how to build intelligent machines teaching mechatronic...

Teaching Mechatronic Engineers how to build intelligent machines

at Curtin University of Technology,at Curtin University of Technology,Perth, Western Australia (1995Perth, Western Australia (1995--20020066))

Students & Projects supervised byStudents & Projects supervised byDr Sam Cubero, PhD, BE Dr Sam Cubero, PhD, BE MechMech (Hons)(Hons)

Email: Email: s.cubero@curtin.edu.aus.cubero@curtin.edu.auWebsite: Website: www.mechwww.mech--eng.curtin.edu.au/staff.eng.curtin.edu.au/staff.cfmcfm

(most of these slides are actually playable movies)

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Objectives�� To describe & demonstrate important types of To describe & demonstrate important types of

tools & technologies useful to machine designers, tools & technologies useful to machine designers, automation engineers & control specialistsautomation engineers & control specialists

�� To show many different kinds of interesting & To show many different kinds of interesting & fascinating inventions, robots & tools that can be fascinating inventions, robots & tools that can be used to solve a variety of real world problemsused to solve a variety of real world problems

�� To highlight very low cost projects designed & To highlight very low cost projects designed & built by engineering students at Curtin University built by engineering students at Curtin University of Technology, Perth, Australia, from 1998of Technology, Perth, Australia, from 1998--2005.2005.

�� Describe Problem Based Learning (PBL) to help Describe Problem Based Learning (PBL) to help most most Mechatronic Mechatronic Engineering students become Engineering students become their own best teachers; creative & effective at their own best teachers; creative & effective at finding, solving or even identifying problems.finding, solving or even identifying problems.

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Topics�� What is What is mechatronicsmechatronics engineering?engineering?�� Example of a Example of a mechatronic mechatronic engineering projectengineering project�� Mechatronics Mechatronics at Curtin University (Australia)at Curtin University (Australia)�� Mechanical design (with CAD & CAM)Mechanical design (with CAD & CAM)�� Manufacturing & automation systemsManufacturing & automation systems�� Software design & data communicationsSoftware design & data communications�� Electric, pneumatic & hydraulic actuatorsElectric, pneumatic & hydraulic actuators�� Sensors, machine vision & laser measurementSensors, machine vision & laser measurement�� Mobile vehicles, field robotics, flying robotsMobile vehicles, field robotics, flying robots�� Handy tips for Problem Based Learning (PBL)Handy tips for Problem Based Learning (PBL)

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What is mechatronics engineering?�� As the name suggests, As the name suggests, mechmechatronicsatronics combines certain combines certain

skills from skills from mechamechanical and elecnical and electronicstronics engineering.engineering.�� Definition:Definition: MechatronicsMechatronics is the science & practice ofis the science & practice of

designing, building, controlling and communicating designing, building, controlling and communicating with devices, machines and automation systems that with devices, machines and automation systems that move or control physical variables; it involves move or control physical variables; it involves deep deep understanding & skill to control physical variablesunderstanding & skill to control physical variables such such as position, tilt, speed, flow rate, timing, temperature, as position, tilt, speed, flow rate, timing, temperature, force, torque, pressure, current, volts, data signals, etc.force, torque, pressure, current, volts, data signals, etc.

�� It is a It is a multimultidisciplinary applied science requiring a wide disciplinary applied science requiring a wide range of knowledge & skills in the fields of: range of knowledge & skills in the fields of: machine machine design, materials, load & stress analysis, robotics, design, materials, load & stress analysis, robotics, manufacturing, electronics, manufacturing, electronics, microcontrollersmicrocontrollers, PC , PC programming, motion control & mathematics.programming, motion control & mathematics.

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What do mechatronics engineers do?�� Mechatronics Mechatronics engineers are presented with engineers are presented with

different types of automation and control different types of automation and control problems to solve problems to solve –– sometimes this requires sometimes this requires design or prototyping of machines & control design or prototyping of machines & control systemssystems that have never been built before.that have never been built before.

�� They must be They must be highly knowledgeable, hard highly knowledgeable, hard working & imaginativeworking & imaginative in order to in order to conceive & conceive & achieveachieve successful, lowsuccessful, low--cost solutions.cost solutions.

�� He/she needs to have a highly “He/she needs to have a highly “connectiveconnective”, ”, curiouscurious & & creative mindcreative mind, (working “hands on” , (working “hands on” with development tools and building with development tools and building hardware) in order tohardware) in order to turn ideas into reality!turn ideas into reality!

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�� 11stst and and foremostforemost, , mechatronicsmechatronics engineers use their engineers use their ideas, ideas, skills, knowledge & toolsskills, knowledge & tools to to control variables and solve control variables and solve many types of automation and motion control problems many types of automation and motion control problems by by developing new hardware, software and/or controllers.developing new hardware, software and/or controllers.

�� What is control? What does motion control involve?What is control? What does motion control involve?�� Definition:Definition: Control involves making variable(s) adopt Control involves making variable(s) adopt

certain value(s) that you want in order to achieve goals.certain value(s) that you want in order to achieve goals.�� eg. We want variable eg. We want variable xx to reach a target value quickly!to reach a target value quickly!�� Actual value measured by sensor Actual value measured by sensor xx , Velocity = , Velocity = dxdx//dt dt = = vv�� Target value = Reference = Desired value you set = Target value = Reference = Desired value you set = xxtt�� ++ Error = What you want to minimise = Error = What you want to minimise = xxee = = xxtt –– xx�� ++ Force = Force = F = KF = KPP xxee –– KKDD vv : Simple PD law serves to : Simple PD law serves to

drive an actuator (which can change or drive an actuator (which can change or ⇑⇑ or or ⇓⇓ xx ) so that ) so that xxee can be minimized towards zero as quickly as possible.can be minimized towards zero as quickly as possible.

