ECE 477 Final Presentation ECE 477 Final Presentation Group 7 Group 7 Spring 2005 Spring 2005

OutlineOutline

• Project overviewProject overview• Block diagramBlock diagram• Professional componentsProfessional components• Design componentsDesign components• Success criteria demonstrationsSuccess criteria demonstrations• Individual contributionsIndividual contributions• Project summaryProject summary• Questions / discussionQuestions / discussion

Project OverviewProject OverviewAn autonomous vehicle designed to look for An autonomous vehicle designed to look for

moving heat-emitting targets and engage them moving heat-emitting targets and engage them

while patrolling a limited area and avoiding while patrolling a limited area and avoiding

ground obstacles.ground obstacles.

+ =

Gorgeous! Isn’t it?Gorgeous! Isn’t it? (The sky blue color (The sky blue color scheme really gives it that extra something)scheme really gives it that extra something)

Block DiagramBlock Diagram

Professional ComponentsProfessional Components

• Constraint analysis and component selection Constraint analysis and component selection rationalerationale

• Patent liability analysisPatent liability analysis• Reliability and safety analysisReliability and safety analysis• Ethical and environmental impact analysisEthical and environmental impact analysis

Constraint AnalysisConstraint AnalysisMajor ConstraintsMajor Constraints - Many peripheral devices- Many peripheral devices

- 1 Airsoft Gun Motor- 1 Airsoft Gun Motor- 4 Passive Infrared Sensors- 4 Passive Infrared Sensors- 1 Ultrasonic sensor- 1 Ultrasonic sensor- 1 Servo- 1 Servo- 2 Drive Motors- 2 Drive Motors- 1 LCD - 1 LCD

- Small Package Size/Weight- Small Package Size/Weight- Small Tank base (4.5” x 8”)- Small Tank base (4.5” x 8”)

- Mobile Battery Power Supply- Mobile Battery Power Supply

- 2 7.2V NiMH Rechargeable Batteries - 2 7.2V NiMH Rechargeable Batteries - 4 9V Alkaline Batteries- 4 9V Alkaline Batteries

- Time of Flight Computation Requirement- Time of Flight Computation Requirement- Ultrasonic Ping flight time needed to be found- Ultrasonic Ping flight time needed to be found

- No major cost constraints- No major cost constraints

Component Selection RationaleComponent Selection RationaleRobot Base:Robot Base: Rogue Robotics RT-ATR Rogue Robotics RT-ATR

- Small design easy to work with- Small design easy to work with- Flexible/Expandable design for attaching - Flexible/Expandable design for attaching many peripheralsmany peripherals

Micro-controller:Micro-controller: Motorola M68MOD912C32 Motorola M68MOD912C32- Contains requisite I/O for each peripheral- Contains requisite I/O for each peripheral- Capable of pulse measurement for Time of Flight- Capable of pulse measurement for Time of Flight- Compact module design allows for small PCB to - Compact module design allows for small PCB to fit on small tank basefit on small tank base

Component Selection RationaleComponent Selection RationalePassive Infrared Sensors:Passive Infrared Sensors: Kitsrus K30Kitsrus K30

- Interfaced well with HC(S)12- Interfaced well with HC(S)12- Small design/lightweight- Small design/lightweight- Good Range (Approx. 120 degree range)- Good Range (Approx. 120 degree range)

Liquid Crystal Display:Liquid Crystal Display: Optrex DMC20261A Optrex DMC20261A- Worked well with HC(S)12 SPI port- Worked well with HC(S)12 SPI port

- 2 x 20 Character display was good size for- 2 x 20 Character display was good size for displaying engagement count/reload statusdisplaying engagement count/reload status

Component Selection RationaleComponent Selection RationaleServo Motor:Servo Motor: JR NES-537 JR NES-537

- Easy to interface/operate compared to stepper motor- Easy to interface/operate compared to stepper motor

- High torque rating ( 45 oz-in )- High torque rating ( 45 oz-in )

- Very small/lightweight- Very small/lightweight

Ultrasonic Sensor:Ultrasonic Sensor: Devantech SRF04Devantech SRF04 - Small/lightweight- Small/lightweight- Used for short ranges (3 cm to 3 m)- Used for short ranges (3 cm to 3 m)- Directly interfaces with HC(S)12- Directly interfaces with HC(S)12

Paintball Gun:Paintball Gun: KTC 210910 KTC 210910- Fully Automatic- Fully Automatic

- Electronic Trigger- Electronic Trigger

- Small ( 9” after cut down )- Small ( 9” after cut down )

- Light weight ( less than 1 lb )- Light weight ( less than 1 lb )

- Little or No kickback on gun fire- Little or No kickback on gun fire

Patent Liability AnalysisPatent Liability Analysis

• Results of Patent SearchResults of Patent Search– Many patents relate with our projectMany patents relate with our project

• Autonomous robot with 2 sets of rotorsAutonomous robot with 2 sets of rotors• Robot operating in multiple modesRobot operating in multiple modes• Autonomous robot with obstacle detectionAutonomous robot with obstacle detection

– Recommended actionRecommended action• Doctrine of equivalentsDoctrine of equivalents

