</subentry> </entry> <entry> <index>0x6202</index> <name>Direction Control Variables (RPDO3)</name> <subentry>



</subentry> </entry> <entry> <index>0x6103</index> <name>Wheel Measurement Variables (TPDO4)</name> <subentry>

<subindex>0x01</subindex> <name>Measured displacement</name> <type>INTEGER16</type>


<subindex>0x02</subindex> <name>Measured velocity</name> <type>INTEGER16</type>


<subindex>0x03</subindex> <name>Velocity error</name> <type>INTEGER16</type>

</subentry>


96



<subentry> <subindex>0x04</subindex> <name>Actuator command</name> <type>INTEGER16</type>

</subentry> </entry> <entry> <index>0x6203</index> <name>Wheel Control Variables (RPDO4)</name> <subentry>

<subindex>0x01</subindex> <name>Desired velocity</name> <type>INTEGER16</type> </subentry>


</subentry> </entry> <entry> <index>0x6300</index> <name>Articulation 1 Sensor Configuration Parameters</name> <subentry>

<subindex>0x01</subindex> <name>Resolution</name> <type>REAL32</type>


<subindex>0x02</subindex> <name>Offset</name> <type>REAL32</type>

</subentry> </entry> <entry> <index>0x6400</index> <name>Articulation 1 Command Configuration Parameters</name> <subentry>

<subindex>0x01</subindex> <name>Deadband</name>

<type>UNSIGNED8</type> </subentry> <subentry>

<subindex>0x02</subindex> <name>Change direction</name> <type>BOOLEAN</type>


<subindex>0x03</subindex> <name>Absolute maximum value</name> <type>REAL32</type>

</subentry> </entry> <entry> <index>0x6500</index> <name>Articulation 1 PID Configuration Parameters</name> <subentry>

<subindex>0x01</subindex> <name>Feed-Forward gain</name> <type>REAL32</type>


<subindex>0x02</subindex> <name>Proportionnal gain</name> <type>REAL32</type>


<subindex>0x03</subindex> <name>Integral gain</name> <type>REAL32</type>


<subindex>0x04</subindex> <name>Derivative gain</name> <type>REAL32</type>


<subindex>0x05</subindex> <name>Minimum command</name> <type>REAL32</type>




97



<name>Maximum command</name> <type>REAL32</type>

</subentry> </entry> <entry> <index>0x6600</index> <name>Articulation 1 PDO Scaling Factors</name> <subentry>

<subindex>0x01</subindex> <name>Measured position scaling factor</name> <type>REAL32</type>


<subindex>0x02</subindex> <name>Measured velocity scaling factor</name> <type>REAL32</type>


<subindex>0x03</subindex> <name>Position error scaling factor</name> <type>REAL32</type>


<subindex>0x04</subindex> <name>Actuator command scaling factor</name> <type>REAL32</type>


<subindex>0x05</subindex> <name>Desired position scaling factor</name> <type>REAL32</type>

</subentry> </entry> <entry> <index>0x6301</index> <name>Articulation 2 Sensor Configuration Parameters</name> <subentry>




</subentry> </entry> <entry> <index>0x6401</index> <name>Articulation 2 Command Configuration Parameters</name> <subentry>

<subindex>0x01</subindex> <name>Deadband</name> <type>UNSIGNED8</type>





</subentry> </entry> <entry> <index>0x6501</index> <name>Articulation 2 PID Configuration Parameters</name> <subentry>








98







<subindex>0x06</subindex> <name>Maximum command</name> <type>REAL32</type>

</subentry> </entry> <entry> <index>0x6601</index> <name>Articulation 2 PDO Scaling Factors</name> <subentry>










</subentry>

</entry> <entry> <index>0x6302</index> <name>Direction Sensor Configuration Parameters</name> <subentry>




</subentry> </entry> <entry> <index>0x6402</index> <name>Direction Command Configuration Parameters</name> <subentry>






</subentry> </entry> <entry> <index>0x6502</index> <name>Direction PID Configuration Parameters</name> <subentry>


</subentry>


99



<subentry> <subindex>0x02</subindex> <name>Proportionnal gain</name> <type>REAL32</type>









</subentry> </entry> <entry> <index>0x6602</index> <name>Direction PDO Scaling Factors</name> <subentry>










</subentry> </entry> <entry> <index>0x6303</index> <name>Wheel Sensor Configuration Parameters</name> <subentry>

<subindex>0x01</subindex> <name>Displacement resolution</name> <type>REAL32</type>