What do mechatronics engineers do?

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PART 1 (1 hour)Mechanical Design & Manufacturing

�� Designing & building new & useful products Designing & building new & useful products and hardware from raw materialsand hardware from raw materials

�� StateState--ofof--thethe--art 3D CAD/CAM/CAE art 3D CAD/CAM/CAE software: eg. Inventor, software: eg. Inventor, MasterCAMMasterCAM, , SolidWorksSolidWorks, ANSYS, , ANSYS, CosmosWorksCosmosWorks

�� CNC Milling/Lathe turning, 3D PrintingCNC Milling/Lathe turning, 3D Printing

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Example of a Mechatronic Eng Project: STIC Insect, by Sam Cubero (1994-97)

Designed with AutoCADTM

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Pneumatic actuator (position control)

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Pneumatic steering joint for a robot leg

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Knee joint flexing

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STIC Insect robot standing up

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STIC Insect robot crouching lower

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STIC Insect robot (natural) instability

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STIC Insect Leg control testing

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STIC Insect robot simulation in 3D

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3D Simulation demonstration

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STIC Insect robot in a forward walk gait

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STIC Insect walking robot (first steps)

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STIC Insect clinging to ceiling

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Mechatronics at Curtin University�� The Department of Mechanical Engineering at The Department of Mechanical Engineering at

Curtin University currently manages a highly Curtin University currently manages a highly successful successful Mechatronic Mechatronic engineering degree engineering degree program that prepares students for solving almost program that prepares students for solving almost any type of machine design, motion control & any type of machine design, motion control & automation problem imaginable.automation problem imaginable.

�� Curtin University Curtin University Mechatronics Mechatronics students spend students spend much of their time much of their time working on real world working on real world problems; usingproblems; using statestate--ofof--thethe--art hardware & art hardware & software development tools and learning useful software development tools and learning useful techniques techniques which can be applied in industrywhich can be applied in industry

�� Emphasis is on Emphasis is on developing practical skills while developing practical skills while promoting creative, independent thinking abilitypromoting creative, independent thinking ability

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Mechatronics at Curtin University�� So far, about 95% of our graduate students have So far, about 95% of our graduate students have

been able to find suitable work within 6 months been able to find suitable work within 6 months after their graduation; student enrolments have after their graduation; student enrolments have more than doubled in numbers over 10 yearsmore than doubled in numbers over 10 years

�� The knowledge, experience and skills of ourThe knowledge, experience and skills of ourmechatronicmechatronic engineering academic staff, engineering academic staff, developed through much hard work, tenacity & developed through much hard work, tenacity & perseverance, places us in an excellent position perseverance, places us in an excellent position to conduct new & innovative “world first” to conduct new & innovative “world first” research in almost any area of research in almost any area of mechatronicsmechatronics..

�� The following slides show examples of typical The following slides show examples of typical Mechatronic Mechatronic projects & research (1998projects & research (1998--2005) 2005) and actual teaching assignments & projects.and actual teaching assignments & projects.

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Mechanical design (with CAD & CAM)�� AutoCADAutoCADTMTM (2D drawing & 3D), parametric (2D drawing & 3D), parametric

solid modelling with AutoDesksolid modelling with AutoDesk InventorInventorTMTM

�� Selecting fits, Dimensioning & Selecting fits, Dimensioning & tolerancingtolerancing�� Material properties, stress analysis, FEA, Material properties, stress analysis, FEA,

beam design & analysis, combined loading & beam design & analysis, combined loading & failure analysis, design against fatigue failure failure analysis, design against fatigue failure & buckling, power transmission design, & buckling, power transmission design, roller/ball bearings, vibration, dynamics, roller/ball bearings, vibration, dynamics, statics, kinematics, robot inverse kinematicsstatics, kinematics, robot inverse kinematics

�� CAD/CAM (eg.CAD/CAM (eg. MasterCAMMasterCAM) ) toolpathtoolpathgeneration & CNC machining with multigeneration & CNC machining with multi--axis axis mill & lathe, manufacturing processesmill & lathe, manufacturing processes

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22ndnd year year Engineering Graphics 321Engineering Graphics 321 (12.5 cp) 12 weeks(12.5 cp) 12 weeks�� Syllabus: AutoCAD 2D & 3D solid modelling, Syllabus: AutoCAD 2D & 3D solid modelling,

Microsoft Word (Drawing Tool, Equation Editor) Microsoft Word (Drawing Tool, Equation Editor) &Excel (Charts); Eng. drawing, dimensioning, fits, Excel (Charts); Eng. drawing, dimensioning, fits, tolerancing tolerancing standards, tolerance loop analysis; Intro standards, tolerance loop analysis; Intro to 3D Inventor solid modelling & to 3D Inventor solid modelling & MasterCAMMasterCAM

�� Weekly teaching pattern: 2 hour lecture & 3 hour Weekly teaching pattern: 2 hour lecture & 3 hour AutoCAD lab; all drawing skills are demonstratedAutoCAD lab; all drawing skills are demonstrated

�� Assessments: 10 x 2D drawings, 5 x 3D drawings, Assessments: 10 x 2D drawings, 5 x 3D drawings, SemesterSemester- -long 3D design project as a User Manual long 3D design project as a User Manual +detail drawings (Design report on a 2 degreedetail drawings (Design report on a 2 degree--ofof--freedom device/machine to perform a useful task;freedom device/machine to perform a useful task; nofewer than 7 unique & necessary components)fewer than 7 unique & necessary components)

Mechanical design (with CAD & CAM)

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�� Example: 2 Example: 2 dof dof DualDual--spring spear launcherspring spear launcherEngineering Graphics 321 project

