Ongo01 – OSCAR

Client – Department of Electrical and Computer Engineering

Faculty Advisor – Ralph Patterson

Team Members –

9 December 2003

2nd Semester Students:

Patrick Jordan CprE / Math

Farrukh Mian EE

James Sweeney CprE / Psych

Michael VanWaardhuizen CprE / EE

Abdul Qazi CprE      

1st Semester Students:

Argenis Acosta CprE

Daniel Marquis EE

Cory Farver CprE

Abdallah Mwita CprE

Matthew Frerics EE

Jason Olson CprE

Daniel Humke A EE

Fahad Wajid EE

Presentation Overview

Introduction & Overview

Motion Control

Power

Sensors

Software

General Summary

Introduction

OSCAR is a demonstration robot for use in outreach to students and community

Its goal is to excite and interest students in engineering fields

Comprised of several subsystems, each the responsibility of a subteam

History

ISU Robotics Club

CYbotSuccessful DemosWidely remembered, Goal

OSCARNext generation technologiesMore student development

Problem Statement

To successfully integrate all subsystems into a functional, safe and usable robot

Create demonstrations of interest to the public of the OSCAR’s capabilities

Perform demonstrations for interested groups and for university outreach efforts

Users and Uses

UsersTeam membersOthers who have been trained on the

system’s safe operation

UsesOutreach and public relationsEducation of K-12 students

Operating Environment

Indoors or prepared outdoor areas

Level surfaces

Moderate Temperatures (>65F)

Free of obstacles shorter than 2.5ft

Team Structure

SubteamsMotion ControlPowerSensorsSoftware

Subteam Leader Coordination

Members:Matt Frerichs (EE – 1st) – Team Leader

Alexandre Moulin (ME – 1st)

Tom Shedek (ME – 1st)

Fahad Wajid (EE – 1st)

Motion Control – Ongo01a

Introduction

The Motion Control Subteam of OSCAR is responsible for controlling the movement of OSCAR as a whole as well as the construction and movement of the arm.

DefinitionsDefinitions

H-Bridge – Motor control circuit, controls the direction of the motor

PCB – printed circuit board

LM629 – Motion control circuit, outputs PWM and direction signals for speed and direction control

PWM – pulse width modulation

Problem Statement

Complete implementation of motion control circuitry that has been designed in previous semesters

Re-design motion control circuitry if needed

End ProductDescription

Movement achieved in the base motors of OSCAR

Movement achieved in OSCAR’s arm

AssumptionsAssumptions and Limitationsand Limitations

Software will be ready to control the motion control circuitry

The power supplied will be sufficient for the needs of the controllers

Sufficient funding will be available

Previous AccomplishmentsPrevious Accomplishments

Motion control circuits designed

Some parts of motion control circuits built and preliminary testing started

Milestones

Achieve base motor movement (65% complete)

Achieve arm motor movement (65% complete)

Future Work

Work with software team on arm control software

Improve performance of gripper and actuator

Find different funding sources in order to implement more up to date solutions

Design ActivitiesDesign Activities

Worked on new motion control scheme with different H-Bridge circuits

Implementation ActivitiesImplementation Activities

H-Bridges soldered on new PCBs

Acquire new gripper actuator motor

Testing and Modification ActivitiesTesting and Modification Activities

Tested LM629 motion control board

Tested old H-Bridge circuits

Testing of new H-Bridge Circuits

Personnel UtilizationCurrent Hours

Original

Estimate

Revised

Estimate

Matt Frerichs 60.5 95 63

Alex Moulin 38 94 40

Tom Shedek 61 93 62

Fahad Wajid 49 88 51

Financial ResourcesHours Rate With

Hours

Matt Frerichs 60.5 $20.00 $1210.00

Alex Moulin 38 $20.00 $760.00

Tom Shedek 61 $20.00 $1220.00

Fahad Wajid 49 $20.00 $980.00

Other ResourcesQuantity Estimated Actual

Poster 1 $5.00/each $3.00/each

Motion Control Components

1 $62.50 $0.00

Aluminum 1 $50.00 $0.00

Machine Shop Usage

1 TBD $0.00

Total $117.50 $3.00/each

Summary

Made progress with OSCAR’s motion control circuit

Accomplished some base motion and arm motion

Work accomplishedWork accomplished

Researched new gripper design

Assembled Arm

Created working CAD drawings of arm

Work accomplishedWork accomplished

Machined parts to assemble arm

Designed the shoulder to attach the arm to OSCAR

Assembled the arm

Future Work

Improve performance of gripper and actuator

Attach the arm to Oscar

Continue fabricating parts

Design shafts for elbow and shoulder

Machine a new hand

Design new arm

Summary

Have completed the fabrication and assembly of OSCAR’s arm

Team Members:Daniel J. Marquis (EE – 1st) – team leader

Hong Nguyen (EE – 2st)

