special vehicle for transporting unstable chemicals

Special Vehicle for Transporting

Unstable Chemicals

By

Gong, Zhangxiaowen

Ma, Jun

Zhou, Wenjia

Final Report for ECE 445, Senior Design, Spring 2012

TA: Fortier, Justine

1 May 2012

Project No. 15

Abstract

This project is to design a special vehicle for transporting volatile substances. The purpose is to minimize the

vibration and inclination of the vehicle when moving on an uneven surface.

The design actualizes the following functions: an omni-directional movement system that not only eliminates the

centrifugal force when the vehicle turns but also makes the vehicle agile in compact lab environment, an auto leveling

system that allows the vehicle to adapt uneven surface thus reduces vibration, and a real time wireless communication

channel between the vehicle and an upper computer that provides features such as remote control and sensor data

recording for further analysis.

Most functionalities described above have been fulfilled as intended. However, a torque issue impedes the performance

of the auto leveling. As a result, a re-design for the mechanical system is scheduled in the future.

i

Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Purpose and Goal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Design Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Design Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1.1 Mechanical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1.2 Electrical/Electronic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Design Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2.1 Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2.2 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Design Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1 Master Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2 MEMS Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3 ODM System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4 AL System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.1 Accomplishments and Future Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.2 Uncertainties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.3 Ethical considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Appendix A Requirement and Verification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A.1 Main Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A.2 MEMS Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

A.3 Side Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A.4 Wireless Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A.5 Omni-directional Movement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

A.6 Active Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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A.7 PC Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A.8 Power Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Appendix B Full Schematics and PCB Layouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

B.1 The Master Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

B.2 The Slave Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

B.3 The PC Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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1 Introduction

1.1 Purpose and Goal

Our project is to design a special vehicle for transporting chemicals. The motivation came to us during a

chemistry lab session. We noticed that when using a normal cart to carry chemicals, the carrier experienced

significant bumps. Since volatile and hazardous chemicals should be treated carefully, we decided to address

the issue by building a robot that performs safe and efficient transportation for those unstable chemicals.

The major goal for the design is to keep the chassis level and stable; therefore, the vehicle has to limit the

vibration and the tilt of the chassis while traveling on different road conditions.

1.2 Functions

The system has 4 major functions:

1. Motion analysis: The on-board processor acquires data from MEMS (MicroElectroMechanical Sys-

tems) sensors and calculates real-time tilt angle according to the readings. In order to eliminate noises,

the raw data from the sensors have to be filtered.

2. AL (Auto Leveling) system: A worm motor based auto leveling system allows the vehicle to adapt

uneven surface thus reduces vibration. In order to effectively reduce vibration, the suspension has to

respond to uneven surfaces within 0.3s. The maximum dynamic tilt angle between the chassis and the

horizontal surface also has to be constrained in 5 degree.

3. ODM (Omni-Directional Movement) system: A system built by servos and PID controlled

motors not only eliminates the centrifugal force when the vehicle turns but also makes the vehicle agile

in compact lab environment. All 4 wheels in the system should be adjusted to the same direction,

rotate at the same speed, and modify their speed respectively when encountering uneven surface.

4. Real time wireless communication A wireless link between the vehicle and an upper computer

provides features such as remote control and sensor data recording for further analysis.

1.3 Design Block

The project consists of seven modules. Figure 1 is the main block diagram of the system.

1

Active lev-

eling and

omni-direction

movement

system

Slave con-

trollers

Master

controller

Power man-

agement

MEMS sensors

Wireless

interfacePC receiver

PWM

Position

feedback

SPI

USB

I2C

I2C

Electrical

Vehicle

Mechanical

Figure 1: Main block diagram

1. Master Controller: The main controller is based on a 32-bit AVR microcontroller that performs

various tasks including gathering data from MEMS sensors, making decision to balance the chassis,

printing debug information on an OLED (Organic Light Emitting Diode) display, and communicating

with a PC via wireless.

2. Slave Controllers: The side controllers is based on 8-bit AVR microcontrollers. Each MCU (Micro-

Controlling Unit) receives commands from the main controller and controls 1 servo, 1 regular DC

motor, and 1 worm motor.

3. MEMS sensors: An InvenSense MPU-6050 3-axis gyroscope and 3-axis accelerometer measures the

state of the chassis. It performs 6-axis sensor fusion inside the chip and sends the results to the main

controller in integer quaternions.

4. Power Management: The vehicle is powered by a 3-cell 11.1V 2200mAh LiPo battery. The on-

board step-down and step-up regulators then provide 3.3V, 5V, and 13.8V power for different uses.

The power management scheme for the model vehicle is designed to support the whole system for 1

hour of continuous operation on heavy load, which is enough for demo purpose.

5. Mechanical system: It includes the AL system and the ODM system. They take control signals

from the slave controllers and deliver feedback for closed-loop control.

6. Wireless Interface: In order to analyze the system performance, the vehicle constantly send the

sensor readings to a host computer. The wireless link for the transmission is built upon nRF24L01P

2.4GHz RF solution. The MCUs can send commands and packages to the RF chip via SPI (Serial

Peripheral Interface).

7. PC Receiver: An 8-bit AVR microcontroller that has a built-in USB controller handles the computer

side RF chip. In addition, a computer software is developed to visualize the sensor readings, to

store/playback the data, and to remotely control the vehicle.

2

2 Design

2.1 Design Procedure

2.1.1 Mechanical System

The mechanical system consists of two parts – an ODM system and an AL system.

1. Traditionally, a typical ODM system is built up by mounting 3 ∼ 4 omni-wheels onto the chassis with

120 or 90 between each adjacent pair respectively. Since each omni-wheel has multiple passive wheels

that allow it to move along the axis perpendicular to its active rolling direction[1], a vector calculation

is able to yield the velocity of each omni-wheel that moves the vehicle towards any direction without

rotating the chassis. However, the design introduces the following problems:

(a) The passive wheels cause the omni-wheel having a non-perfect-round shape, which vibrates when

rolling.

(b) The small size of the passive wheels hinders the vehicle when encountering obstacles.

(c) Since the passive wheels can rotate freely, an external horizontal force exerting on the chassis may

result the vehicle to slide.

As a result, we adopted a novel design that adjusts the rotation direction of each of the four regular

wheels independently. For a full-size final product, the mechanism should be done by closed-loop

controlled motor; nonetheless, we applied RC servos on the model system due to size issue.

2. The AL system is responsible for keeping the chassis level. Therefore, the height of each wheel has

to be altered autonomously. To actualize the function, a closed-loop controlled worm motor with a

15kg · cm torque is attached to each driving wheel on the model system. However, a hydraulic system

is preferred for a real product.

Moreover, both the ODM system and the AL system follow the control scheme described in Figure 2. They

provide rotational encoder or potentiometer feedback for speed or position PID control respectively, and the

saturation filter confines the PID output in a reasonable range.

PID Controller Saturation Filter Motor Drivercontroller output motor output

+

Figure 2: Control scheme for the ODM system and the AL system

2.1.2 Electrical/Electronic System

1. Since the on-vehicle system performs various functions ranging from analyzing sensor data to controlling

motors, we adopted a master-slave structure multiple microcontroller approach. Since the master

controller is required to execute multiple independent tasks simultaneously, a 32-bit microcontroller is

preferred. Considering that most of the data analysis work in this design is performed upon floating

point data, we eventually chose AT32UC3C2256C – an MCU with hardware FPU (floating point

unit) – to fill the row. On the other hand, the slave controllers mainly deal with the actuators;

3

hence, a microcontroller model with high anti-noise ability is needed. Fortunately, the 8-bit AVR

microcontroller family, which provides up to 40mA current output ability per I/O (Input/Output) pin

and works at control-friendly 5V supply voltage, fulfills the requirements. Because the functions of the

slave controller are relatively simple, we eventually chose a low-end model – ATmega8A.