Example project concept & model by Sam Cubero, created using AutoCAD 2002

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View showing launcher carriage fully retracted View showing launcher carriage fully retracted by purple hydraulic extension cylinderby purple hydraulic extension cylinder

Engineering Graphics 321 project example

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�� Example: 2 Example: 2 dof dof DualDual--spring spear launcherspring spear launcher�� 33rdrd angle orthographic views & 3D viewangle orthographic views & 3D view

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Trigger mechanism locked on piston (Trigger mechanism locked on piston (wireframewireframe))

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�� Release mechanism for launching spearRelease mechanism for launching spear

Back of spear

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Mechanical design (with CAD & CAM)�� InventorInventorTMTM model of model of BossongBossong welding robotwelding robot

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Mechanical design (with CAD & CAM)Animation of X-axis assembly, Peter Sotiroski, Curtin University 2002

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Mechanical design (with CAD & CAM)�� Assembly procedure animated by InventorAssembly procedure animated by Inventor

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Mechanical design (with CAD & CAM)�� PiePie--making machine showing operationmaking machine showing operation

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Hardwired sequential control circuit

�� Pneumatic control circuit for sequence controlPneumatic control circuit for sequence control

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Mechanical design (with CAD & CAM)�� Many exams & assignments are based on real world Many exams & assignments are based on real world

hardware; eg. Chairlift transmission design: select a hardware; eg. Chairlift transmission design: select a suitable motor, safe tube section & do failure analysissuitable motor, safe tube section & do failure analysis

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33rdrd year year Mechanical Design 335Mechanical Design 335 (25 cp); 12 weeks(25 cp); 12 weeks�� Syllabus: Force & Moment equilibrium analysis for 2D/3D Syllabus: Force & Moment equilibrium analysis for 2D/3D

loads acting on a free body diagram; basic eng. material loads acting on a free body diagram; basic eng. material properties (stress/strain), stress states (uniaxial, biaxial), properties (stress/strain), stress states (uniaxial, biaxial), beam theory, SFD, BMD, Von Mises & FEA yield analysis, beam theory, SFD, BMD, Von Mises & FEA yield analysis, combined loading, fatigue failure, deflection (M/EI), shaft combined loading, fatigue failure, deflection (M/EI), shaft design, buckling failure, roller/ball bearings, weld analysis, design, buckling failure, roller/ball bearings, weld analysis, motor/actuator selection based on force/torque & reflected motor/actuator selection based on force/torque & reflected inertia calculations, common machine components & inertia calculations, common machine components & manufacturing processes, dimensioning/manufacturing processes, dimensioning/tolerancing tolerancing fitsfits

�� Weekly teaching: 2 hour lecture & 2 hour tutorial Weekly teaching: 2 hour lecture & 2 hour tutorial Assessments: SemesterAssessments: Semester--long design project (1 long design project (1 dof dof mechanism per team member) + 3 hour final Exammechanism per team member) + 3 hour final Exam

Mechanical design (with CAD & CAM)

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Deflection &Stress Analysis using ANSYS

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Manufacturing & automation systems�� MechatronicsMechatronics also involves the manufacture or also involves the manufacture or

prototyping of machines and automation systems.prototyping of machines and automation systems.Mechanical & Manufacturing lecturers are skilled in Mechanical & Manufacturing lecturers are skilled in the following areas & even teach these topics…the following areas & even teach these topics…

�� Manufacturing & machineManufacturing & machine--shop processes: Lathe shop processes: Lathe turning, milling, metrology, precision grinding, turning, milling, metrology, precision grinding, tapping/threading, boring, drilling, sheet bending, tapping/threading, boring, drilling, sheet bending, oxy & arc welding (MMAW, MIG), soldering, PCB oxy & arc welding (MMAW, MIG), soldering, PCB design & manufacture, foundry practices, casting, design & manufacture, foundry practices, casting, mould & pattern making, plastics manufacturing, mould & pattern making, plastics manufacturing, PM, STL, 3D printing, CAM, CFRP, ceramics, etc.PM, STL, 3D printing, CAM, CFRP, ceramics, etc.

�� If students don’t know how to manufacture a part, If students don’t know how to manufacture a part, they have little chance of designing it properly!they have little chance of designing it properly!

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�� MasterCAMMasterCAMTMTM toolpathstoolpaths for CNC machiningfor CNC machiningManufacturing (with CAD & CAM)

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�� MasterCAMMasterCAMTMTM toolpathstoolpaths for CNC machiningfor CNC machiningManufacturing (with CAD & CAM)

Actual products created using Actual products created using MasterCAMMasterCAMTMTM

Manufacturing (with CAD & CAM)

CNC Lathe example

2D & 2.5D CNC Milling

Beer bottle opener

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�� MasterCAMMasterCAMTMTM toolpathstoolpaths for CNC machiningfor CNC machiningManufacturing (with CAD & CAM)

Aluminiumblock millingsimulation

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Manufacturing (with CAD & CAM)

3D surface milling example: contouring, pocketing, projected letters & engraving; designed in MasterCAM

Steel V-block Turned SteelPlumb bob

Aluminium block

Examples of products that can be designed & milled out using CAM

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Manufacturing (with CAD & CAM)2D construction sketches are positioned accurately in 3D.

Centre hub is a simple revolution of a half section (closed area), with holes & countersinks added.

Sharp edges are removed by localised filleting of edges and curves. MasterCAM analyses model & generates toolpaths based on tools user specifies.

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Manufacturing (with CAD & CAM)2D construction geometry is created for 1 “spoke”, lofts & sweeps are used to create the solid, then the 4 other spokes are copied in a polar array. Rim is a simple revolution.

Block is chosen, 2 roughing cuts, 1 finishing cut and 1 final pencilling cut to sharpen edges.

