Robotics Development Platform

Presented by:Michael CarrChristina Welk

Advisors: Dr. K. Pashin

Nikaaien

Professor Gordon Jenkins

Course: GE-492Sponsor: Z-Buffer inc.

Concept

•Modular Design•300 Pound Carrying Capacity•At Least 30 Minute Battery Life•5-25 mph Speed Range•Climbs Stairs•Fits in Buildings and Cars

•Onboard Mini ATX Motherboard•Local Data Acquisition•Real Time Reaction to Sensor Input•Speed Controller Interface•Wireless Connection to Laptop•Joystick Input

Six Sigma Tools

• Gemba • Kano Analysis• Quality Function Deployment (QFD)• Risk Mitigation• Failure Modes and Effects (FMEA)• 1 Page Scope Statement• Input Specification Requirements• Design of Experiments (DOE)

Risk Mitigation

Computer Hardware• Via ME600

– Mini ATX form factor– 600mhz fan less processor– 256 MB DDR ram– One PCI Slot– Standard ATX I/O

• Ituner 200 watt ATX to dc power supply

• Netgear MA311 802.11b PCI wireless card

• Fujitsu 20 GB hard drive• Microsoft SideWinder

USB joystick

CS Progress• All hardware

components selected• Fedora Core 2

installed on via board• CVS server set up• UML design

- Actor/goals list– Use cases– Sequence diagrams– Domain models– Class diagrams

Domain Model

Mechanical Design• Drive Train Design

• Tank Tread Design

• Batteries and Control Systems

• Heat Exchanger Design

• Suspension Design

• Structural Analysis

Drive Train Design

Briggs and Stratton EtekDC Electric Motor

• 24 – 48V

• 21 Pounds

• 1.14 in-lbf/A

• 72 RPM/V

• 89% Peak Efficiency

• 15 hp Peak Power

• 330 A max for 2 minutes

Tank Tread Design

Batteries and Control SystemsConcorde Sun

Xtender PVX-1040T AGM Sealed Battery

• 100 Ah at 20 hr rate• 66 pounds each• Group 27: 12.03” X 6.77” X 8.93”

RoboteQ AX2550 Dual Channel, Electronic Speed Controller

• Fully Digital, Microcomputer Design• Advanced Data Logging• 200 mA Idle Current Draw• 2.5 mW ON Resistance MOSFETs• 120A for 15 seconds, 80A Extended• 16kHz Pulse Width Modulation

Heat Exchanger Design

Heat Exchanger Design(cont.)

Heat Exchanger Design(cont.)

Suspension Design• Studied 3 different materials• Conducted 3 experiments todetermine stiffness, creep andabrasion properties• Based on these results,selected molded polyurethanestraps rated to 2 times their original length

• Used the ANSYS finite element analysis software package

• Examined 8 worst case scenario load cases

• Also analyzed axles for structural integrity

• Found and corrected all cases where the stresses exceeded half of the yield strength of steel

Structural Analysis

Classes UsedDirect Use• CM-410: Advanced Engineering Com.• MA-130: Calculus I• MA-140: Calculus II• MA-150: Calculus III• MA-210: Fundamentals of Linear Algebra• MA-250: Principles of Differential Equations• MA-320: Numerical Analysis• SC-235: Physics I• SC-245: Physics II• CS-190: C++ Programming• CS-270: Structured Computer Organization• CS-360: Advanced Program Design• CS-430: Data and Computer Com. Networks• CS-440: Software Engineering• CS-450: Operating Systems

Survey Use• HM-480: Moral and Ethical Issues• CM-100: Written and Oral Com.• CM-110: Scientific and Business Com.• MA-290: Discrete Structures• MA-330: Probability and Statistics• ME-350: Engineering Vibrations• GE-210: Engineering Economics

•GE-110: Engineering Graphics•GE-201: Engineering Statics•GE-202: Engineering Dynamics•GE-203: Engineering Mechanics of Materials•GE-205: Engineering Materials•GE-290: Introduction to Engineering Design•GE-305: Electrical Circuit Analysis•ME-204: Mechanics and Materials Laboratory•ME-301: Fluid Statics and Dynamics•ME-320: Heat and Mass Transfer•ME-390: Introduction to Mechanical Design•ME-415: Kinematics and Mechanisms•ME-420: Finite Element Analysis•ME-460: Introduction to Robotics

•SC-195: General Chemistry•CS-210: Data Structures and Algorithms•CS-291: Theory of Computation•CS-480: Computer System Architecture•EE-310: Microprocessor Systems•EE-360: Digital Circuit Design

Complete Budget Fall-Through

Updated Risk Mitigation:

Updated Risk Mitigation:

Complete Budget Fall-Through

Our Sponsorship Evaporated Now What?

• The design process went on hold

• Alternate projects were researched and evaluated

- Reduced design (approximately 100 pounds)

- Small design (25-50 pounds)

- Small hybrid/electric vehicle conversions

• Opted to complete a full scale prototype with slightly modified implementation details

- Single battery pack on delivery

- Sensor array to be implemented as a module

• This process, as well as the enduing redesigns, caused a massive schedule lapse

• As a result, we have failed to make almost every single deadline set at the onset of this project.

Senior Design Project Schedule, First Phase

Senior Design Project Schedule, Second Phase

Budget

ConclusionsTo date, we have:

• addressed all major design issues and concerns

• developed finished mechanical designs and domain models

• completed the development phase and are now ready to move on to implementation

“this is going to be the best prom ever”

Questions?