</subentry> </entry> <entry> <index>0x6403</index> <name>Wheel Command Configuration Parameters</name> <subentry>





<subindex>0x03</subindex> <name>Absolute maximum value</name>


100



<type>REAL32</type> </subentry> </entry> <entry> <index>0x6503</index> <name>Wheel PID Configuration Parameters</name> <subentry>












</subentry> </entry> <entry> <index>0x6603</index> <name>Wheel PDO Scaling Factors</name> <subentry>

<subindex>0x01</subindex> <name>Measured displacement scaling factor</name>

<type>REAL32</type> </subentry> <subentry>



<subindex>0x03</subindex> <name>Velocity error scaling factor</name> <type>REAL32</type>




<subindex>0x05</subindex> <name>Desired velocity scaling factor</name> <type>REAL32</type>

</subentry> </entry> </objectdictionary> <processdata>

<data> <name>Articulation 1 measured position</name> <id>0x188</id> <startbit>0</startbit> <endbit>15</endbit> <type>INTEGER16</type> <units>deg</units>

</data> <data>

<name>Articulation 1 measured velocity</name> <id>0x188</id> <startbit>16</startbit> <endbit>31</endbit> <type>INTEGER16</type> <units>deg/s</units>

</data>


101



<data> <name>Articulation 1 position error</name> <id>0x188</id> <startbit>32</startbit> <endbit>47</endbit> <type>INTEGER16</type> <units>deg</units>

</data> <data>

<name>Articulation 1 actuator command</name> <id>0x188</id> <startbit>48</startbit> <endbit>63</endbit> <type>INTEGER16</type> <units>%</units>

</data> <data>

<name>Articulation 2 measured position</name> <id>0x288</id> <startbit>0</startbit> <endbit>15</endbit> <type>INTEGER16</type> <units>deg</units>

</data> <data>

<name>Articulation 2 measured velocity</name> <id>0x288</id> <startbit>16</startbit> <endbit>31</endbit> <type>INTEGER16</type> <units>deg/s</units>

</data> <data>

<name>Articulation 2 position error</name> <id>0x288</id> <startbit>32</startbit> <endbit>47</endbit> <type>INTEGER16</type> <units>deg</units>

</data> <data>

<name>Articulation 2 actuator command</name>

<id>0x288</id> <startbit>48</startbit> <endbit>63</endbit> <type>INTEGER16</type> <units>%</units>

</data> <data>

<name>Direction measured position</name> <id>0x388</id> <startbit>0</startbit> <endbit>15</endbit> <type>INTEGER16</type> <units>deg</units>

</data> <data>

<name>Direction measured velocity</name> <id>0x388</id> <startbit>16</startbit> <endbit>31</endbit> <type>INTEGER16</type> <units>deg/s</units>

</data> <data>

<name>Direction position error</name> <id>0x388</id> <startbit>32</startbit> <endbit>47</endbit> <type>INTEGER16</type> <units>deg</units>

</data> <data>

<name>Direction actuator command</name> <id>0x388</id> <startbit>48</startbit> <endbit>63</endbit> <type>INTEGER16</type> <units>%</units>

</data> <data>

<name>Wheel measured displacement</name> <id>0x488</id>


102



<startbit>0</startbit> <endbit>15</endbit> <type>INTEGER16</type> <units>rev</units>

</data> <data>

<name>Wheel measured velocity</name> <id>0x488</id> <startbit>16</startbit> <endbit>31</endbit> <type>INTEGER16</type> <units>rpm</units>

</data> <data>

<name>Wheel velocity error</name> <id>0x488</id> <startbit>32</startbit> <endbit>47</endbit> <type>INTEGER16</type> <units>rpm</units>

</data> <data>

<name>Wheel actuator command</name> <id>0x488</id> <startbit>48</startbit> <endbit>63</endbit> <type>INTEGER16</type> <units>%</units>

</data> </processdata></cxl>


103



TOOLKIT MAIN ELECTRICAL SYSTEM


104



TOOLKIT ELECTRICAL POWER SUPPLY REGULATION MODULE


105



HPI HYDRAULIC POWER UNIT PERFORMANCE CURVES


106



HPI HYDRAULIC POWER UNIT PERFORMANCE TABLES


107



UNCLASSIFIED SECURITY CLASSIFICATION OF FORM (highest classification of Title, Abstract, Keywords)

DOCUMENT CONTROL DATA (Security classification of title, body of abstract and indexing annotation must be entered when the overall document is classified)

1. ORIGINATOR (the name and address of the organization preparing the document. Organizations for who the document was prepared, e.g. Establishment sponsoring a contractor's report, or tasking agency, are entered in Section 8.)