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Manufacturing (with CAD & CAM)

Actual wheel pattern modelled & machined by MasterCAM

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Manufacturing (with CAD & CAM)

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Manufacturing (with CAD & CAM)

Complex 3D solids can be modelled using extrusions, “Coon” surfaces, sweeps, lofts and revolved shapes.

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Manufacturing (with CAD & CAM)

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Manufacturing (with CAD & CAM)

3D Laser Scanned face in STL format for machining a mould on a CNC milling machine; vacuum forming is used to force hot soft plastic sheet over mould.

Comfortable, custom fitted face masks are made using plastic formed by machined moulds. eg. to keep faces of cancer patients very still during radiation treatment to kill brain tumors/cancers.

Courtesy of Bob Gilbert & Sir Charles Gardner Hospital,Perth, Western Australia

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Manufacturing (with CAD & CAM)

Most 3D CAD software can export STL file formats for importing into MasterCAM

Mask & holes for eyes, nostrils & mouth are cut outFace mask is made in 40 minutes rather

than 1 day using conventional plaster methods.

Patients are spared from uncomfortable & slow plastering procedures; scanning is fast!

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SolidWorks SolidWorks & 3D Printing (courtesy of & 3D Printing (courtesy of InterCADInterCAD))Manufacturing (with CAD & CAM)

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Manufacturing (with CAD & CAM)Robot hand designed with SolidWorks & created with a 3D Printer

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Manufacturing (with CAD & CAM)Robot hand designed with SolidWorks & created with a 3D Printer

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Printed Circuit Board design & manufacture�� 17 Downloader & Serial communications boxes for the17 Downloader & Serial communications boxes for the

MechatronicsMechatronics Studio to Studio to optoisolateoptoisolate & protect lab PCs& protect lab PCsAccessory board

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PCB design & manufacture�� Designed onDesigned on ProtelProtelTMTM CAD softwareCAD software�� DoubleDouble--sided PCB for AVR 8535: w/ 8 sided PCB for AVR 8535: w/ 8

ADCs, 3 timers/counters, 2 PWM, ADCs, 3 timers/counters, 2 PWM, UART, Flash ROM, 40 I/O pinsUART, Flash ROM, 40 I/O pins

�� Useful for many control applicationsUseful for many control applications

Motor driver circuit

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PART 2 (2 hours)Actuators, Controllers & Sensors

�� PLCsPLCs, PC computer control, microcontrollers, PC computer control, microcontrollers�� Common software programming languages & Common software programming languages &

useful hardware & software tools for control useful hardware & software tools for control (open & closed(open & closed--loop) & data communicationsloop) & data communications

�� Actuators (electric, pneumatic, hydraulic), Actuators (electric, pneumatic, hydraulic), controllers (hardwired or programmable), controllers (hardwired or programmable), sensors (proximity, vision, laser rangesensors (proximity, vision, laser range--finders)finders)

�� Hints & tips for achieving impressive learning Hints & tips for achieving impressive learning outcomes & skills development through PBLoutcomes & skills development through PBL

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�� eg. PLC (Programmable Logic Controller) system: eg. PLC (Programmable Logic Controller) system: FESTOFESTOTMTM STL “Statement List”, Ladder diagram & STL “Statement List”, Ladder diagram & SCADA are used to control modular pickSCADA are used to control modular pick--andand--place place robots & pneumatic/hydraulic actuators, monitor robots & pneumatic/hydraulic actuators, monitor sensor status and respond to control button inputssensor status and respond to control button inputs

Manufacturing & automation systems

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Software design & data communications�� Curtin Curtin MechatronicsMechatronics engineering students are engineering students are

exposed to modern software & development exposed to modern software & development tools so they can design useful, realtools so they can design useful, real--world world machinery, machinery, mechatronicmechatronic products and systemsproducts and systems

�� eg. Development languages & tools such as: eg. Development languages & tools such as: C/C++, Visual Basic, BASCOM, C/C++, Visual Basic, BASCOM, CodeVisionCodeVisionC, Java, STL, Ladder, Assembly (HC12 & C, Java, STL, Ladder, Assembly (HC12 & AtmelAtmel AVR), AVR), MatlabMatlab//SimulinkSimulink, , LabviewLabview, etc., etc.

�� Data communications methods are also used Data communications methods are also used by students in major projects: USB, Ethernet by students in major projects: USB, Ethernet TCP/IP, RSTCP/IP, RS--232/422/485, 802.11b/g 232/422/485, 802.11b/g WiFiWiFi, , 1394 1394 FirewireFirewire, Bluetooth, , Bluetooth, DevicenetDevicenet, etc., etc.

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Software design & data communications�� MotionMotion--capture data glove using the HC11capture data glove using the HC11

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Software design & data communications�� Using a PC to read brightness data from a CCD lineUsing a PC to read brightness data from a CCD line--

scan array chip (AVR assembly language & RSscan array chip (AVR assembly language & RS--232 232 MSMS--CommComm control), eg. Minicontrol), eg. Mini--vision systemsvision systems

�� Reading & analysing serial colour/Reading & analysing serial colour/bwbw image data image data from a 2D CCD camera (using any video source in from a 2D CCD camera (using any video source in Windows, eg. using DirectShow, VB vision DLLs)Windows, eg. using DirectShow, VB vision DLLs)

�� TCP/IP (eg. MSTCP/IP (eg. MS--Winsock) & UDP to send data Winsock) & UDP to send data between any 2 LAN computers (eg.between any 2 LAN computers (eg.XPortXPort & & WiPortWiPort))

�� SCADA, Statement List, Ladder PLC programmingSCADA, Statement List, Ladder PLC programming�� RS232, RS422, RS485/CAN, USB, TCP/IP, UDP, RS232, RS422, RS485/CAN, USB, TCP/IP, UDP,

