adtec kulim robocon workshop v2

8/11/2019 ADTEC Kulim ROBOCON Workshop v2

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ROBOCON 2008

Workshop

Facilitator: Ober Choo Sui HongCytron Technologies Sdn Bhd


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Prepared by Ober Choo

www.cytron.com.my 2

Presentation Outline

Day 1

Preparation Connector

Power

Motor

Sensor

AR40B Introduction

Packing list

Board Layout

Power Supply

Driving Motors (tires)

Encoder

Driving Relays

Digital Inputs

Analog Inputs

General Purpose Output

Programmer


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Day 2

C Programming

C template Compile and download program

AR40B description

Using AR40B (programming) Brushless motor (Linix and Vexta)

Brush motor (MD10A and MD30A)


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Day 3 Using AR40B (programming)

Relays (MD10A and MD30A)

Rotary encoder

Digital Inputs (RGB, FX301, Limit switch) Analog Inputs (Distance sensor, Ultrasonic)

Constructing a Robocon robot Assembly robot base, body and mechanism Sensor position and calibration

Writing program for line following


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Day 4

Test Run

Line following

Extra Mechanism

Modes selecting

Improvements


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Day 5 ROBOCON discussion

Game rules and strategies discussion

Robot maintenance and troubleshooting

Test run and training

Motivation

Q & A


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ROBOCON Msia and ABU

ROBOCON is an annual robotic competition in Japan for many years ago, organized by NHK

Japan. Only few country is invited to participate, Indonesia and Thailand have joined beforeyear 2002.

In 2002, ABU decided to organize ROBOCON and invite all countries of ABU to participate.

There will be two level of competition, Domestic and Asia Pacific.

Host country may send two representative teams.

Every year have different theme and rules based on the country culture and organizingcommittee.

2002(Reach to Mount Fuji, MalaysiaMMU, ABUVietnam (at Japan).

2003(Takraw Space Conqueror), MalaysiaUTM, ABUThailand (at Thailand).

2004(Reunion of Separated Lover), MalaysiaUTM, ABUVietnam (at Korea).

2005(Climb the Great Wall, Light the Holy Fire), Malaysia - UTM, ABU - Japan (at China).

ROBOCON 2006(Building the worlds Tallest Twin Tower), MalaysiaMMU, ABUVietnam (at Malaysia).

ROBOCON 2007(Halong Bay Discovery), MalaysiaUTM, ABUChina (at Vietnam).

ROBOCON 2008 (Govinda), at India


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ROBOCON 2002

Theme: REACH FOR THE TOP OF MT FUJ I

Venue: Tokyo, J apanDat e: 31st August 2002


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ROBOCON 2003

Theme: TAKRAW- SPACE CONQUEROR

Venue: Bangkok, Thai l andDat e: 24t h August 2003


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ROBOCON 2004

Theme: THE REUNI ON OF SEPERATED LOVER

Venue: Seoul , Kor ea

Dat e: 11t h Sept ember 2004


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ROBOCON 2005

Theme: CLI MB THE GREAT WALL, LI GHTTHE HOLY FI RE

Venue: Bei j i ng, Chi naDat e: 27t h August 2005


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ROBOCON 2006

Theme: BUI LDI NG THE WORLD TALLEST TWI NTOWER

Venue: Kual a Lumpur , Mal aysi aDat e: 11t h Sept ember 2006


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ROBOCON 2007

Theme: HALONG BAY DI SCOVERY

Venue: Hanoi , Vi et nam

Dat e: 26t h August 2007


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ROBOCON 2008

Theme: Govi nda

Venue: Pune, I ndi a

Dat e: 31st August 2008


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Total Development

Process (ROBOCON)

Strategies


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Understand Rules, discuss strategies

Auto Machine (MCU) Manual Machine (MCU or logic)

Divide group

Weekly update, debugging,

target and meeting

Stabilizing and training

Register and form a team

Workshop (learn technical knowledge)