Collineo inc. 1375 rue Gay-Lussac, bureau A Boucherville QC J4B 7K1

2. SECURITY CLASSIFICATION (overall security classification of the document, including special

warning terms if applicable)

Unclassified

3. TITLE (the complete document title as indicated on the title page. Its classification should be indicated by the appropriate abbreviation (S, C or U) in parentheses after the title).


4. AUTHORS (Last name, first name, middle initial. If military, show rank, e.g. Doe, Maj. John E.)

Lambert, Guillaume

5. DATE OF PUBLICATION (month and year of publication of document)

December 2006

6a. NO. OF PAGES (total containing information, include Annexes, Appendices, etc) 107

6b. NO. OF REFS (total cited in document)

0

7. DESCRIPTIVE NOTES (the category of the document, e.g. technical report, technical note or memorandum. If appropriate, enter the type of report, e.g. interim, progress, summary, annual or final. Give the inclusive dates when a specific reporting period is covered.)

Final Report for the Micro-hydraulic Toolkit Platform

8. SPONSORING ACTIVITY (the name of the department project office or laboratory sponsoring the research and development. Include the address.)

Defence R&D Canada – Suffield, PO Box 4000, Station Main, Medicine Hat, AB T1A 8K6

9a. PROJECT OR GRANT NO. (If appropriate, the applicable research and development project or grant number under which the document was written. Please specify whether project or grant.)

9b. CONTRACT NO. (If appropriate, the applicable number under which the document was written.)

W7702-03R975

10a. ORIGINATOR'S DOCUMENT NUMBER (the official document number by which the document is identified by the originating activity. This number must be unique to this document.)

DRDC Suffield CR 2008-212

10b. OTHER DOCUMENT NOs. (Any other numbers which may be assigned this document either by the originator or by the sponsor.)

11. DOCUMENT AVAILABILITY (any limitations on further dissemination of the document, other than those imposed by security classification)

( x ) Unlimited distribution ( ) Distribution limited to defence departments and defence contractors; further distribution only as approved ( ) Distribution limited to defence departments and Canadian defence contractors; further distribution only as approved ( ) Distribution limited to government departments and agencies; further distribution only as approved ( ) Distribution limited to defence departments; further distribution only as approved ( ) Other (please specify):

12. DOCUMENT ANNOUNCEMENT (any limitation to the bibliographic announcement of this document. This will normally corresponded to the Document Availability (11). However, where further distribution (beyond the audience specified in 11) is possible, a wider announcement audience may be selected).

Unlimited UNCLASSIFIED SECURITY CLASSIFICATION OF FORM

UNCLASSIFIED SECURITY CLASSIFICATION OF FORM

13. ABSTRACT (a brief and factual summary of the document. It may also appear elsewhere in the body of the document itself. It is highly desirable that the abstract of classified documents be unclassified. Each paragraph of the abstract shall begin with an indication of the security classification of the information in the paragraph (unless the document itself is unclassified) represented as (S), (C) or (U). It is not necessary to include here abstracts in both official languages unless the text is bilingual).

The Micro-Hydraulic Toolkit is an integrated set of modular components to create articulated vehicles for mobile robotics and teleoperation applications. Its components involve mechanical, electrical, electronic and hydraulic technologies and can be assembled in various ways to build different vehicle configurations depending of the final application.

14. KEYWORDS, DESCRIPTORS or IDENTIFIERS (technically meaningful terms or short phrases that characterize a document and could be helpful in cataloguing the document. They should be selected so that no security classification is required. Identifies, such as equipment model designation, trade name, military project code name, geographic location may also be included. If possible keywords should be selected from a published thesaurus, e.g. Thesaurus of Engineering and Scientific Terms (TEST) and that thesaurus-identified. If it is not possible to select indexing terms which are Unclassified, the classification of each should be indicated as with the title.) robotics teleoperation

UNCLASSIFIED SECURITY CLASSIFICATION OF FORM

Defence R&D Canada R & D pour la défense Canada Canada's Leader in Defence

and National Security Science and Technology

Chef de file au Canada en matière de science et de technologie pour la défense et la sécurité nationale

www.drdc-rddc.gc.ca

micro-hydraulic toolkit report

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