– ““Robot performing social interactivity”Robot performing social interactivity”• Patent lawyer and/or licensingPatent lawyer and/or licensing

Reliability/Safety AnalysisReliability/Safety Analysis

• OverviewOverview– Mean Time To Failure (MTTF) analysis of Mean Time To Failure (MTTF) analysis of

crucial componentscrucial components– FMECA worksheet for entire schematicFMECA worksheet for entire schematic

Reliability/Safety Analysis – mean time to failure Reliability/Safety Analysis – mean time to failure (MTTF) analysis of crucial components(MTTF) analysis of crucial components

• Freescale 9S12C32 Microcontroller Freescale 9S12C32 Microcontroller – failures every 10failures every 1066 hours : 1.388 hours : 1.388 – MTTF : 7.205 xMTTF : 7.205 x 101055 hours hours– Not acceptableNot acceptable

• Linear Tech LT 1374-5 Switching Regulator – failures every 10failures every 1066 hours : 2.33 hours : 2.33 – MTTF : 4.292 xMTTF : 4.292 x 101055 hours hours– Not acceptableNot acceptable

• Linear Tech LT 1376-5 Switching RegulatorLinear Tech LT 1376-5 Switching Regulator– failures every 10failures every 1066 hours : 2.33 hours : 2.33 – MTTF : 4.292 xMTTF : 4.292 x 101055 hours hours– Not acceptableNot acceptable

• 4N28 Phototransistor Output Optocoupler 4N28 Phototransistor Output Optocoupler – failures every 10failures every 1066 hours : 5.4912 hours : 5.4912 – MTTF : 1.8211 xMTTF : 1.8211 x 101055 hours hours– AcceptableAcceptable

Reliability/Safety Analysis - FMECA worksheet for Reliability/Safety Analysis - FMECA worksheet for entire schematicentire schematic

• Chip Power Supply (Block A) Chip Power Supply (Block A) • Motors Power Supply (Block B)Motors Power Supply (Block B)• Microcontroller and interface headers Microcontroller and interface headers (Block C)(Block C)• PIR interfaces (Block D)PIR interfaces (Block D)• LCD interface (Block E)LCD interface (Block E)• H-Bridge and Servo motor interfaces H-Bridge and Servo motor interfaces (Block F)(Block F)• Gun interface (Block G)Gun interface (Block G)

Reliability/Safety Analysis - FMECA worksheet for Reliability/Safety Analysis - FMECA worksheet for entire schematicentire schematic

• Two levels of criticality:Two levels of criticality:– High : High :

• Cause injury to the user or permanent damage Cause injury to the user or permanent damage to the robotto the robot

• Expected to have failure rate Expected to have failure rate smaller than 10 smaller than 10-9-9 – Low : Low :

• Robot does not function properly but does not Robot does not function properly but does not cause injury or permanent damagecause injury or permanent damage

• Expected to have failure rate Expected to have failure rate

between 10between 10-9-9 and 10 and 10-4-4

Ethical/Environmental AnalysisEthical/Environmental Analysis

• Ethical AnalysisEthical Analysis

- Warning Labels and Cautions in - Warning Labels and Cautions in

DocumentationDocumentation

- Remote “Kill Switch”- Remote “Kill Switch”

- Durability- Durability

Ethical/Environmental AnalysisEthical/Environmental Analysis

• Environmental AnalysisEnvironmental Analysis

- Product Manufacture- Product Manufacture

- Surface Mount Technology- Surface Mount Technology

- Material Substitution- Material Substitution

- Reuse/Recycle- Reuse/Recycle

- Normal Use- Normal Use

- Disposal- Disposal

- PCBs- PCBs

- Batteries- Batteries

- Base- Base

Design ComponentsDesign Components

• Packaging design considerationsPackaging design considerations• Schematic design considerationsSchematic design considerations• PCB layout design considerationsPCB layout design considerations• Software design considerationsSoftware design considerations

Packaging DesignPackaging Design Many componentsMany componentssqueezed into small squeezed into small space includingspace including9 separate PCB’s.9 separate PCB’s. - Main Board- Main Board - 4 PIR PCB’s- 4 PIR PCB’s - 1 Ultrasonic PCB- 1 Ultrasonic PCB - 1 H-Bridge PCB- 1 H-Bridge PCB - 1 RF switch PCB- 1 RF switch PCB - 1 LCD PCB- 1 LCD PCB

Key Packaging DecisionsKey Packaging Decisions- Low battery weightLow battery weight- Readable LCD Readable LCD

positioningpositioning- Hidden PIR in gun Hidden PIR in gun

Schematic DesignSchematic Design

• Voltage regulatorsVoltage regulators• LCD interfaceLCD interface• PIR interfacePIR interface• Ultrasonic sensor interfaceUltrasonic sensor interface• Servo interfaceServo interface• H-Bridge and drive motors interfaceH-Bridge and drive motors interface• Gun trigger interfaceGun trigger interface• MCU MCU

Schematic/Theory of Operation – Schematic/Theory of Operation – Final SchematicFinal Schematic

PCB Layout DesignPCB Layout Design• 12 mil traces – Standard12 mil traces – Standard• 50 mil traces – Power/Ground50 mil traces – Power/Ground• Footprints created: headers, LT1374-5 Footprints created: headers, LT1374-5

(regulator), surface mount diode(regulator), surface mount diode• Decoupling capacitorsDecoupling capacitors

Routing is…Routing is…

the root of all EVIL!the root of all EVIL!