2. MEMS sensor is an essential part of the design. We initially planed to obtain data from individual

gyroscope, accelerometer, and magnetometer, so we can then perform a software sensor fusion based on

Kalman filter to reduce noise. Nevertheless, we eventually decided to use an ASIC (Application-Specific

Integrated Circuit) MPU-6050 that integrates a 3-axis gyroscope and a 3-axis accelerometer. The most

valuable feature of MPU-6050 is that it applies a complementary filter[2] within the chip and outputs

quaternion directly, which significantly frees the MCU’s load. In addition, the single chip sensor also

reduces both cost and power consumption. After test, we confirmed that the complementary filter is

able to produce results with similar quality with that from the Kalman filter.

3. The rated voltage and current of the worm motor that we use on the model system are 12V and 1A

respectively, so a typical integrated H-bridge is enough for driving it. However, since the design should

later move towards a full-size vehicle, we still decided to make discrete H-bridges. The NMOS we

adopted on the H-bridge can drive a motor with up to 55V and 110A rated voltage/current[3], and test

results showed that the PCB traces with thick solder on them can hold 20A safely, which is enough for

a big motor.

4. Although the output voltage of the 3-cell Li-Po battery used on the model system is within the VGS

range of the NMOS on the H-bridge, we use a step-up regulator to convert a regulated 5.0V voltage to

13.8V for the VGS . The reason is also for compatibility with future designs. The current power scheme

allows any voltage from 7V to 40V to power up the system.

5. The choices for wireless solution is wide; available ones includes Bluetooth, ZigBee, etc. Since the

communication range of even a class 1 Blootooth transceiver is still quite short (about 100m)[4], we

quickly eliminated it from the choice list. The ZigBee standard gives a relatively high effective range;

however, on the unlicensed 2.4GHz carrier frequency, ZigBee only provides a 250Kbps data rate[5].

Because our project may introduce telepresence feature in the future, which demands a high band-

width for real-time video transmission, we did not adopt ZigBee. Finally, we managed to find a

solution with both qualified range and band-width. The nRF24L01P 2.4GHz wireless module that we

finally chose integrates a PA (Power Amplification) circuit for transmitting and a LNA (Low Noise

Amplification) circuit for receiving; consequently, a pair of such module can communicate in 500m at

2Mbps data rate. Furthermore, its 10Mbps SPI (Serial Peripheral Interface) bus allow high speed data

exchange with the microcontrollers[6], which enhances the overall performance of the system.

6. In order to control the wireless interface on a computer, we need to set up a link between the RF

chip and a computer USB (Universal Serial Bus) port. A common way is to use a FTDI chip that

extends a virtual serial port on the computer and reconstruct the USB packages into UART (Universal

Asynchronous Receiver/Transmitter) packages that are supported by most MCUs. Nonetheless, adding

such chip not only raise the cost and power consumption but also limits the USB functionalities. As a

result, we picked an AVR 8-bit MCU with built-in USB 2.0 device controller instead. To reduce the

complexity of the computer side USB driver, we designed the MCU side USB driver following a CDC

(Communication Device Class) pattern, which essentially emulates a virtual serial port. However,

different from the FTDI approach, the driver does not really translate packages between USB and

UART; therefore, the data rate is not limited by the serial port baud rate setting at all, thus ensures

4

the efficiency of the transmission.

2.2 Design Details

2.2.1 Schematics

The main controller uses AT32UC3C2256 as processor. The communication modules that are utilized in

the design include I2C (Inter-Integrated Circuit, a.k.a TWI, Two-Wire Interface), SPI, and USB. We also

connect the external interrupt pins of the MCU to other modules such as the RF transceiver and the MEMS

sensor. Figure 3 is the core circuitry that supports the MCU, including oscillator, power filtering circuit,

USB interface for bootloader, reset circuit, etc.

Figure 3: AT32UC3C2256 core system

Since the main MCU runs at 3.3V while the side ones work at 5V, a bidirectional level converter is required

to establish the I2C bus between them. We adopt a design that uses N-channel MOSFETs in a symmetric

manner[7], which is presented in Figure 4. In the figure, VCC is 3.3V. Label TWD1 and TWCK1 belong to

the 3.3V bus, and label TWI10 and TWI11 are the 5V ones. The circuit in the figure looks not symmetric;

in fact, the 3.3V lines do have pull-up resistors although they are not shown in the figure due to being inside

a resistor pack.

5

Figure 4: Bidirectional level shifter

The power management part on the main controller provides 3 distinct positive voltage levels: 5V, 3.3V,

and 13.8V. The system first regulates the approximately 11.1V supply voltage to 5V and then step it up to

12V as well as down to 3.3V. The 5V regulator we use is LM2596, a highly efficient switching converter that

works at 150KHz and has 3A current output capacity[8]. It supplies power for both generating the other

two voltages and serving the side MCUs. Figure 5 includes its work state switch and output filtering circuit.

Figure 5: 5V regulator

We use a MAX629 switching step-up regulator for 13.8V supply. The chip needs two resistors to designate

the output voltage from its internal 1.25V reference, R1 = R2 × (Vout

Vref− 1)[9] With 47KΩ as R1 and 4.7KΩ

as R2, the resulting output voltage becomes 13.8V. Figure 6 shows the circuit.

Figure 6: 13.8V regulator

Instead of using a switching regulator, we use LM1117, a linear regulator with 500mA maximum output

current, for stepping 5V down to 3.3V. The reasons for this choice are:

6

1. The 3.3V system consists of the 32-bit MCU, 2.4GHz wireless transceiver, MEMS sensor, and the logic

supply for OLED display, which draw a small total current.

2. The voltage drop from 5V to 3.3V is only 1.7V. Suppose the average current consumption by the 3.3V

system is 100mA, the average dissipation power caused by the voltage drop is 1.7V ×100mA = 170mW ,

which is acceptable.

3. The linear regulator requires much less external components that a switching one does.

Figure 7 presents the circuit.

Figure 7: 3.3V regulator

Since we are using a module integrating the nRF24L01P wireless transceiver, the interface with the wireless

module is just a header. The OLED display takes two voltage supplies: 5V for biasing the display and 3.3V

for powering the logics. It takes data from the main MCU’s SPI interface. Figure 8 shows the circuit.

Figure 8: OLED display

Initially we planed to perform a 9-axis sensor fusion by attaching a 3-axis magnetometer HMC5883L to the

MPU-6050 chip as an auxiliary. The magnetometer is useful for compensating the drift on the gyroscope’s

yaw output by taking reference to the Earth’s magnetic field. However, later we found that the yaw data

are not necessary for the system. As a result, we cut the magnetometer off from the design. Nonetheless, its

place is still kept on the schematic as presented in Figure 9.

7

Figure 9: MEMS sensors

The side controllers use ATmega8A as processors. Besides GPIO (General Purpose Input/Output), we

utilize the MCU’s PWM (Pulse-Width Modulation) generator, external interrupt, and I2C interface. Figure

10 is the core system, including oscillator, power filtering circuit, reset circuit, etc. Because we have totally

4 identical side controllers in the system, in order to apply consistent programs to every chip, we connect

a 4-bit DIP switch to the MCU’s GPIO so that each chip can determine the low 4-bit of its 7-bit I2C

slave upon booting up. The microcontroller is powered up by the 5V that comes from the main controller.