Bluetooth & 802.11b/g wireless communications etc.Bluetooth & 802.11b/g wireless communications etc.�� Creating userCreating user--friendly “GUIs” (Graphical User friendly “GUIs” (Graphical User

Interfaces) for intuitive PC control, using QBasic, Interfaces) for intuitive PC control, using QBasic, Turbo C, Turbo C, MatlabMatlab, Visual Basic or C++, .NET, Delphi, Visual Basic or C++, .NET, Delphi

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�� Students are shown realStudents are shown real--world examples of openworld examples of open--loop & closedloop & closed--loop control systems, PID software loop control systems, PID software programming (numerical nonprogramming (numerical non--linear), adaptive linear), adaptive control, state space representation; mathematical control, state space representation; mathematical modelling & computer simulation methods are used modelling & computer simulation methods are used to simulate & control position, speed, force, etc.to simulate & control position, speed, force, etc.

�� The same principles of feedback control can be The same principles of feedback control can be applied to almost any type of actuator (pneumatic, applied to almost any type of actuator (pneumatic, electric or hydraulic) & those not even invented yet!electric or hydraulic) & those not even invented yet!

�� Mechatronic Mechatronic Automation 321 class requires all Automation 321 class requires all students to write their own dynamic computer students to write their own dynamic computer graphics simulation to control the position, velocity graphics simulation to control the position, velocity and force of a pneumatic piston using a realistic and force of a pneumatic piston using a realistic model; theory & methods were developed by John model; theory & methods were developed by John Billingsley & Sam Cubero during 1994Billingsley & Sam Cubero during 1994--1997.1997.

Electric, pneumatic & hydraulic actuators

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Real-time air cylinder simulation

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Real-time air cylinder simulation

Hydrobug: 6-legged & 4-wheeled robotWalking & driving simulations prove this design to be technically feasible & controllable as a passenger vehicle

Feet can be placed automatically if surface geometry is known

Hydrobug: 6-legged & 4-wheeled robotHydraulic circuit for controlling 18 independent cylinders & 4 motorsof the Hydrobug (1 leg was built & is now under computer control)

20 hp Petrol Engine prime

mover

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Steering control simulation for Hydrobug2D Visual Basic simulation by Mr Richard Thien, 4th year student, Curtin

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Hydraulics for a 6-legged walking robot

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�� DC motors (powered by Darlington drivers, DC motors (powered by Darlington drivers, MOSFETS, relays, etc) & linear leadMOSFETS, relays, etc) & linear lead--screwsscrews

�� Stepper motors, unipolar & microStepper motors, unipolar & micro--stepperssteppers�� AC motors (with Allen AC motors (with Allen BradleyBradleyTMTM industrial industrial

motion controller; encoders/resolvers, etc)motion controller; encoders/resolvers, etc)�� PatentPatent--pending Electropending Electro--Magnetic Actuated Magnetic Actuated

Piston (EMAP), a directPiston (EMAP), a direct--drive variabledrive variable--position/velocity/force computer controlled position/velocity/force computer controlled linear actuator (under development)linear actuator (under development)

�� SMA: Shape Memory Alloy actuatorsSMA: Shape Memory Alloy actuators�� Radiation pressure (& ionic wind) enginesRadiation pressure (& ionic wind) engines

Electric actuators

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Flying aircraft built at Curtin UniversityQTAR: Quad Thrust Aerial Robot: can control direction, hover height, pitch, roll, translation forwards/back/left/right; is battery powered & carries a wireless video camera – built & programmed in 2005 by Joshua Portlock & Brett Hammil; Project supervisor: Dr Sam Cubero

The QTAR is easier to fly and control & is cheaper to make than the commercial “Dragonflyer” quad-rotor aerial robot. QTAR uses unique adaptive control algorithms based on feedback sensors to maintain stability. Total cost AUD$800

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Flying aircraft built at Curtin University

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Sensors, machine vision & measurement�� Industrial proximity sensors (onIndustrial proximity sensors (on--off type); eg. inductive, off type); eg. inductive,

capacitive, optical, magnetic, air, switches (reed, capacitive, optical, magnetic, air, switches (reed, mechanical), Hall Effect, Ultrasonic sensors, etcmechanical), Hall Effect, Ultrasonic sensors, etc

�� Variable analogue, digital & frequency output sensors Variable analogue, digital & frequency output sensors (eg. sensors for measuring position, angular rotation/ (eg. sensors for measuring position, angular rotation/ tilt, acceleration, force/torque/stress/pressure, gas or tilt, acceleration, force/torque/stress/pressure, gas or liquid liquid flowrateflowrate, temperature, light intensity, ultra, temperature, light intensity, ultra--sonic sonic transcieverstranscievers) with interfacing & ADC/data capture ) with interfacing & ADC/data capture circuitry for computers/microscircuitry for computers/micros

�� Machine vision: LineMachine vision: Line--scan or 2D array CCD cameras scan or 2D array CCD cameras with software & image control & analysis, pattern with software & image control & analysis, pattern recognition & identification, 3D scanning with a striperecognition & identification, 3D scanning with a stripe

�� 1D distance measurement & 2D or 3D laser scanning 1D distance measurement & 2D or 3D laser scanning (using the SICK LMS rangefinder)(using the SICK LMS rangefinder)

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SPI – Straying Prevention Indicator Driver fatigue & lane departure alarm

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Machine vision with 1D line-scan camera

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Machine vision with 1D line-scan cameraAll image processing is performed on-board via a microcontroller chip, which also controls steering

Speed & steering is automatically controlled based on image data. Image data can also be monitored on a PC screen (optional feature)

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Machine vision using 2D camera

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Machine vision: Object tracking

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Machine vision: Road edge detection

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Artificial Neural Network

Weights are trained based on road edge data obtained from video images taken during human training mode. Robot controller imitates how a human drives based on vision data.