Power - Ongo-01c

Definitions

DC/DC Power Supply – DC Voltage ‘A’ to DC Voltage ‘B’

DC/AC AC/DC Power Supply – DC Voltage ‘A’ to AC 120V – AC 120V to DC Voltage ‘B’

Presentation Outline

Introduction – to power sub team project

Project Activities – past, present, future

Resources & Schedules – where we are

Conclusions – results & implications

Problem Statement

Primary Problem – Inefficient DC/AC AC/DC

Secondary Problem –Sensors wall powered

Tertiary Problem – Maintenance / Support

Intended Users & Uses

Users – OSCAR team members(Software, Sensors,

and Motion Control)

Uses – Power OSCAR during demos

(The power system is not intended to provide power to non-related devices like home theater systems, full fledged desktop computers, electric lawn mowers, and halogen lamps.)

Assumptions and Limitations

Short Demonstrations

Sensitive Power System Isolation

Limited Battery Power

End Product(s)

DC-DC power supply system for computer

Power budget for OSCAR

Onboard power supply for sensors (either temporary or permanent)

Previous Accomplishments

DC/DC Converter Designed (Spring ‘02)

DC/DC Converter Constructed (Fall ’02)

Battery Sensors Installed (Fall ’02)

Present Accomplishments

DC/DC Testing Commenced

Power Budget Made

Documentation updated & posted on web

Concluded DC/DC not up to spec.

Future Required Activities

Maintain Power System (ongoing)

Improve Fusing (Spring 2004 & ongoing)

Commercial Power Supply Evaluation (Spring 2004)

Approaches Considered and the One Used

Sensor Power - Rechargeable Battery Pack - DC/AC/DC Conversion Setup - DC/DC Converter (Future) - Run off of PC (Used Now)

Project Definition Activities

Not Applicable

Research Activities

Not Applicable

Design Activities

Not Applicable (though did improve the previous term’s team’s documentation)

Implementation Activities

Not Applicable

Testing and Modification Activities

Tested DC/DC Power Supply

Tested old DC/AC AC/DC System

Other Significant Project Activities

Found DC/DC Converters

Created & Posted Documentation

Replaced 3 DC/DC Voltage Regulators (one exploded during a DC/DC power up)

Repaired Fried Traces on PC Boards

Two DC/DC Converters Inside Box

DC/DC Converters Outside of Box

Resources & Schedule

Resource 1/2

Current Hours

Original

Estimate

Revised

Estimate

Daniel J. Marquis 96.25 70 110

Hong Nguyen 70 67 87

Time (as of 7 December 2003)

Overall Hours Spent

Making report51%

Ordering parts1%

Search for / Read

documentation 11%

Research1%

Physical installation and testing

18%

Meetings18%

Resource 2/2

Money (as of 7 December 2003)

Item Estimated Actual Difference (Estimated-Actual)

Project Poster (Cost to Sub-Team) $50.00 $6.00 $44.00

Fuses $0.00 $3.00 -$3.00

Voltage Regulators $0.00 $0.00 $0.00

TOTAL $50.00 $9.00 $41.00

Schedule

Task From Day Month To Day Month Length of Time(total day)

Provide Temp Power

Research testing circuit(DC/DC)Testing DC/DC circuit

Research testing circuit(Monitor Battery)Testing Monitor Battery

Provide Power

21 9

21 9

30 9

21 9

30 9

26 10

23 11

26 10

30 10

26 10

30 10

25 12

45

25

23

25

23

44

Behind due to DC/DC failures

Project Evaluation

Milestone Priority Completion

DC-DC Converters Found High 100%

Power Budget Created High 30%

Battery Status Verified High 100%

Fuse Protection Implemented / Verified High 25%

DC-DC Converters Tested Medium 80%

Battery Indicators Verified Low 0%

Temp Sensor Power Solution Researched Low 25%

Temp Sensor Power Solution Built and Installed Low 90%

Temp Sensor Power Solution Tested Low 90%

Recommendations for additional work

Inline, Accessible Fuses

Commercial DC/DC

Summary

DC/DC

DC/AC AC/DC

Documentation

Commercial Solution

Members:Michael Van Waardhuizen (CprE/EE – 2nd) – Team Leader

Farrukh Mian (EE – 2nd)