However, each side controller still embeds a LM2596 regulator. The extra 3A current capability provided by

the regulator goes to the 5V DC motor that drives the wheel.

Figure 10: ATmega8A core system

Figure 11 is the design of the H-bridge for driving the worm motors. In the circuit, we use two IR2104

half-bridge chips to provide a 520 nanosecond deadtime to prevent instant short circuit when switching the

direction of the motor. Besides, we also have other circuitry consists of Schottky diodes and resistors that

protects the chips from reverse EMF (ElectroMotive Force). Note that IR2104 requires N-channel MOSFET

instead of typical P-channel ones for the upper arms in the H-bridge. In order to provide the floating VGS for

the NMOS in the upper arms, a bootstrap circuit built from a diode, a Tantalum capacitor, and a charging

resistor, is demanded. In order to charge the capacitor in the bootstrap circuit, we need a certain time of

low level in the driving signal. As a result, the PWM signal provided to the H-bridge cannot reach a 100%

duty cycle; instead, the peak duty cycle is limited at about 95%. The logics on the lower left side of the

figure are responsible to translate the direction and PWM signals into logics that IR2104 accepts. Thanks

to the logics, we are able to generate forward, backward, and breaking commands from two direction inputs

8

Figure 11: H-bridge

The MCU used on the PC side receiver is ATmega32U4. We use two communication modules provided by

the chip: USB for PC communication and SPI for interfacing with the wireless chip. Figure 12 is the core

system of the MCU. Its USB interface is also utilized by a built-in bootloader for programming the chip.

The wireless module on the receiver board is identical to that on the main controller. The receiver board

also has an LM1117 regulator for powering the wireless module up.

Figure 12: ATmega32U4 core system

2.2.2 Software

Because the master controller performs a number of independent tasks, we build the software upon an RTOS

(Real-Time Operating System) to coordinate all the functions. The pre-emptive scheduling provided by the

RTOS ensures high priority tasks to be served in real-time. Table 1 shows a list of tasks that are scheduled.

9

Table 1: RTOS tasks on the master controller

Task function Priority Wake up period

AL system algorithm highest 50ms

Update sensor reading high 10ms

Refresh OLED display low 100ms

Process received command and coordinate the ODM sys-

tem

low 100ms

Send sensor data over wireless low 50ms

System idle task that cleans up dynamic memory and an-

alyzes CPU usage

lowest N/A

Among the tasks, the AL system algorithm has the highest priority. It’s general flowchart is described in

Figure 13.

acquire sensor data

convert quaternions

to Eular angles

tilt angle > 1 degree

wait for new data

lift appropri-

ate wheels

acquire sensor data

tilt angle > 1 degree

set desired angle

to PID controllerwait for new data

yes

no

yes no

Figure 13: General AL system algorithm

10

Although the ODM system has a low priority, it’s still one of the most essential components of the system.

Figure 14 is the mounting coordinates of the servos in the system. The shaded parts in the graph are the

effective angles that the servos can reach, and the numbers at the end points of each half-circle are the

position commands sent to the servo for reaching those angles. In order to keep all the wheels parallel to

each other, a coordinate translation is required for all servos. Imagine that the positive direction on the y

axis in the graph stands for 0 in the whole system; hence, the positive direction on the x axis is 90, and the

negative direction on the y axis is −90. An example of the coordinate translation is also illustrated in the

figure. For the upper right servo, the system coordinate 0 is reinterpreted as 45 in the servo coordinate.

Nonetheless, since each servo can only rotate within 180, the system 180, which is the negative direction

on the y axis, cannot be directly translated into the upper right servo’s coordinate. As a result, we can still

map it to 45 in the servo coordinate and toggle the rotational direction of the corresponding driving wheel.

Any other angle is also able to be translated in the same manner. Therefore, a pseudo 360 coordinates

mapping is done. Table 2 is the complete mapping strategy for all servos. A negative sign at the front stands

for a toggled direction is demanded for the corresponding driving wheel, and the position command sent to

the servo is actually the value within the parentheses. If the calculated result exceeds the upper or lower

limits (±180), the final command should be decreased or increased by 360 respectively.

x

y 45

90

90

−90 90

−90

−90

90 −90

90

Figure 14: Coordinates of the ODM system

Table 2: Servo coordinates mapping strategy

System angle θ Upper left Upper right Lower left Lower right

[−45, 135) N/A 45− θ −(45− θ) N/A

(−180,−45)∪[135, 180] N/A −(−θ − 135) −θ − 135 N/A

[−135, 45) −θ − 45 N/A N/A −(−θ − 45)

(−180,−135)∪[45, 180] −(−θ + 135) N/A N/A −θ + 135

11

In order to achieve maximum performance, all the peripheral and communication module drivers are designed

with non-blocking algorithms.

1. The I2C driver is optimized for RTOS, which means it suspends the calling task when a block read/write

is required and resumes the task after the transaction finishes. This mechanism allows other task to

obtain the CPU resource when a task is waiting for a transaction. The driver also utilizes a DMA

(Direct Memory Access) channel that significantly reduces the CPU load. Furthermore, the fully

automatic streaming algorithm hides the low level interrupt implementation from the RTOS, fulfilling

an OOP (Object Oriented Programming) pattern.

2. The SPI driver also uses a DMA channel as well as a streaming scheme. Besides, the driver packs

the operation mode of the target device into each packet. For instance, the RF chip works at 10MHz

while the OLED is as fast as 33MHz. Therefore, the SPI hardware is able to switch among different

modes autonomously. Different from the I2C driver, the SPI one does not do the RTOS trick. The

reason is that the SPI bus works at high speed comparing to the 400KHz I2C bus; thus, frequent

context switching among tasks may introduce additional overhead. Hence, whether or not to suspend

the calling task has a performance trade off.

The wireless transceiver that we introduce to the project – nRF24L01P – uses a built-in protocol called

Enhanced ShockBurstTM to perform handshaking and error checking so that the MCU can save computing

power for other tasks. The driver for the transceiver embraces the same design idea with the lower level

drivers described above. The driver takes buffers from user and streams them out in a FIFO (First In First

Out) manner. Since the Enhanced ShckBurstTM protocol allows variable length package with maximum

length at 32 bytes[6], if the buffer given by a user has content larger than 32 bytes, the API for appending

package will first recurse to divide the buffer into multiple packages and then add them into the send queue.

The transceiver has two work modes: PTX (Primary Transmitter) and PRX (Primary Receiver), our strategy

is to configure it as PRX when it is idle, and only switch it to PTX when the send queue has packages waiting

to be streamed out. The transceiver has 3 maskable interrupt sources, and uses a pulse on the IRQ pin to

report an interrupt. The sources are: RX DR (RX data ready), TX DS (TX data sent), and MAX RT (TX

maximum retry reached). The driver makes use of all of them, and to handle them as follow:

1. RX DR:

(a) Read the length of the incoming package

(b) Allocate a buffer that fits the length

(c) If the receive queue has too many packages waiting for the user to fetch, then remove and free

the head from the receive queue

(d) Add the incoming package to the tail of the receive queue

2. TX DS:

(a) Check if more packages are in the send queue. If so, continue to send the next package

(b) If not, go to PRX mode

3. MAX RT, this interrupt is triggered when the transmitter loses connection with the receiver, so we

handle it as:

(a) Flush the TX FIFO in the transceiver

(b) Rewrite the last package into the TX payload

12

In contrast to the master controller, the software for the slave ones is relatively simple. It adopts a traditional

foreground-background design, which has an background infinite loop for executing commands and multiple

interrupt service routines as foreground events. As an I2C slave device, the slave controllers follow the I2C

register convention. Table 3 is the list of commands that the controller accept.