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Image analysis & object identification�� Vision system can recognize 3 different hand gestures (rock, Vision system can recognize 3 different hand gestures (rock,

paper & scissors) & distinguish the difference between thempaper & scissors) & distinguish the difference between them

S-Psi edge graphSoftware can be modified to identify almost any closed shape

Can be used forhand gesture recognition &pointing devices.Software designed for Windows XP by Harvarinder Singh & Dr S Cubero 2006

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Genetic Algorithm for a 2-legged robot to learn how to crawl efficiently (Caleb Paget)

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3D Laser scanner built at Curtin

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Examples of 3D images using a scanner built at Curtin University Mechatronics labs

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Automated soil hardness testing machine controller for mining & drilling operations

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Automated soil hardness testing machine controller for mining & drilling operations

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Automated soil hardness testing machine controller for mining & drilling operations

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�� Remote controlled grape harvester Remote controlled grape harvester -- operationaloperational�� Remote controlled, wireless mine detection & video Remote controlled, wireless mine detection & video

surveillance robot using surveillance robot using Bluetooth Bluetooth -- operationaloperational�� Wireless communications systems for road vehicles & Wireless communications systems for road vehicles &

“smart traffic sign” safety systems “smart traffic sign” safety systems -- operationaloperational�� QTAR aerial VTOL (Vertical Take Off & Landing) QTAR aerial VTOL (Vertical Take Off & Landing)

flying robot flying robot –– now now operationaloperational under remote controlunder remote control�� CARbot CARbot lineline--scan camera guided robot scan camera guided robot -- operationaloperational�� VIC 2DVIC 2D--visionvision--guided ANN robot car guided ANN robot car -- operationaloperational�� Hydrobug Hydrobug 66--legged walking & wheeled passenger legged walking & wheeled passenger

carrying robot (carrying robot (1 leg operational1 leg operational, work in progress!), work in progress!)

Mobile vehicles & field roboticsExamples of projects built by Curtin Uni students:

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Mobile vehicles & field robotics�� 20032003--2004: 2004: CARbot CARbot mobile robot racing contest mobile robot racing contest

(racing against the clock on a closed loop track), (racing against the clock on a closed loop track), involving manual control of speed & steeringinvolving manual control of speed & steering

�� 2005: 2005: CARbot CARbot boxbox--grabbing competition, where up grabbing competition, where up to 4 players manually control their robot to collect as to 4 players manually control their robot to collect as many boxes as possible on an obstacle course and many boxes as possible on an obstacle course and return the boxes to their bases, within a time of 3 return the boxes to their bases, within a time of 3 minutes (Story shown in local newspaper)minutes (Story shown in local newspaper)

�� 2006: Robot wars & robot sumo! 2 minute news 2006: Robot wars & robot sumo! 2 minute news story featured nationwide on Channel 10 Newsstory featured nationwide on Channel 10 News

�� 2007 & beyond: Walking robots, exoskeleton robots 2007 & beyond: Walking robots, exoskeleton robots for enhancing human strength & speed, farm robots for enhancing human strength & speed, farm robots for herding & mustering animals in a fieldfor herding & mustering animals in a field

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22ndnd year year Mechatronic Mechatronic Project 234Project 234 (12.5 cp); 12 weeks(12.5 cp); 12 weeks�� Syllabus: Binary number system review, ASCII codes, Syllabus: Binary number system review, ASCII codes,

procedural programming, variable data types & storage procedural programming, variable data types & storage limitations, program flow control, decision making & limitations, program flow control, decision making & comparison tests, downloading compiled software code, bicomparison tests, downloading compiled software code, bi--directional serial communications with the AVR (UART, directional serial communications with the AVR (UART, MAX232, RS232), regulated power supply, MAX232, RS232), regulated power supply, optoisolationoptoisolation & & current protection, reading/writing I/O pins, using current protection, reading/writing I/O pins, using LEDsLEDs, , relays, timers/counters, interrupts, ADC, PWM, DC & relays, timers/counters, interrupts, ADC, PWM, DC & stepper motors, Hstepper motors, H--bridge motor drivers, bridge motor drivers, LCDsLCDs, matrix , matrix keypads, DAC, Darlington Driver, steering & speed controlkeypads, DAC, Darlington Driver, steering & speed control

�� Weekly teaching pattern: 1 hour lecture & one 3 hour labWeekly teaching pattern: 1 hour lecture & one 3 hour lab�� Assessments: 8 labs to develop skills in using an AVR Assessments: 8 labs to develop skills in using an AVR

microcontroller, microcontroller, CARbot CARbot contestcontest & Final report on & Final report on CARbotCARbot

Example of a Problem Based Learning Unit

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�� Race against clock & finish Race against clock & finish 1 lap of the racetrack to get 1 lap of the racetrack to get the fastest time! Students the fastest time! Students design, build & program design, build & program thetheir ir ownown robot robot controllercontroller

CARbot 2003/2004

CARbot competition 2003 & 2004Fastest time to complete 1 entire lap wins! If all 4 wheels leave the white track, “Speed Score” = 0. Students work in pairs & compete… “Completion Score = (No. zones completed/8 ) * 20%” (max 8 zones); “Speed Score = (No. robots–Rank+1) / (No. robots) * 20% (maximum)

TOTAL MARK (40%) = Completion Score +

Speed Score

Students must submit a complete design report describing their robot’s electronic circuit design, control scheme, control algorithms, guidance sensors & software

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Robotic box collecting contest 20053 or 4 robots race against the clock to collect the most boxes!