Construct Robots, Write Program

Preparation for Competition

Controller, Sensor, Mechanism,

Motor, Wheel, Battery

Funding

Team work

Motivation

Dedication

Strategies

Information


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Hardware Preparation

Collect and Prepare all

hardware


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Hardware and materials

AR40B + PIC PS40B + PIC

Vexta brushless motor + Connector

Brush motor + Connector

MDX0A

Battery + Connector + Charged Rotary Encoder + Connector

FX301 + Connector, Limit Switch + Connector


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Vexta control pin


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MDX0A control pin


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FX301 control pin


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Encoder control pin


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Auto and Manual

Robot


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Auto Robots

One operation to start. Need a controller to

operate automatically.

Must fit in 1000mm x1000mm zone.

Combination of

controller, software and

mechanism.


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Manual Robot

Operated by human. Controller box is either

logic or microcontroller.

Must fit in 1000mm x1000mm zone.

Operator and mechanism

are the most important

element.


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Robots Basic Elements

ControllerSensor

Motor

BatteryMechanism


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Line Following RobotMotors and wheels (Leg)

Sensors (Eye)

Controller(Brain)

Mechanism

Battery


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Controller

Control a robot. Mostly automatic robot, manual robot mayhave controller to control simple routine work.

Controller boards: (not limited to) Handy Board

Basic Stamp Cytrons AR40B

ComputerEmbedded PC, PC or Laptop

Microcontroller: (not limited to)

PIC from Microchip 6811 from Motorola

AVR, AT89C2051 from Atmel

Must be light weight, low powered, easy to develop, easyto learn and easy to get (availability).


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Controller


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Simple factors A system will need at least a minimum hardware to work.

In this case, it involved electronics interface. There are 4 important points to take care:

Voltage

Maximum or Minimum of operating

Analog or Digital

Current

Maximum or Minimum of operating (motor)

Polarity Positive and Negative

Short circuit

Clearance of your circuit

It seem simple, but these are the famous factors for those circuit that cannot

works


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PIC Microcontroller

The Brain of AR40B


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Why PIC MCU?

Peripheral Interface Controller


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Why PIC MCU? Low cost, from RM15-RM60.

Easy to get, you can order from Cytron, Farnell, RS and evenelectronics store.

Less instructions.

PDIP Packaging. MPLAB, WinPIC, C compiler, Assembler and many software

is distributed as freeware.

Plenty of free project and sources code from Internet.

Easy to load program. large program memory space.

Low cost programmer, Bootloader and Startup Kit areavailable in market.


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PIC16F877A

40 pins package (PDIP).

35 instructions. External clock is required, maximum crystal speed is 20MHz,

Time for 1 instruction = 200ns (Crystal=20MHz)

8,092 14bit FLASHprogram memory, can be reprogrammed formore than 1,000 times. You can write 8092 lines of assembly codes.

368 8bit data memory or registers (File registers).

Interrupt capability. 33 GPIO.

Other peripherals: 8 channel 10bit ADC, USART/I2C/SPI, 16bits & 8 bits timers/counter, PWM, Compare and Capture.

Features: ICSP-In Circuit Serial Programming.

Note: Refer to Data Sheet


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PIC16F877A

PIC16F87XA datasheet pg.5


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PIC16F877As Peripherals

Different PICs have different on-boardperipherals

PIC16F877A common peripherals are: Digital I/O pins.

Analog to Digital Converters (ADC) (10bit).

Serial communications: UART (RS-232), SPI, I2C.

Pulse Width Modulation (PWM) (10bit). Timers and counters (8 and 16bit).

Watchdog timers, Brown out detect.

16 8 A i


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16F877A Pins

Diagram


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Ports (Digital I/O)

40 pins 16F877A has 5 Ports with 33 digital I/O pins.

Every port has 2 control registers TRISx sets whether each pin is an input or output.

PORTx sets their output bit levels or hold input status.

Most pins have 25mA source/sink (directly drives LEDs) What is source/sink?