Table 3: I2C slave commands

Command

number

Read/write Function

0x01 W Set the PWM output of the driving wheel

0x02 W Set the PWM output of the worm motor

0x03 W Set the position of the servo

0x04 W Set the calibration data to the servo

0x05 W Set the threshold of the saturation filter

0x06 W Break the worm motor

0x07 W Break the driving wheel

0x08 W Give the PID set point to the driving wheel

0xFE R Read the speed of the driving wheel

0xFF R Read the position of the worm motor

When the slave controller receives a command that sets the PID destination of the driving wheel (command

0x08), it loops to execute the control strategy demonstrated in Figure 15 until the error between the set

point and feedback is reduced to a certain range. By tuning the PID constant Kp, Ki, Kd in the figure, the

control scheme finally reaches a 300ms settling time. With this control system, the ODM system is able to

output the same speed to all its 4 wheels, which successfully maintains the heading direction of the whole

vehicle stable.

Ki ×∫ τ0e(τ)dτ

Kp × e(t)

Kd × de(t)dt

Saturation Filter Motor Systemcontroller signal e(t) output

−+

+

Figure 15: Motor control strategy

13

In order to pair with the main controller, the receiver on the PC side also uses an nRF24L01P. Although the

driver for it is also based on stream, it handles the modes differently. Unlike the driver on the AVR32, which

switches to PTX for sending packages, the driver on the receiver side always stays at PRX. When there

are packages ready to send, it utilizes the acknowledgment package specified in the Enhanced ShckBurstTM

protocol to send them[6]. An acknowledgment package is the same with a normal TX package in term of

length; however, it is sent passively when the receiver is acknowledging the transmitter. Therefore, it is never

sent until the link is established between the transmitter and the receiver; thus, the MAX RT interrupt will

never happen under this configuration.

The USB controller in ATmega32U4 has a control endpoint (EP0) with a bank up to 64 byte and 6 other

programmable endpoints. Besides the default EP0, the CDC specification uses other 3 endpoints. One

is used by the CDC class interface, and the other two are used by the data interface. We configure the

endpoints in the AVR as follow:

1. Endpoint 1 is configured in bulk IN mode and has two 64 byte banks in ping-pong mode. It sends the

data from the wireless interface to the PC.

2. Endpoint 2 is configured in bulk OUT mode and has a 32 byte single bank. It receives data from the

PC. The reason not using a 64 byte bank is that 32 byte matches the maximum package size of the

RF chip. This configuration effectively prevents the incoming USB packages from overflow.

3. Endpoint 3 is configured in interrupt IN mode and has a 64 byte single bank. It works as the man-

agement endpoint for the CDC class interface. This endpoint is essentially a dummy one. We do not

need to handle any event from it.

After finish the embedded software, we also need to install the PC driver to test it. Since Windows has a

built-in driver for CDC devices, all we need to do is constructing an .inf file that describes the device. In

order to identify our device, we have to set up the VID (Vendor ID) and PID (Product ID) first. Nonetheless,

applying for valid VID and PID is expensive. Fortunately, ATMEL provides several sets of free VID and

PID for products that uses AVR. The free set for CDC devices are VID=0x16C0 and PID=0x05DF. Figure

16 is a screen shot of the Windows device manager when the receiver is connected.

Figure 16: The Windows device manager identifies the receiver.

Since the receiver is working, we moved on to develop the PC interface software. The resulting GUI (Graphic

User Interface) is shown in Figure 17. The program delivers the following functions so far:

1. Read from the virtual serial port and decode the received data into the real-time roll, pitch, and yaw

information of the vehicle. The low level serial port communication support is provided by a third

party library called QExtSerialPort.

2. Send encoded command to the virtual serial port for controlling the movement of the robot according

the the interaction between the GUI widgets and the operator.

3. Provide intuitive illustration for the incoming data by reflecting the Eular angles on 3D models.

4. Real-time line charts of the data present the trends of the vehicle’s movement.

14

5. Received data can be stored in a special compact file format for future playback and analysis.

Figure 17: GUI software

15

3 Design Verification

This section discusses the general result that the major parts of the system yield. For the full requirements

and verification table, please see the Appendix A.

3.1 Master Controller

The main controller is fully functional according to the verification table. Besides, thanks to the RTOS, we

managed to develop a method to probe the CPU usage of the main processor by counting how much time the

system idle task occupies the CPU comparing to the total time that the CPU runs. Two different counting

methods delivered the ceiling and the floor of the performance. Figure 18 shows the surprising result of the

test: because of the high performance non-blocking asynchronous drivers that we designed, the CPU usage

is as low as around 0.1%∼ 4.6.

1. Performance ceiling: We consider the CPU at idle only when the idle task occupies a whole OS tick

(1ms).

2. Performance floor: We consider the CPU at idle if during an OS tick the idle task is ever resumed.

Figure 18: CPU usage chart

3.2 MEMS Sensors

The MEMS sensor is able to provide roll, pitch and yaw tilt in quaternion format. With its built-in filter,

the results show no pattern of drift and notable noise. The data is verified by keeping the robot still for

a certain period and tracking the sensor reading. After test, we found the standard deviation of total 978

data points is 0.0534, which is satisfying. Furthermore, the long term drift is almost zero in the result chart

(Figure 19). In the plot, the blue trace is the roll reading while the violet one the from pitch. Since the

yaw data are irrelevant to the project, we exclude them from the graph. Conclusively, the sensor output is

robust and credible.

16

Figure 19: MEMS sensor test

3.3 ODM System

The overall ODM system has achieved a stable performance. The PID control system for the driving wheel is

able to keep a 300ms settling time. The servos are calibrated to output the same angle with errors confined

in 5.

3.4 AL System

Due to the mechanical limitation of the worm motor, we could not test the active suspension system of the

vehicle in real world scenarios. However, we still tested the system using software simulation and later proved

that our design is viable. The first verification conducted was to test the settling time of the control system.

The original requirement for it was 50ms. After a careful reconsideration, we changed the requirement to

300ms. Several reasons exist for this change. First, our control feedback sampling period is 50ms, a greater

settling time should be allowed for feedback to become effective. Second, a 50ms settling time will result

in big PID constants, which would make the system unstable by introducing larger overshoot. Last but

not least, a 300ms settling time is quick enough for the system to react. Figure 20 presents the simulation

results. The white signals are randomly generated ramps, and the violet ones shows the system’s reaction.

The graph justifies the quick response rate of the AL algorithm.