Students design & build their own hardware

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2nd year Problem Based Learning unitMechatronic Project 234: teams of 2 students work on designing the mechanical gripper/box-holder, electronics & control software

Collect the most boxes within 3 minutes to win! (like these 2)

Return boxes to your base area

CARbot competition 2005

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Robotic arm for an electric scooter�� Used for picking up & retrieving Used for picking up & retrieving

products on high supermarket products on high supermarket shelves, to aid the elderly & infirmshelves, to aid the elderly & infirm

Project supervised byDr Sam Cubero, 2005

Final year project of Mr Nyan Naung

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RARE: Remote Area Robotic Explorer�� Wireless remote controlled mobile robot can detect presence of lWireless remote controlled mobile robot can detect presence of land and

mines & send back live video images from camera on a 360mines & send back live video images from camera on a 360°° rotating rotating platform. The digital video can be saved as movies on a PC.platform. The digital video can be saved as movies on a PC.

Project by Nishant D’Souza & KC Anyaegbu. Supervisor: Dr S Cubero

Front arm swivels left & right holding a metal detector monitored by an AVR

Controlled withBluetooth ™ wireless radio communication

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�� GOALS:GOALS:

�� To help students become effective, independent learners To help students become effective, independent learners and thinkers; able to and thinkers; able to plan, investigate, discover & plan, investigate, discover & think think creatively so they can contribute new, useful knowledgecreatively so they can contribute new, useful knowledge

�� To create an environment that stimulates creative To create an environment that stimulates creative thinking & independent problem solving by students, thinking & independent problem solving by students, with minimal supervision effort by a lecturer/instructorwith minimal supervision effort by a lecturer/instructor

�� To challenge & develop the creativity & problem solving To challenge & develop the creativity & problem solving abilities of students in a fun, engaging way, so students abilities of students in a fun, engaging way, so students will like their work & enjoy doing it!will like their work & enjoy doing it!

Problem Based Learning at Curtin Uni

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Problem Based Learning at Curtin Uni�� Lab work/assignments are based on a project or problemLab work/assignments are based on a project or problem�� Lectures should be as Lectures should be as easyeasy--toto--understandunderstand as possible using as possible using

simple descriptions, relevantsimple descriptions, relevant examples & sample code or examples & sample code or methods they can use or modify for their projectmethods they can use or modify for their project

�� Learning should be Learning should be applied quicklyapplied quickly & practical results & practical results must be seen in labs must be seen in labs ASAPASAP in same week as the lecture!in same week as the lecture!

�� Students test their own ideas & Students test their own ideas & experience the act of experience the act of discoverydiscovery & problem solving on their own, without help& problem solving on their own, without help

�� Students should be Students should be allowed to solve their own problemsallowed to solve their own problems & & even even design & plan their own strategies or experimentsdesign & plan their own strategies or experiments

�� If students If students understand WHYunderstand WHY they are doing what they are they are doing what they are doing & believe that it is useful and helpful to their careers, doing & believe that it is useful and helpful to their careers, they will be keen to keep up to date & work hard!they will be keen to keep up to date & work hard!

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�� The goal of PBL is The goal of PBL is not to programnot to program students with lots of students with lots of information but to information but to guide students by example! guide students by example! Provide the Provide the basic concepts, information sources & tools, then let basic concepts, information sources & tools, then let students students form their own mental connections & formulate form their own mental connections & formulate relationships between important variablesrelationships between important variables while working while working towards clearly towards clearly defined project goals/objectivesdefined project goals/objectives in labs.in labs.

�� Students appreciate & remember things best via handsStudents appreciate & remember things best via hands--on on discoverydiscovery, not by being told what to do! Spoon feeding , not by being told what to do! Spoon feeding students with all the answers is pointless because that students with all the answers is pointless because that only encourages students to be very dependent on you for only encourages students to be very dependent on you for information & solutions. information & solutions. Let them think for themselves!Let them think for themselves!

�� Software & hardware always become obsolete or updated Software & hardware always become obsolete or updated so so students must learn how to learn & adapt to changes!students must learn how to learn & adapt to changes!

�� Each student must Each student must learn from mistakes & practice asking learn from mistakes & practice asking the right questionsthe right questions which may lead to the right answers!which may lead to the right answers!

Problem Based Learning philosophies

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�� Students learn & appreciate what works & what doesn’t Students learn & appreciate what works & what doesn’t work!work! There is usually only enough time in lectures to There is usually only enough time in lectures to show what does work & not enough time to show what is show what does work & not enough time to show what is wrong with bad designs or methods, thus labs are needed!wrong with bad designs or methods, thus labs are needed!

�� MechatronicMechatronic engineers spend much of their time running engineers spend much of their time running many tests on new designs in order to many tests on new designs in order to fully understand & fully understand & discover everything that can possibly fail. discover everything that can possibly fail. Students must Students must learn how to find & fix problems & errors themselves by learn how to find & fix problems & errors themselves by testing all possible inputs & outputs & the behaviour of testing all possible inputs & outputs & the behaviour of every component in the systemevery component in the system or software they designed.or software they designed.

�� If a circuit, software code or design does not work as If a circuit, software code or design does not work as expected, expected, students will do everything in their power to fix students will do everything in their power to fix it, if they can see that their peers have succeededit, if they can see that their peers have succeeded. Most . Most students will make it a matter of personal pride to succeed!students will make it a matter of personal pride to succeed!

Useful tips for Problem Based Learning

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�� Set small goals in labs that are attainable for even the lowest Set small goals in labs that are attainable for even the lowest achievers (50%achievers (50%--65% Course Weighted Average, or non65% Course Weighted Average, or non--honours students); honours students); make all lab tasks asmake all lab tasks as SIMPLE and easy to SIMPLE and easy to complete as possible and ensure they see useful results!complete as possible and ensure they see useful results!

