MSD P07302 End of Project Review 1

Motor Controller SubsystemMSD P07302

Project Sponsor: KGCOE

Project Members:D. Shenoy Project ManagerS. Tallau Software DesignM. Oesterling Hardware DesignL. DeSnots Signal ConditioningA. Karani Hardware LayoutR. Gupta Power DesignR. Cooper Hardware Design

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Outline:

Overview

Customer Needs

Design

Project Strengths/Weaknesses

Future Improvements

Q & A

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Project Description:

- An open source motor controller that is- ScalableScalable: support for various vehicle platforms- ReusableReusable: modular design- ProgrammableProgrammable: reconfigurable functionality- ReliableReliable

- Must be able to sense, control and drive several motors using the CAN protocol.

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Project Applications:

- Foundation for future MSD projects

- US First Robotics Competition - www.usfirst.org

- Component in other research projects

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Product Specifications:

- PC104 form factor

- Maximum CPU usage of 25%

- 12V DC power supply

- One hour run-time

- Scalable motor controller- 10, 100, 1000 kg platforms

90 mm

96 mm

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Design:

Contains the power circuitry to provide the

PC104 with the required power to

operate.

Contains the necessary components required to communicatecommunicate with the motors using the CANCAN

protocol.

Runs the main motor controller softwaresoftware

system. The PC104 system operates using

a “minimal” Linux operating system.

PC104 Power PCBMotor Controller PCB

PC104 system

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Design:

P07302: Motor Controller Subsystem

• Motor Controller and Power PCB can stack vertically on the PC104 platform

• All boards conform to the specified PC104 form factor

• Standard Connectivity (DB9 CAN connection)

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Design:

PC104 Contains C Program to issue motor commands

CPLD VHDL code implementing ISA and SPI. Handles Communication and Data between the PC104 and CAN.

CAN Controller IC that handles CAN Data

CAN Transceiver Sends and Receives CAN packets

PC104CAN

ControllerCPLDISA bus SPI bus

CANTransceiver

Rx

Tx

Motor Controller Data Flow:

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Design: End of Design

• Software System

–Instruction-Set Implementation

–Menu-based Interface

–Polling-based I/O

–CPU Usage < 10%

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Design: End of Design

• Hardware System

–Protocol Functionality

• ISA Bus

• SPI Controller (CPLD)

• CAN Controller/Transceiver

–Optional PWM Generator

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Design: End of Design Cost

• Controller PCB Cost–$166.50 each for prototype

–$75.60 each for ten

–$27.41 each for fifty

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Design: End of Design Cost

• Power Board PCB Cost (Estimated)–$130 each for prototype–$50 each for ten–$20 each for fifty

• IC Cost (for both boards)–$570 for prototype

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• PC104 Constraint

• Number of Protocols

–ISA SPI CAN

• Concurrent Project Development

–Inter-Project Dependence• High Level of VHDL Complexity

Design Weaknesses

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Design Strengths

• Future Development Potential

–Modular Design

–Extensible

• Software –Easily Reconfigurable

–Open Source

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Design Strengths

• Hardware –Reconfigurable and

Programmable CPLD

–Open Source

–CAN Controller and CPLD Allow for Added Functionality

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Future Improvements

• Interrupt Handling

• Integration of Battery Power

• Real-time Control and Feedback

–User Input

–Application Interface

• Control and Drive Several Types of Vehicles

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Questions?