BeforeBefore

AfterAfter

Software DesignSoftware Design

• AssemblyAssembly• Metrowerks CodeWarriorMetrowerks CodeWarrior• Polling LoopPolling Loop• ModulesModules - GROVER - Servo- GROVER - Servo - Ultrasonic - AirSoft- Ultrasonic - AirSoft - H-Bridge - H-Bridge - PIR - PIR - LCD- LCD

TargetDetected?

Display Ammo Status/ Engagements

Poll PIR Sensors

Poll UltrasonicSensor

ObstructionDetected?

Turn MotorsON FWD

1 3*2

Turn 90o

Right

Turn MotorsOFF

Stop TurretFire Weapon /Update Ammo

SetEngagement

Flag

EngagementFlag Set?

IncrementEngagement Count on LCD

Pause for10 Seconds

ClearEngagement Flag

/ Reset Turret

Turret SensorTriggered?

Turn Maxed?

Step TurretRight 15o

Step TurretLeft 15o

Reset Turret

InitializationReset TurretClear LCD

Start

Which PIR Sensor?

Yes

YesTurn Motors

OFF

Yes

Yes

Yes

No

No

No

No

No

ResetVariables

No

* Note: PIR Sensors 1 and 3 have priority over 2.

See‘Center Sweep’

Turn Grover 90o

in Direction of Turn

Ammo= 0?

No YesStop

Program Flow

Success Criteria DemonstrationsSuccess Criteria Demonstrations

• An ability to avoid collisions with inanimate objectsAn ability to avoid collisions with inanimate objects

Success Criteria DemonstrationsSuccess Criteria Demonstrations

• An ability to detect a heat-emitting targetAn ability to detect a heat-emitting target• An ability to turn weapon to face target An ability to turn weapon to face target • An ability to fire the weaponAn ability to fire the weapon

Success Criteria DemonstrationsSuccess Criteria Demonstrations

• An ability to determine and display the number of An ability to determine and display the number of engagementsengagements

Individual ContributionsIndividual Contributions

• Team Leader – Joel StubbsTeam Leader – Joel Stubbs• Team Member 2 – Stan MillerTeam Member 2 – Stan Miller• Team Member 3 – Andrew ParcelTeam Member 3 – Andrew Parcel• Team Member 4 – Edwin TjandranegaraTeam Member 4 – Edwin Tjandranegara

Team Leader – Joel StubbsTeam Leader – Joel Stubbs

• Researched, developed, and tested initial Researched, developed, and tested initial software prototyping and communication for software prototyping and communication for Ultrasonics module and ServoUltrasonics module and Servo

• Developed and tested gun opto-isolator Developed and tested gun opto-isolator interface circuitinterface circuit

• Put together main PCBPut together main PCB• Contributed key packaging ideas & Packaged Contributed key packaging ideas & Packaged

portion of designportion of design• Organized team/Helped Motivate MeetingsOrganized team/Helped Motivate Meetings

Member 2 – Stan MillerMember 2 – Stan Miller

• Gun and servo-turret packagingGun and servo-turret packaging• Tank motor, weapon sensor, and battery Tank motor, weapon sensor, and battery

mountingmounting• PCB design and layoutPCB design and layout• Patient liability analysisPatient liability analysis• Final packagingFinal packaging

Member 3 – Andrew ParcelMember 3 – Andrew Parcel

• GROVER Software DesignGROVER Software Design• Environmental/Ethical ConstraintsEnvironmental/Ethical Constraints• Prototyping Prototyping • Initial InterfacingInitial Interfacing• WebmasterWebmaster

Member 4 – Edwin TjandranegaraMember 4 – Edwin Tjandranegara

• LCD and SPI software design and interfaceLCD and SPI software design and interface• Power supplies and circuit designPower supplies and circuit design• Schematic designSchematic design• Reliability and Safety analysisReliability and Safety analysis• Co-webmasterCo-webmaster• H-bridge, RF remote and PIR sensors H-bridge, RF remote and PIR sensors

interfaceinterface

Project SummaryProject Summary

• Important lessons learnedImportant lessons learned– Mark power/ground consistentlyMark power/ground consistently– Don’t order too many expensive partsDon’t order too many expensive parts– Check part specificationsCheck part specifications– Keep a timeline and stick to itKeep a timeline and stick to it

Project SummaryProject Summary

• Second iteration enhancementsSecond iteration enhancements– All parts surface mountAll parts surface mount– Bigger…better…base!Bigger…better…base!– Fiberglass shellFiberglass shell– Secondary control through internetSecondary control through internet– Remotely fire gun with key fobRemotely fire gun with key fob– Fit more to main PCBFit more to main PCB

Questions / DiscussionQuestions / Discussion