Figure 20: AL algorithm simulation

17

4 Cost

4.1 Parts

Table 4: Itemized budget

Part name Unit

cost ($)

Manufacturer Number

required

Subtotal

($)

Actual

Cost ($)

AT32UC3C2256 13.78 ATMEL 1 13.78 13.78

ATmega8A 1.84 ATMEL 4 7.36 7.36

ATmega32U4 3.38 ATMEL 1 3.38 3.38

Worm motor 7 from China 4 28 28

Servo 4 from China 4 16 16

DC motor 4 from China 4 16 16

Encoder 2 from China 4 8 8

Battery 8.2 from China 1 8.2 8.2

nRF24L01P RF module 10.0 Nordic Semiconductor 2 20.0 20.0

MPU-6050 7.14 InvenSense 1 7.14 29.28

IRF3205S 0.42 International Rectifier 16 6.72 6.72

IR2104 0.62 International Rectifier 8 4.96 4.96

MAX629 1.54 MAXIM 1 1.54 0

LM2596S-5.0 0.31 Texas Instrument 4 1.24 0

LM1117-3.3 0.05 Texas Instrument 2 0.10 0.10

LM2594-3.3 1.54 Texas Instrument 1 1.54 1.54

OLED Display 4.92 Univision 1 4.92 4.92

oscillator 0.77 from China 6 4.62 4.62

PCB 20 from China 3 60 60

Misc. components from

China

N/A N/A 5 5

Total 218.5 237.86

4.2 Labor

Machine shop estimation: $1000

Zhangxiaowen Gong: $35/hr × 12hr/week × 10 weeks = $4200

Wenjia Zhou: $35/hr × 12hr/week × 10 weeks = $4200

Jun Ma: $35/hr × 12hr/week × 10 weeks = $4200

Total: $4200 × 3 × 2.5 = $31500

The total expense is $31500 + $237.86 = $1000 = $32737.86

18

5 Conclusion

5.1 Accomplishments and Future Work

We are satisfied with the performance of our vehicle. The ODM system, on-board task management, and

the wireless interface all work flawlessly. Our design has fulfilled most of the requirements and functioned as

expected except that the AL system does not work due to the insufficient torque from the worm motor that

we use. Nonetheless, the simulation results give promising data to justify the AL algorithm. As a result,

a redesign to the physical AL system should deliver successful outcome. A possible alternative approach is

to replace the worm motor with linear actuator. The latter one is slower yet more stable and stronger. We

may also attach a pressure sensor to each driving wheel to examine whether the wheel is firmly touching the

ground so that the measured vehicle state is more credible. In addition, the open-loop controlled RC servos

are hard to be calibrated to output the same angle; hence, we may later adding sensors such as Hall effect

sensors to transform the system into a closed-loop controlled one. Another possible improvement is on the

processor side. Since the CPU usage shows that the main microcontroller is significantly overpowered, we

may also substitute it with a low end ARM Cortex-M3 processor, which may cost only around $3 each.

5.2 Uncertainties

The mechanical part on the small size model system deviates from an actual full size vehicle notably.

Therefore, although we successfully implement the design on the model system, all the parameters in the

control system have to be re-calculated for the real system. Furthermore, an operating system based software

tends to hide subtle synchronization bugs, which may result in hanging the system. For critical operations

like carrying dangerous chemicals, such system failure is intolerable. Consequently, the software has to be

carefully examined to eliminate any of such bugs.

5.3 Ethical considerations

We commit ourselves to the IEEE code of ethics, the ethical concerns we have is as follows:

‘to accept responsibility in making decisions consistent with the safety, health and welfare of

the public, and to disclose promptly factors that might endanger the public or the environment;’

In the case of our project, our design is intended for laboratory use. Nonetheless, we cannot neglect the pos-

sibility that our design is used by unauthorized person or group for transporting unexpected and dangerous

chemical, for instance, any sort of poisons or explosives. If our product is to be used, we will make sure we

only hand it to authorized person or group, and make sure only they know how to operate the system.

19

References

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2012. [Online]. Available: http://www.omnixtechnology.com/direct components.html

[2] App Note: 9-Axis MotionFusion & Calibration Algorithms, InvenSense Inc., Sunnyvale, CA,

2011. [Online]. Available: http://www.invensense.com/developers/index.php? r=downloads&ajax=

dlfile&file=AppNote%20-%209-Axis%20MotionFusion%20and%20Calibration%20Algorithms.pdf

[3] “IRF3205S IRF3205L,” Datasheet, International Rectifier, 2002. [Online]. Available: http:

//www.irf.ru/pdf/irf3205s.pdf

[4] “Class 1 Bluetooth Dongle Test,” Web page, accessed May 2012. [Online]. Available: http:

//www.amperordirect.com/pc/r-electronic-resource/z-reference-bluetooth-class1-myth.html

[5] IEEE 802.15.4d-2009 IEEE Standard for Information Technology - Specific Requirements – Part 15.4:

Wireless Medium Access Control (MAC) and Physical Layer (PHY) Specifications for Low-Rate

Wireless Personal Area Networks (WPANs), IEEE, New York, NY, 2009. [Online]. Available:

http://standards.ieee.org/getieee802/download/802.15.4d-2009.pdf

[6] “nRF24L01+ Product Specification,” Datasheet, Nordic Semiconductor, 2008. [Online]. Available:

http://www.nordicsemi.com/kor/nordic/download resource/8765/2/23366062

[7] Bi-directional Level Shifter for I2C-bus and Other Systems, Philips Semiconductors, 1997. [Online].

Available: http://ics.nxp.com/support/documents/interface/pdf/an97055.pdf

[8] “LM2596 SIMPLE SWITCHER Power Converter 150 kHz3A Step-Down Voltage Regulator,” Datasheet,

Texas Instrument, 2002. [Online]. Available: http://www.ti.com/lit/ds/symlink/lm2596.pdf

[9] “MAX629 28V, Low-Power, High-Voltage, Boost or Inverting DC-DC Converter,” Datasheet, Maxim

Integrated Products, 1997. [Online]. Available: http://pdfserv.maxim-ic.com/en/ds/MAX629.pdf

20

http://www.omnixtechnology.com/direct_components.html

http://www.invensense.com/developers/index.php?_r=downloads&ajax=dlfile&file=AppNote%20-%209-Axis%20MotionFusion%20and%20Calibration%20Algorithms.pdf

http://www.invensense.com/developers/index.php?_r=downloads&ajax=dlfile&file=AppNote%20-%209-Axis%20MotionFusion%20and%20Calibration%20Algorithms.pdf

http://www.irf.ru/pdf/irf3205s.pdf

http://www.irf.ru/pdf/irf3205s.pdf

http://www.amperordirect.com/pc/r-electronic-resource/z-reference-bluetooth-class1-myth.html

http://www.amperordirect.com/pc/r-electronic-resource/z-reference-bluetooth-class1-myth.html

http://standards.ieee.org/getieee802/download/802.15.4d-2009.pdf

http://www.nordicsemi.com/kor/nordic/download_resource/8765/2/23366062

http://ics.nxp.com/support/documents/interface/pdf/an97055.pdf

http://www.ti.com/lit/ds/symlink/lm2596.pdf

http://pdfserv.maxim-ic.com/en/ds/MAX629.pdf

Appendix A Requirement and Verification Table

A.1 Main Controller

Table 5: Requirement and verification for the main controller

Item Requirement and verification (Y/N) Test/calibration procedure

OLED dis-

play 1. Display characters at spe-

cific coordinates (Y)

1. (a) Command the OLED to display

strings with various lengths at dif-

ferent location

(b) See if all 128 × 64 pixels are opera-

tional

(c) See if all ASCII characters are

mapped to pixels correctly

(d) See if the designated coordinates are

translated to right positions

(e) Check if the strings wrap around

correctly

DSP filter (if

present) 1. Finish each filter compu-

tation within 10ms (Soft-

ware filter is aban-

doned)

2. Filter at least 90% vibra-

tional noise out

1. (a) Turn on the built-in 16-bit T/C

(timer/counter) before starting the

calculation and record the value in

the T/C register right after the

computation finishes

(b) Calculate the delay from the T/C

reading and its clock source setting

2. (a) Send both filtered and raw data to

a computer

(b) Calculate and compare the stan-

dard deviation of each set of data

Continued on next page

21

Table 5 – continued from previous page


I2C interface

1. Signals have almost verti-

cal edges maximum clock

speed at 400KHz (Y)