WARNING: Other peripherals SHARE pins! Example: Port A share digital I/O with Analog input

Applications: Inputs: Digital sensor, push button (keyboard)

Outputs: LED, Buzzer, motor driver, LCD.

Note: Refer to Data Sheet


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TRISx and PORTx


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16F877As ADCs


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ADCs Analog Digital Converter (ADC).

Store Analog voltage in digital value.

ADC can operate during sleep mode. (internal RC clock)

10bit What does 10bit means?

Can generate an interrupt on ADC conversion done.

Page 126.

Applications: Audio volume control, temperature sensor, position sensor, ECG signal


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16F877As CCP


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CCP Modules

Capture/Compare/PWM (CCP). 10bit PWM (Pulse Width Modulation) width within 8bit PWM

period (frequency).

Some time PWM is used to give external speed for DC

brushless motor.

Normally is used to control speed of DC motor.

Applications: DAC (Digital to Analog Converter) Control speed of motor using PWM

Generate frequency pulse for stepper motor.


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PWM on PIC Registers involved:

PR2 register: PWM period

CCPR1L and CCP1CON:

10-bit duty cycle

Basic operation: Start of period

Timer TMR2 cleared

CCP1 pin set to high

10-bit duty cycle latched toCCPR1H

When TMR2 = CCPR1H

Clear CCP1 (duty cycle over)

When TMR2 = PR2

New period starts


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CCP1CON Register


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16F877As Timer


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Timers

Available in all PICs.

May generate interrupts on timer overflow.

Some 8bit, some 16bit, some have prescalers.

Can use external pins as clock in/clock out(Counting encoder motor feedback).

Warning: some peripherals share Timer resources

PWM share Timer 2 in 16F877A. Applications:

Encoder feedback from motor.


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PIC16F877A Interrupt


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Batteries


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Batteries

There are various type of battery available in the

market.

Depending on the application, we try to balance

up the weight and current needed.

The higher current capacities, the heavier battery.


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Sealed Lead Acid Following are some examples of SLA:

12V 12Ah 12V 7Ah

6V 4Ah

We can simply charge SLA with ordinary power supply


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Lithium ion Polymer (LiPo)


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Lithium ion Polymer (LiPo) Each pack is 11.1V.

Come with different capacity (800mAh, 1800mAh) No memory effect.

Advantages:

Lighter than NiMH higher current capacities

Higher discharging rate

Drawbacks: require special charger

Hazardous (will exploded if in-correct charging)

Suitable for high current application.


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Precautions

Never connect both terminal of battery together. It

will spoil the battery.

Be careful when using or charging LiPo battery.

Lets see video of Lipo overcharge.


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Q & A

Batteries


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Programming

MPLABPICC Lite


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MICROCHIP MPLAB IDE


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Installation of MPLAB IDE

PICC Lite


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How to use MPLAB IDE?1. Install and run the MPLAB IDE, you can see the

screen as below.


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How to use MPLAB IDE?1. Since we are using PICC Lite, please refer to

another file for PICC Lite

PICC Lite


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MPLAB IDE & PICC Lite

Any Question???

If no, we will proceed with

Assembly Language and realprogramming

AR40B


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AR40B

Autonomous Robot

Controller


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AR40B Enhanced version of AR40A.

Utilize all 33 I/O pins of PIC. Industrial grade PCB with heavy copper material.

On board USB programmer.

ZIF (Zero Insert Force) socket for ease of changing PIC.

Fully compatible for 40 pins PIC such as PIC16F877A or PIC18F452. 8 relays output with maximum current allowed up to 10 Amp to control

4 motors in 2 directions.

External port for 30 Amp motor driver (MD30A).

Able to drive Oriental AXH series and LINIX series of brushless motor.

Up to 8 digital inputs and 3 analog inputs which can be connected tovarious kinds of sensors and switches.

3 input push button.

15mm x 25mm expandable zone is prepared for additional circuit and

advance application.


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AR40B


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AR40B

Going through AR40B Instruction Manual

Power

Driving motors

Relays

Rotary Encoder

Digital Inputs Analog Inputs

Programmer

AR40Bs


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Pin Assignments


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Practical +

Assignments

Using AR40B


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Assignments

Before we can operate AR40B, we mustensure it is properly connected andpowered up.