Cory Farver (CprE – 1st)

Daniel Humke (EE – 1st)

Faculty Advisor: Professor Ralph Patterson III

Client: Department of Electrical and Computer Engineering

Iowa State University

Sensors – Ongo-01d

Outline

Problem Statement

End Product Description

Assumptions & Limitations

Previous and Current Accomplishments

Technical Approaches

Current Activities

Resources

Conclusion

Definitions

Azimuth The horizontal angular distance from a reference direction, usually the northern point of the horizon, usually measured clockwise.Micro-controller A microcontroller is an embedded, complete system. A microcontroller typically includes small amounts of memory, timers, and I/O ports.Basic-X24 BasicX-24 is one of the most powerful BASIC programmable microcontrollers.Thermistor A resistor made of semiconductors having resistance that varies rapidly and predictably with temperature

Problem Statements

OSCAR requires functional sonar system for navigation (has not functioned since Spring 2002)

Temperature sensors does not operate

Compass sensor does not operate

Solution Approaches

Research replacement sonar systems, compass system

Test hardware components individually

Simplify software components

End Product Description

Functional sonar array

Functional compass

Functional temperature sensor

Operable by on board computer without assistance

AssumptionsAssumptions and Limitationsand Limitations

Power system will provide adequate and stable enough power

Sonar detect distances from only 1.33 - 35 feet (+/- 3%)

The compass sensor must be allowed 2.5 to 3.5 seconds to settle from rotational displacement

Limitations cont.

The compass sensor must be positioned to have a tilt of no more than +/- 5° with respect to the ground. A successful compass reading can only be done on flat terrain.The compass sensor may have limited accuracy (+/- 5° Azimuth) due to electromagnetic interference from drive motors, computers and power supplies The sonar will not experience electromagnetic noise such that prevents proper operation

Previous AccomplishmentsPrevious Accomplishments

Completed sensors system: 8 directional sonar array Compass Temperature Sensor

Malfunction left unsolved, array semi-functional at end of last semester, requiring a connection board rework/replacement

Sonar System

Present Accomplishments

Replacement of the microcontrollerNetworked OSCAR’s hard drives Researched alternative sonar systemResearched alternative compass circuitsMiscellaneous repairsInitial functional testing of our projects subsystems.

Future Activities

Research into sensor extensibility

System maintenance

Replacement of compass to provide increased accuracy

Mapping algorithm

Approach 1

Replacement of old system with new technology:Pros: A fresh start, re-evaluation of

necessary capabilitiesCons: Would require a large amount of

money, brand new system isn’t guaranteed to work

Approach 2

Testing & Repair of existing circuitryPros: Certain that system worked once, low

costCons: Errors and bugs difficult to find,

especially in hardware, existing system may break again

Chose approach 2 for budgetary reasons.

Design & Implementation ActivitiesDesign & Implementation Activities

Redesign of a connection board

Replacement of microcontroller

Hardware repairs for system integrity

Networking of OSCAR hard drives

Testing and Modification ActivitiesTesting and Modification Activities

Complete testing of 3 microcontrollers to establish if replacement was necessary

Testing of software for PC and microcontroller to establish operating system dependence

Testing of sonar modules, compass, and temperature sensor for functionality

Personnel Utilization

Current Hours

Original

Estimate

Revised

Estimate

Michael VW 45 27 45

Farrukh Mian 33 27 40

Cory Farver 85 26 75

Dan Humke 41 25 45

Personal Util. cont.