2. No malfunction in high-

noise environment (Y)

3. Communication between

3.3V I2C bus and 5V I2C

bus (Y)

4. The streaming algorithm

is able to save over 70%

CPU cycles from simple

synchronous drivers (Y)

1. (a) Set the I2C bus to 400KHz and then

use an oscilloscope to probe the SCL

and SDA lines

(b) Check the edges on the signals and

determine of the curve on the edges,

which are caused by the capacitance

on the trace/wire and the pull-up

resister specified in the I2C stan-

dard, is in an acceptable shape

2. Test the transmission when the H-bridges

and motors are turned on, and see if any

data loss occurs

3. Test the level shifting circuit to see if it

converts signals bidirectionally

4. Loop to append 100 I2C transactions and

see how many packages remain in the

queue after the appending operation is

done; the more packages still stay in the

queue the better the algorithm is


22



SPI interface

1. Internal shift register is

functional (Y)

2. No malfunction in high-

noise environment (Y)

3. When addressing one slave

device, no interference

coming from the others

(Y)

4. Utilize the DMA channel

for both transmitting and

receiving data (Y)

1. Check if the slave data shift to the master

correctly when the master shift its data

out

2. Test the transmission when the H-bridges

and motors are turned on, and see if any

data loss occurs

3. (a) Pull down the chip select lines on

different slaves and see if data go to

correct receiver

(b) Check if the master changes SPI

mode (clock phase, clock polar-

ity, etc.) correctly when switching

among slaves that adopt different

modes

(c) Keep addressing various slaves for

10 minutes and capture any mal-

function

4. (a) Turn on the inner-loop function of

AVR32’s SPI module, which inter-

connect its input to its output

(b) Set one DMA channel to transmit

data in a block of memory

(c) Set the second DMA channel to re-

ceive data and to store them in an-

other block of memory

(d) After the transmission finishes,

check the consistency of the content

in the two memory blocks

23

A.2 MEMS Sensors

Table 6: Requirement and verification for the MEMS sensors


MPU-6050

1. Be configured with proper

work mode (sensitive

range, interrupt output,

etc.) (Y)

2. Allow the main controller

to configure its auxil-

iary sensor (HMC5883L)

(HMC5883L is aban-

doned)

3. Accelerometer and gyro

scope data are consistent

(Y)

1. (a) Read values from all registers from

the sensors’ register map and check

with the default value stated in

their datasheets

(b) Change values in several registers

and then read back to see if the op-

erations succeed

(c) Move/turn the sensor at certain

rate and check if the output is in

the expected range

2. (a) Use the sensor’s internal MUX to

hand the auxiliary sensor to the

main controller temporarily

(b) Let the main controller to verify if

it can change the auxiliary sensor’s

registers correctly

(c) Get the auxiliary sensor back from

the main controller and try to read

its output

(d) Let the main controller to address

the auxiliary sensor again; the op-

eration should fail now

3. (a) Put sensor unit on the table, tilt a

little bit, and record the output

(b) Calculate θ from accelerometer’s x-

axis (x) and z-axis (z) data: θ =

arctan(−xz )

(c) Calculate γ from gyroscope’s z-axis

(ω) output: γ = ω × t(d) θ should be close to γ


24



HMC5883L


work mode (gain, in-

terrupt output, etc.)

(HMC5883L is aban-

doned)

2. Error is controlled within

2

1. Perform similar procedure that checks

the MPU-6050

2. (a) Place the sensor on the table and

tilt 45 at a time

(b) Record the output and compare

it to the actual angle; error =

actual − output(c) Repeat the step (a) and (b) until the

total angle tilted reaches 720

(d) Calculate the peak and average of

the errors

A.3 Side Controllers

Table 7: Requirement and verification for the side controllers


I2C interface

1. Robust communication

with no data loss and

bus errors in high-noise

environment (Y)

2. Multiple side MCUs can

communicate with the

main controller via a single

I2C interface without

suffering bus conflict (Y)

1. Perform the test 1 and 2 in the I2C part

in section 3.1.1

2. (a) Send commands to different slave

MCUs to verify the addressability

(b) Let the main controller keep chang-

ing the slave MCU for 10 minutes and

see if the bus fails in the duration

PWM

1. Generate 3 PWM signals

with different duty cycles

simultaneously (Y)

1. (a) Write a program that generate 3

PWM signals with different duty cy-

cles and changes the duty cycle every

10 seconds

(b) Use 2 oscilloscopes to probe the 3

PWM output pins

(c) Check the correctness of each signal

over time


25



H-bridge

1. Require no heat sink when

driving current stables at

the worm motor’s rated

current, which is 1.10A

(Y)

2. Respond to PWM signals

that have duty cycles rang-

ing from 15% to 95% (Y)

1. (a) Connect an ammeter between the H-

bridge output and the worm motor

(b) Set the H-bridge to output at full

speed (95% duty cycle PWM) and

increase the load on the worm mo-

tor until the ammeter reading reaches

1.10A

(c) Keep the motor spinning for 2 min-

utes

(d) Put on antistatic wrist strap and

feel the temperature on the driving

MOSFET with bare finger; the fin-

ger should not feel hot

2. (a) Set the PWM signal to 15%

(b) Let the H-bridge drive a motor with

no load for 1 minute and see if the

speed is constant

(c) Repeat (a) and (b) with a 10% in-

crease in duty cycle each time untile

the duty cycle reaches 95%

26

A.4 Wireless Communication

Table 8: Requirement and verification for the wireless communication


nRF24L01P


work mode (channel, ad-

dress, data rate, etc.) (Y)

2. Communication range is

higher than 100m outdoor

(Y)

3. Communication is not af-

fected if the transceivers

have a wall in between (Y)

1. Perform the test 1 in the MPU-6050 part

in section 3.1.2

2. (a) Put the transmitter and receiver at

the two corners of the Quad

(b) Turn on both transceivers and check

for stable transmission

(c) If fail to establish the data link, hold

the transmitter and walk towards the

receiver until stable data appears

(d) Mark the final locations of the

transceivers on a scaled map and

measure the distance

3. (a) Put the two transceivers in two ad-

jacent rooms and start the transmis-

sion

(b) If the data is stable, move the

transceivers to rooms that have two

walls in between

(c) Increment the number of walls in be-

tween and perform the test until ei-

ther the transmission is blocked of

the number reaches 5

(d) Repeat the test with transceivers

placed in different floors


27



Driver

1. Connect/disconnect au-

tomatically when the

paired transceivers are

in-range/out-of-range (Y)

2. Automatically resend

packages that is not ac-

knowledged by the receiver

(Y)

3. The streaming algorithm

is able to save over 70%

CPU cycles from simple

synchronous drivers (Y)

1. (a) Make the transmitter keep sending

packages

(b) Switch the on/off state of the receiver

several times

(c) See if the link is reestablished auto-

matically

2. In the above test, check if any package is

lost during the off state of the receiver

3. Perform the test 3 in the I2C part in sec-

tion 3.1.1

A.5 Omni-directional Movement

Table 9: Requirement and verification for the omni-directional movement


DC motor

1. With speed control algo-

rithm, all motor respond

the speed command (0 ∼255) identically (Y)

1. (a) Set the speed commands for all mo-

tors to 50

(b) Use a tachometer to record the speed

of each motor

(c) Repeat (a) and (b) with a 50 increase

in speed command each time until

the command reaches 250


28



Servo

1. All servos respond to posi-

tion commands identically,

which means turning to the

same angle (Y with error

in 5circ)