�� Avoid setting tasks that are too complex or too time Avoid setting tasks that are too complex or too time consuming (failure to complete set tasks may discourage) consuming (failure to complete set tasks may discourage) Labs should allow students to build useful things that work!Labs should allow students to build useful things that work!

�� Tell students in advance about common problemsTell students in advance about common problems they might they might experience in labs & their remedies; eg. check wire experience in labs & their remedies; eg. check wire connections/poor contacts, power supply, wrong polarity etcconnections/poor contacts, power supply, wrong polarity etc

�� Urge students to Urge students to carefully test each & every small feature or carefully test each & every small feature or component or bit of software code added to the systemcomponent or bit of software code added to the system to to minimize unexpected errors & save much debugging time!minimize unexpected errors & save much debugging time!

Useful tips for Problem Based Learning

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Many students will not like PBL at first!�� Many students who are not used to thinking for themselves Many students who are not used to thinking for themselves

or learning on their own will find PBL to be a big shock!or learning on their own will find PBL to be a big shock!�� Creativity & imagination are not “taught” or “assessed” in Creativity & imagination are not “taught” or “assessed” in

most Universitymost University--level engineering degree courses!level engineering degree courses!�� SEEQ (Student Evaluation of Education Quality) surveys SEEQ (Student Evaluation of Education Quality) surveys

show that students valued the PBL subjects more than other show that students valued the PBL subjects more than other subjects, however, the majority believed the PBL subjects subjects, however, the majority believed the PBL subjects were less “organised” than conventional textbookwere less “organised” than conventional textbook--based based “follow the procedure” subjects, despite all necessary “follow the procedure” subjects, despite all necessary information being given to them 1 week before each lab.information being given to them 1 week before each lab.

�� Moral of the story: Moral of the story: No pain, no gain!No pain, no gain! Students experience Students experience creative creative “brain pain”“brain pain” because they are forced to because they are forced to organise & organise & studystudy datadata--sheets, sample code and circuits & sheets, sample code and circuits & solve many lab solve many lab problems on their own problems on their own , without a complete solution or , without a complete solution or correct answer to copy & no guarantee of success in the labscorrect answer to copy & no guarantee of success in the labs

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�� GOALS ACHIEVED:GOALS ACHIEVED:�� Students are better at learning on their own and solving Students are better at learning on their own and solving

problems on their ownproblems on their own, better able to , better able to learn & apply new learn & apply new information quickly & effectivelyinformation quickly & effectively. (This will help them in . (This will help them in their future careers because hardware & software their future careers because hardware & software technology keeps getting updated with newer products)technology keeps getting updated with newer products)

�� PBL allows students the chance to learn from their own PBL allows students the chance to learn from their own mistakesmistakes, affording them the opportunity to engage in , affording them the opportunity to engage in “problem identification” & trouble“problem identification” & trouble--shooting activities, shooting activities, requiring some technical “detective work” & creative requiring some technical “detective work” & creative questioning to solve problems not found in textbooks!questioning to solve problems not found in textbooks!

�� Students begin thinking like innovators, inventors and real Students begin thinking like innovators, inventors and real scientists & researchersscientists & researchers, capable of discovering and , capable of discovering and applying new knowledge, technologies and new ideas.applying new knowledge, technologies and new ideas.

�� Students all Students all learn to organize disorganized informationlearn to organize disorganized information..

Problem Based Learning at Curtin Uni

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Handy Problem Solving Philosophies�� To solve problems efficiently, try to think To solve problems efficiently, try to think QUICKER:QUICKER:�� QQuestions/goals must be defined: Know what you want!uestions/goals must be defined: Know what you want!�� UUnderstand relevant objects or variables: their purpose, nderstand relevant objects or variables: their purpose,

behaviour, inputs/outputs & limits. Study & observe them behaviour, inputs/outputs & limits. Study & observe them carefully, carefully, run experiments & become familiar with them!run experiments & become familiar with them!

�� IImagine relationships between these objects or variables, magine relationships between these objects or variables, but but do not believe in untested assumptions.do not believe in untested assumptions. Test all ideas!Test all ideas!

�� CChoose the simplest solution & hoose the simplest solution & SMILESMILE (because (because SSimple imple MMakes akes IIt t LLots ots EEasier) asier) –– Fewer things to go wrong! Less Fewer things to go wrong! Less effort & stress! Don’t bother learning irrelevant things!effort & stress! Don’t bother learning irrelevant things!

�� KKeep an open mind & consider the advice of experts!eep an open mind & consider the advice of experts!�� EExamine all the advantages & disadvantages of all your xamine all the advantages & disadvantages of all your

options but options but do not believe in untested assumptions!do not believe in untested assumptions!�� RResults come from action & persistent effort, not excusesesults come from action & persistent effort, not excuses

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Thanks for listening… Any questions?

For more information or to give feedback, please contact:Dr Sam Cubero, WARCAMP secretary, www.warcamp.netDepartment of Mechanical Engineering, Building 204, Rm 525Curtin University of Technology, Bentley, Western AustraliaTel: (08) 9266 7047 Mail: GPO Box U1987 Perth 6845or talk to one of our Mechatronic Engineering lecturers:Euan, Graham, Brad or Sam ( s.cubero@curtin.edu.au )Staff website: www.mech-eng.curtin.edu.au/staff.cfm

COPYRIGHT NOTICE© 2006 Copyright Samuel N. Cubero, www.sunsetstudios.com.au and Curtin University of Technology, Perth, Western Australia. All rights reserved.Material from this presentation must not be copied, rented, edited, broadcasted in public or used by other teaching institutes or teachers, without the written & signed permission of the copyright owner (Samuel N. Cubero, Australia).