Personal Hours (204 Hours Total)

Michael

Dan

Cory

Farrukh

Financial ResourcesActual Financial Costs    

     

Item Without Labor With Labor

Previous Semester $40.00 $40.00

Sensor $ - $ -

Transducer (2) $ - $ -

Board Etching $ - $ -

Poster Printing $12.00 $12.00

Miscellaneous Parts $57.00 $57.00

Subtotals $109.00 $109.00

     

Labor at $10.75 per hour    

Previous Session   $2,931.75

Farver, Cory   $913.75

Humke, Daniel   $440.75

Mian, Farrukh   $354.75

VanWaardhuizen, Michael   $483.75

Subtotals   $5,124.75

Totals $109.00 $5,233.75

Schedule

Summary

Sensors did not function at beginning of the semester

Hardware problems mid-semester

Replaced faulty hardware

System works, in testing for accuracy

Integration with OSCAR for navigation to come

Members:James Sweeney (CprE – 2nd) – team leader

Abdul Nasir (CprE – 2nd)

Patrick Jordan (CprE – 2nd)

Jason Olson (CprE – 1st)

Abdallah Mwita(CprE – 1st)

Argenis Acosta (CprE – 1st)

Software – Ongo01e

Introduction

The software sub-team on OSCAR is charged with developing the software controls to OSCAR’s hardware and also creating demonstrations utilizing that hardware.

Problem Statement

Create a simple software interface for OSCAR system using Java

Deploy effective code and document versioning system

Explore available upgrade paths, both hardware and software

Ensure portability of code

Design Objectives

Create new low level IO interface for Motion Control

Verify that existing demonstrations work with new interface

Develop new demonstration capabilities

Set up system to organize all of OSCAR’s code and documentation in one repository.

Past Accomplishments

Initial, functional code base

Interface with Motion Control LM 629

Speech Capabilities via ViaVoice

Initial arm interface code

Present Accomplishments

Successful interface with sensors

Delivery of new Motion Control interface

Deployment of a versioning system

Replacement of malfunction computer

Implementation of wireless network

Transition to complete Java solution

AssumptionsAssumptions and Limitationsand Limitations

The motion control hardware on OSCAR is functional.

End-effector will be complete.

Sensors are functional and interface via RS232Sufficient resources will be available

End ProductDescription

Code and document repository for use by entire team

Code to run during OSCAR demonstrations.

Documentation detailing the operation of the OSCAR software.

Approaches Considered

Further development on Windows 98Lacks device supportDifficult to find programming resources

Upgrade to more recent Windows OSNot designed for embedded development low level interface code difficult to create

Approach Used

GNU/Linux OS based solutionGrowing use in undergraduate curriculumExtensive developer supportEmbedded versions readily availableSignificant assistance available from

community

Research Activities

OS Choice Low level IO major concern Must be easily picked up by students

Motion Control Boards Simplify Motion Control interface Expensive, must find willing donor

New, lower power computing solution Several solutions Cost major concern

Design and Implementation Activities

Re-implementation of low level IO

Re-factoring of existing software to ensure portability

Testing and Modification

Modification of existing code to ensure portability

Testing of Motion Control interface

Testing of Sensors interface

Technical Approach

Java Codebase

Sensors Hardware

Motion Control Hardware

JNI

Serial Port

I/O Card

Technical Approach

Java Codebase

Sensors Hardware

Motion Control Hardware

Java Comm API

Personnel UtilizationCurrent Hours

Original

Estimate

Revised

Estimate

Jason Olson 54 63 58

Abdul Nasir 34 64 40

Patrick Jordan 65 65 67

James Sweeney 69 61 70

Abdallah Mwita 28 64 30

Argenis Acosta 64 63 65

Resource Utilization

Item Projected Cost Actual Cost

802.11b Card $40 $0 (on loan)

Replacement Computer

Unprojected $0

Poster

(Entire Team)

$50 $50

Milestones

Configure and deploy CVS server for team use. (100% complete)

Code portable and IO tested on multiple OS’s (65% complete)

Demonstration code to run during OSCAR demonstrations (50% complete)

Future Work

Complete the arm code; dependent on arm construction

Refinement of the speech code and demonstration code

Purchase of new lower power computer

Summary

CVS deployed and populatedIO interface changed by Motion Control, new code developedPortability of code base reviewedOptions for alternate OS paths have been evaluatedWireless access, improved interfaces on the way

Lessons Learned

Importance of intra-team communication

Necessity of evaluating changes effects on whole project

The value of versioning systems in large group settings

Risks and Risk Management

Emergent circular dependency Use of redundant development paths

Team failure because of single subteam failure Created several possible development tracks that

can be pursued

Code or document loss Use of CVS with central backup

Closing Summary

Fully functioning sensors suiteMotion Control has new demonstrated functional interfaceSoftware has deployed new low level code for new Motion Control interfaceDemos will be ready after testing and revision on new low level code, returning OSCAR to a functional state

Questions?