Connect necessary components tooperate AR40B.

Try to connect power for motor, connect

a brushed motor, try to operate motorwith relay.


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Loading Program

On Board Programmer


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Programming of Robots

components

Controlling Brushless Motor

Controlling Brush Motor

Assignments


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Motors

Main driver for robot

mechanism


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AR40B - Two methods (Tires)

Either Brush motor + MDX0A

Or Brushless Motor (Vexta or Linix)


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Motors DC brush, DC brushless, Servo, Stepper.


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Using Brushless Motor


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Vexta Brushless Motor Simple interface (logic 0V or 5V), speed output,

driver protection, variable speedand variable gearratio.

Each set included motor, gear, driver and manual.

3 types of power, 50W, 30W and 15W.

Around RM1+++.00 each set.

Weight: 50W=1.8kg, 30W=1.0kg, 15W=0.5kg

Maximum speed of motor = 3000 rpm

24V


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Oriental DC Brushless Motor

Motor Driver

Motor

Gear Head


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DC brushless Control

START, RUN, CW and INT.VRare the 4 driver

inputs that we normally control.

It can be control with direct connection to PIC

output pins (logic-5V or 0V) or switches (manualmachine).

Note:No pull-up resistoris required.


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DC Brushless with Switches


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DC Brushless with uC


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DC Brushless Outputs

There are 2 outputs from DC Brushless Driver

which can be connected to PIC for feedback(close loop control).

Alarm Output (Pin 1) and Speed Output (Pin 2). Output drainPull-up resistoris required.

Note: Be careful with pull-up resistor, it should

be > 5K.

DC Brushless

O C i


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Outputs Connection5V

5K-10K

Alarm Output

Speed Output

Motor Driver

Counter or

Digital Inputs

Microcontroller

DC Brushless

M S d (I l)


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Motor Speed (Internal) There are 2 options for motor speed, internal variable

resistor voltage or external voltage. If internal speed is required, the INT.VR (Pin 8) must be

pulled low.

DC Brushless

M t S d (E t l)


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Motor Speed (External)

External speed maybe applied if the INT. VR

is high (5V).

The are 2 ways, either by connecting a external

variable resistoror connect an external DCpower supply.

DC Brushless

M t S d (E t l)


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DC Brushless

M t S d (E t l)


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DC Brushless

G d T


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Gear and Torque


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DC Brushed Motor


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DC Brushed Motor

Using MDX0A

with Brush motor


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with Brush motor

MD10A


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MD10A

GndPWMCWRUN12V

battery

Motor

MD30A


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MD30A

MD30A


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MD30A


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AR40B

Controlling Driving Motors


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Controlling Driving Motors

Group 1Switch 1 to activate left motor, switch 2 toactivate right motor, switch 3 to stop both motor.

Group 2Switch 1 to activate left motor withminimum speed, switch 2 to increase speed, switch 3

to decrease speed Group 3Switch 1 to activate 2 motors, switch 2 to

change direction (forward), switch 3 to changedirection (backward)

Group 4Switch 1 to activate 2 motors, switch 2 tochange direction (turn left), switch 3 to changedirection (turn right).


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Day 2 - Completed

We continue tomorrow morning

sharp at 9.00 am


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Day 3

Relays

Rotary Encoder

Digital Inputs

Analog Inputs

Driving brush

motors for mechanism


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motors for mechanism

Relays

MD10A

MD30A

Relays


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Relays Allow high current application, can be a switch.

Various combination (poles and throws), various

activation voltage (5V, 6V, 9V, 12V, 24V),

various size, various price.. Can be applied on logic circuit (without uC,

manual controller box).

Control motor direction, but not speed.

Relays


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Relays

Single Pole Double Throw Single Pole Single Throw

Relays


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Relays Bottom view

Double Pole Double ThrowSingle Pole, Double Throw

DPDTSPDT

How to control

motor with Relays


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motor with Relays

1 SPDT relay could only control 1 motor for ON

or OFF.

How aboutbi-directional control of motor? Must use at least 2 SPDT relays.

Schematic of

Relays Control Motor


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Relays Control Motor


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Q & A

Motors

Assignments


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Assignments Brushless motor activation with switch

Brushless motor activation from sensor

Brushless motor speed change with switch

Brushless motor direction with switch DC brush motor with switch

DC brush motor with sensor Using MDX0A


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Encoder

Rotary encoder

Rotary Encoder


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Prepared by Ober Choowww.cytron.com.my 113

y

Rotary Encoder


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y Simple interface (3 pins), 5V to 24V, 500 pulse per

rotation, open drain output (must pull-up and can beany voltage).

5V to 24V

Gnd

Signal

Rotary Encoder


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y AR40B provide option to use internal encoder from

DC brushless driver or external rotary encoder. Connected to RA4 and RC0 of PIC.

Use counter (timer0 and timer1) to accumulate the

pulse.

Calculate robot distance.

Rotary Encoder


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y Connecting rotary encoder to AR40B.

Please move the jumper to EXx.

AR40B - Assignment


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g

Group 1 & 2Switch 1 to activate robot, stoprobot when encoder 2 reach 500 pulse (equal to1 rotation)

Group 3 & 4Switch 1 to activate robot,activate MOTOR1 if encoder 1 reach 750 pulse

ExtraUsing encoder from Vexta brushless

motor Making interrupt for encoder


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Digital Inputs

limit switch, photoelectric

sensor, fiber optic sensor, RGB

SensorU i f b d i f ll k


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Use to sense environment of robot and as input for controller to makedecision.

Switches Limit switch

Push button

Detect object with touch Example: wall, gift(2004), pole(2005), block (2006), island (2007)..

Proximity sensor CX-422 from SUNX

FX-301 from SUNX

Detect object with a distance without touching

Can be used to detect color, line tracking, and also object.

There are other type of sensor, for example: camera.

However we must consider the ease to operate, ease to interface andavailability.

Limit switch


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Normally Close

Normally Open

Common

Photoelectric and

fiber optic Sensors


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SUNX CX-422 Infrared Sensor


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Simple interface (3 pins), 12V to 24V, 80cm

distance, open drain output (must pull-up and can beany voltage).

Is only logic level, therefore no filterrequired.

SUNX CX-422

Photoelectric Sensor


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Can be changed to active high or active low operation.

Adjustable sensing distance.


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FX-301


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FX-301


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Calibration is very important if FX-301 is used

Basic calibration will involve mounting of sensor,threshold setting and testing

Lets see how can we calibrate it


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AR40B - Assignment


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Group 1Switch 1 to activate MOTOR1, SEN1 to

Change direction, SEN2 to stop MOTOR1. Group 2Switch 1 to activate MOTOR2, SEN3 to

stop MOTOR2, SEN4 to activate MOTOR3.

Group 3Switch 1 to activate MOTOR1 andMOTOR2, SEN5 to change direction of MOTOR1,SEN6 to activate MOTOR3.

Group 4

Switch 1 to activate ALL MOTOR, SEN7to stop MOTOR1 and 2, also change direction ofMOTOR3 and 4, SEN8 to stop all MOTOR.

How about ADC?ff l i


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AR40B offers 3 analog inputs

Where can it be used?

How to use it?

Using distance sensorSh ff h d d di


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Sharp offer cheap and good distance sensor

There are several models

Sharp GP2D120 (4cm to 30cm)

Analog output 4.5 to 5V operating voltage

Connecting to AR40BI t t i lt d t i


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Important is voltage and correct pin.

Since is 5V powered, just match the pin.

AR40B Analog input

+

S

-

GP2D1200 4V at 30cm


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0.4V at 30cm

2.8V at 4cm


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Lets Try

Convert ADC to distance (cm)

Using Ultrasonic 42kHz Ultrasonic sensor


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42kHz Ultrasonic sensor

Operates from 2.5-5.5V Low 2mA supply current

20Hz reading rate

RS232 Serial Output - 9600bps

Analog Output - 10mV/inch

PWM Output - 147uS/inch

Small, light weight module

Connecting to AR40B


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AR40B Analog input

+S

-


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Lets Try

Convert ADC to distance (inch)

AR40B - Assignmenti h i b h h


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Group 1Switch 1 to activate robot, ADC1 to change the

speed. Group 2Switch 1 to activate MOTOR1,

If ADC2 > 2.6V, CW

If ADC2 < 2.4V, CCW

If 2.4V


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Q & A

Sensors


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Day 3 - Completed

We continue tomorrow morning

sharp at 9.00 am


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Day 4

Line Following Robot

Sensor calibration

Write program

Combining all components Use AR40B to write program:


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Use AR40B to write program:

Limit switch to start Brush motor Increased Brushless Motors speed slowly (time)

Increased Brushless Motors speed base on ADC

Change Brush Motor direction based on Limit switch

Infrared sensor to stop Brush motor

Encoder to stop Brushless motor

Counter to stop DC brushless motor

Extra: Pivot robot with limit switch status

Constructing a Robot1 Assembly robot base body and mechanism


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1. Assembly robot base, body and mechanism.

2. Sensor position and calibration

3. Robot testing and fine tuning


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Line following algorithm

Li f ll i i i t t i ROBOCON


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Line following is important in ROBOCON.

Try to write a program to simulate line

following.

Line Following RobotMotors and wheels (Leg)


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Sensors (Eye)

Controller(Brain)

Mechanism

BatteryHow to integrate all the componentstogether ; the controller, actuator and

sensors?

Line Following Robot


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Sensors

Left or Middle or Right

sensor triggered

Controller Algorithm process theInputs / sensors reading

Actuators Move direction based

on algorithm written

Line Following RobotFlow chart for 3 line sensors

Start E d


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Start

Middle

Sensors?

TurnLeft

YesRight

Sensors?

No

Left

Sensors?No

No

Error

End

Turn

RightYes

Moving

ForwardYes

Assignment!


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g

Write simple code for line

following!

Line Following Improvement Averaging sensor reading


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Averaging sensor reading

Counting cross

Apply PD control

Combining encoder

Mechanism Require mechanical design.


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You are free to design, be creative! Pneumatic

Motor actuators

Momentum

Spring and rubbers

Reliability Dont stop improving your design and testing.

Learn! Renovate! Improve! But dont copy from the othersdesign!

Modes You can write program for several modes


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You can write program for several modes

By using push button

Write program for team A and team B


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Improvements


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Day 4 - Completed

We continue tomorrow morningsharp at 9.00 am


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Day 5

ROBOCON 2 8 discussion

Robot Maintenance and Troubleshooting

Training

Motivation


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ROBOCON 2008 Discussion

ROBOCON 2008 Game Rulesmust be very familiar and understand

correctly


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correctly. Read and understand FAQ

Ask organizer if you have any doubt

Game strategies

Be creative and dare to try Example, Japan, China, Malaysia and Vietnam.

Task distribution and weekly meeting (short and serious).

Collect information (technical and strategies).

Plan budget wisely.

Training, Training and Training.

Robot Maintenance

and Troubleshooting


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Robot Maintenance

and Troubleshooting Take care your robot like your precious.


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Create a check list for your robot. Possible reasons for non working robot:

Power supply

Hardware Interfacing

Software Algorithm

Components failure (PIC, motor, relays, sensoretc)

Test Run and Training


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Motivation


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Objective and Mission Give your commitment to ROBOCON.


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Dont stop improving your robots. No excuses.

Show that we love Malaysia and do our best toshow other countries we are a strong country.


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Thank You

Q & A

Please!


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Problem/s cannot be solved?

Contact Cytron Technologies at:

[email protected]

Or

Log in to our forum at

www.cytron.com.my

adtec kulim robocon workshop v2

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