2. Turn 60 with regular load

within 0.25 second (Y)

1. (a) Set PPM signals equal to the raw po-

sition commands

(b) Set the duty cycle of the raw com-

mand to 2.5% (0.5 millisecond high

level) and provide it to all servos

(c) Record the position of all servos

(d) Repeat (b) and (c) with a 1.0% in-

crease in duty cycle each time until

the duty cycle reaches 12.5% (2.5 mil-

lisecond high level)

(e) Pick one servo as standard, and then

calculate scalar and offset errors of

the other servos according to the re-

sults

(f) Apply proportional and offset fac-

tors to the raw command to gener-

ate modified signals and do (b) to (d)

several times until all servos respond

to the raw command identically

2. (a) Put the vehicle on the table and let

one servo turn 60

(b) Use a video camera with 60fps frame

rate to capture the movement

(c) Playback the video frame by frame

and count the number of frames

taken to finish the turning

(d) Calculate the actual delay in second

by delay = frametaken60

29

A.6 Active Suspension

Table 10: Requirement and verification for the active suspension


PID algo-

rithm 1. Settling time is controlled

in 50ms (Requirement

changed to 300ms; con-

firmed in simulation)

2. Error between desired an-

gle and actual turned an-

gle is smaller than 2 (Ver-

ified in simulation)

1. (a) Run Simulink in MATLAB and set

the desired angle x as input to the

system

(b) Plot step response in MATLAB

and find the time when the output

reaches 95% of steady state value

(c) Load PID parameter into the vehicle

and run it over a ramp with slope = x

(d) Collect potentiometer reading from

the controller’s ADC (analog to dig-

ital converter), which indicates the

angle turned, and import them to

MATLAB

(e) Mark the delay between the initial

position and the final position by an-

alyzing the data

2. (a) Set 10 as the target angle to the PID

system

(b) Measure the actual turned angle via

a protractor after the system reaches

stable state

(c) Record the error

(d) Repeat from (a) to (c) with a 10 in-

crease in target angle each time until

the target angle reaches 50

30

A.7 PC Receiver

Table 11: Requirement and verification for the PC receiver


USB inter-

face 1. Both PC side driver and

MCU side driver are func-

tional (Y)

2. Data rate is independent

from the virtual serial

port’s baud rate setting

(Y)

1. (a) Connect the receiver to the PC’s USB

port and see if the PC recognize it

with the name specified in the .inf file

we write

(b) Open the corresponding virtual serial

port in the HyperTerminal

(c) Exchange a group of data and verify

the correctness

2. (a) Set the baud rate of the virtual serial

port to 240bps

(b) Loop to send 1KB of random data to

the PC

(c) Check whether the transmission com-

pletes instantly instead of taking

around 4 seconds

PC software

1. Receive real-time data and

reflect them on line charts

(Y)

2. Store data and time in file

and playback afterwards

(Y)

1. (a) Establish the wireless link between

the vehicle and the PC

(b) Move the vehicle randomly by hand

(c) Check if the line charts correctly dis-

play the movement without recogniz-

able delay

2. (a) Write received data to a non-existed

file and check if the file is created suc-

cessfully in the file system

(b) Open the file and check the consis-

tency with the original data

31

A.8 Power Management

Table 12: Requirement and verification for the power management


Voltage reg-

ulation 1. Correctly generate 12V

(10% tolerance), 5V (1%

tolerance), and 3.3V (1%

tolerance) voltages (Y

12V requirement is

changed to 13.8V)

2. Voltages are stable (5%

tolerance) during potential

instant high load (Y)

1. Use voltmeter to probe all 3 generated

voltages

2. (a) Build a voltage divider to translate

all three voltages proportionally to

2V range

(b) Temporarily connect the three trans-

lated voltages to the main controller’s

ADC input pins

(c) Run the vehicle for 5 minutes and

send the ADC readings real-timely to

the host computer

(d) Calculate the standard deviation and

the minimum of the data

(e) Replace the bypass capacitors with

ones having higher capacitance if in-

stant voltage drops are observed, and

then repeat from (a) to (d)

Battery

1. Support the vehicle for 1

hour of continuous opera-

tion (Y)

1. (a) Fully charge the battery

(b) Run the vehicle until the battery dies

(c) Record the duration


32



Power con-

sumption 1. Peak current is lower than

6A (Unable to test)

2. Average current is lower

than 2A (Unable to test)

1. (a) Connect a 0.25Ω 10W sensing resister

in the battery loop

(b) Use AVR32’s differential ADC chan-

nel to probe the voltage drop on the

resister

(c) Run the vehicle for 10 minutes and

send the ADC readings real-timely to

the host computer

(d) Find the peak current among the

data

2. In the above test, continue to calculate the

average of all data

33

Appendix B Full Schematics and PCB Layouts

B.1 The Master Controller

34

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\2.4GHz.Wireless.SchDoc Drawn By:

2.4GHz wireless interface

Zhangxiaowen Gong

CE3

CSN4

SCK5

MOSI6

MISO7

IRQ8

GND1

VCC2RF1

nRF24L01+ board

MOSIMISO

SCKCS

SPI0SPI1

SPI2SPI3

SPI[5..0] SPI[5..0]

CE

VCC

GND

IRQIRQPIRF101

PIRF102

PIRF103

PIRF104

PIRF105

PIRF106

PIRF107

PIRF108

CORF1

PIRF101

PIRF108

NLIRQPOIRQ

PIRF103POCEPIRF102

NLSPI050000POSPI050000

NLSPI050000POSPI050000

POCE

POIRQPOSPI0POSPI1POSPI2POSPI3POSPI4POSPI5POSPI050000

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\My.PCBs\ECE445\AVR32.SchDocDrawn By:

PA00(CANIF-TXLINE[1])1

PA01(CANIF-RXLINE[1]/PEVC-PAD_EVT[0])2

PA02(SCIF-GCLK[0]/PEVC-PAD_EVT[1])3

PA03(SCIF-GCLK[1]/EIC-EXINT[1])4

VDDIO1 5

GNDIO1 6

PA04(ADCIN0/USBC-ID/ACIFA0-ACAOUT)7

PA05(ADCIN1/USBC-VBOF/ACIFA0-ACBOUT)8

PA06(ADCIN2/AC1AP1/PEVC-PAD_EVT[2])9

PA07(ADCIN3/AC1AN1/PEVC-PAD_EVT[3])10

PA08(ADCIN4/AC1BP1/EIC-EXINT[2])11

PA09(ADCIN5/AC1BN1)12

PA16(ADCREF0/DACREF)13

ADCVREFP 14

ADCVREFN 15

PA19(ADCIN8/EIC-EXTINT[1])16

GNDANA 17

VDDANA 18

PA20(ADCIN9/AC0AP0/AC0AP or DAC0A)19

PA21(ADCIN10/AC0BN0/AC0BN0 or DAC0B)20

PA22(ADCIN11/AC0AN0/PEVC-PAD_EVT[4]/MACB-SPEED)21

PA23(ADCIN12/AC0BP0/PEVC-PAD_EVT[5]/MACB-WOL)22

VBUS 23DM 24DP 25

GNDPLL 26

VDDIN_5 27

VDDIN_33 28

VDDCORE 29

GNDCORE 30

(XIN0)PB30 31

(XOUT0)PB31 32

PD02(SPI0-SCK/TC0-CLK2/QDEC0-QEPA)49

PD03(SPI0-NPCS[0]/TC0-B2/QDEC0-QEPB)50

VDDIO3 51

GNDIO3 52

PD11(USART1-TXD/USBC-ID/PEVC-PAD_EVT[6]/MACB-TXD[0])53

PD12(USART1-RXD/USBC-VBOF/PEVC-PAD_EVT[7]/MACB-TXD[1])54

PD13(USART1-CTS/USART1-CLK/PEVC-PAD_EVT[8]/MACB-RXD[0])55

PD14(USART1-RTS/EIC-EXINT[7]/PEVC-PAD_EVT[9]/MACB-RXD[1])56

PD21(USART3-TXD/EIC-EXINT[0])57

PD28(USART0-RXD/CANIF-TXLINE[0]/TC0-B0/MACB-RX_DV)59 PD27(USART0-TXD/CANIF-RXLINE[0]/TC0-A0/MACB-RX_ER)58

PD29(USART0-CTS/EIC-EXINT[6]/USART0-CLK/TC0-CLK0/MACB-TX_CLK)60

PD30(USART0-RTS/EIC-EXINT[3]/TC0-A1/MACB-TX_EN)61

PB00(USART0-CLK/CANIF-RXLINE[1]/EIC-EXTINT[8]/PEVC-PAD_EVT[10]/XIN32)62

PB01(CANIF-TXLINE[1]/PEVC-PAD_EVT[11]/XOUT32)63

RESET 64

PC02(TWIMS0-TWD/SPI0-NPCS[3]/USART2-RXD/TC1-CLK1/MACB-MDC)33

PC03(TWIMS0-TWCK/EIC-EXINT[1]/USART2-TXD/TC1-B1/MACB-MDIO)34

VDDIO2 35

GNDIO2 36PC04(TWIMS1-TWD/EIC-EXINT[3]/USART2-TXD/TC0-B1)37

PC05(TWIMS1-TWCK/EIC-EXTINT[4]/USART2-RXD/TC0-A2)38

PC15(PWM-PWMH[1]/SPI0-NPCS[0]/USART0-RXD/CANIF-RXLINE[1])39

PC17(PWM-PWMH[0]/SPI0-NPCS[2]/IISC-ISDO/USART3-TXD)41 PC16(PWM-PWML[1]/SPI0-NPCS[1]/USART0-TXD/CANIF-TXLINE[1])40

PC18(PWM-PWML[0]/EIC-EXINT[5]/IISC-ISDI/USART3-RXD)42

PC19(PWM-PWML[2]/SCIF-GCLK[0]/IISC-IMCK/USART3-CTS)43

PC20(PWM-PWMH[2]/SCIF-GCLK[1]/IISC-ISCK/USART3-RTS)44

PC21(PWM-EXT_FAULTS[0]/CANIF-RXLINE[0]/IISC-IWS)45

PC22(PWM-EXT_FAULTS[1]/CANIF-TXLINE[0]/USART3-CLK)46

PD00(SPI0-MOSI/TC1-CLK0/QDEC0-QEPI/USART0-TXD)47

PD01(SPI0-MISO/TC1-A0/TC0-CLK1/USART0-RXD)48

U1

AT32UC3C2256

VCC

10uH L1

Inductor

NC GNDOUT VDD

Y1

Osc

K2

SW

0.1uF

C6

Cap Semi

0.1uF

C3Cap Semi

0.01uF

C4Cap Semi

1uF

C5Cap Tant

SPI0SPI1SPI2SPI3

SPI4SPI5

MOSIMISOSCKNPCS0

NPCS1NPCS2

SPI[5..0]

TWI00TWI01

TWI10

TWD0TWCK0

TWD1TWCK1TWI0[1..0]

TWI1[1..0]

SPI[5..0]

TWI1[1..0]

TWI0[1..0]

0.1uF

C2Cap Semi

VBUS1 D-2 D+3 ID4 GND5 GND0USB1

Mini USB

22

R2

Res3

22

R3

Res3

UID

UID

K1SW

0.1uF

C1Cap Semi

4.7K

R1Res3

VCC

GND

EXTINT6EXTINT3

EXTINT0

EXTINT0

EXTINT7

EXTINT5

EXTINT8

EXTINT1

EXTINT2

EXTINT8EXTINT1EXTINT2

EXTINT5EXTINT4 TWCK1

EXTINT[8..0] EXTINT[8..0]

Res1-1 1Res2-1 2Res3-1 3Res4-1 4

Res1-28 Res2-27 Res3-26 Res4-25R6

4 Res Pack

TWI00TWI01

VCC

pull-up resisters for TWI pins

pushing during reset will start the bootloader

Zhangxiaowen Gong

AVCC

AVCC

AVR32 microcontroller core system

Q1BSN20

Q2BSN20

+5V

TWCK1

TWD1

VCC

1K

R4Res3

1K

R5Res3

TWD1TWCK1

TWI11

level convertion between 3.3V and 5V

TXDRXD

USART0USART1

USART[1..0]USART[1..0]

0.1uF

C27Cap Semi

0.1uF

C28Cap Semi

PIC101

PIC102COC1

PIC201

PIC202 COC2

PIC301

PIC302 COC3

PIC401

PIC402 COC4 PIC501

PIC502

COC5

PIC601PIC602

COC6

PIC2701

PIC2702 COC27

PIC2801

PIC2802 COC28

PIK101

PIK102

COK1

PIK201PIK202

COK2

PIL101 PIL102

COL1

PIQ101PIQ102 PIQ103

COQ1PIQ201PIQ202 PIQ203

COQ2

PIR101

PIR102

COR1

PIR201 PIR202COR2

PIR301 PIR302

COR3

PIR401

PIR402COR4

PIR501

PIR502COR5

PIR601

PIR602

PIR603

PIR604PIR605

PIR606

PIR607

PIR608

COR6

PIU101

PIU102

PIU103

PIU104

PIU105

PIU106

PIU107

PIU108

PIU109

PIU1010

PIU1011

PIU1012

PIU1013

PIU1014

PIU1015

PIU1016

PIU1017

PIU1018

PIU1019

PIU1020

PIU1021

PIU1022

PIU1023

PIU1024

PIU1025

PIU1026

PIU1027

PIU1028

PIU1029

PIU1030

PIU1031

PIU1032

PIU1033

PIU1034

PIU1035

PIU1036

PIU1037

PIU1038

PIU1039

PIU1040

PIU1041

PIU1042

PIU1043

PIU1044

PIU1045

PIU1046

PIU1047

PIU1048

PIU1049

PIU1050

PIU1051

PIU1052

PIU1053

PIU1054

PIU1055

PIU1056

PIU1057

PIU1058

PIU1059

PIU1060

PIU1061

PIU1062

PIU1063

PIU1064

COU1

PIUSB100

PIUSB101

PIUSB102

PIUSB103

PIUSB104

PIUSB105

COUSB1

PIY100 PIY101

PIY102 PIY103

COY1

PIR402PIR502

PIC202 PIL101

PIU1014

PIU1018NLAVCC

PIC102

PIC201 PIC301

PIC401 PIC502

PIC601

PIC2701

PIC2801

PIK102

PIK201

PIU106

PIU1015

PIU1017

PIU1026

PIU1030

PIU1036

PIU1052

PIUSB100

PIUSB105

PIY101

PIQ103PIR501

NLTWI1010000

NLTWI10

POTWI1010000

PIQ203

PIR401NLTWI1010000

NLTWI11

POTWI1010000

PIR604

PIU1033NLTWD0

NLTWI0010000

NLTWI00

POTWI0010000

PIR603

PIU1034NLTWCK0

NLTWI0010000

NLTWI01

POTWI0010000

PIC402 PIC501PIU1029

PIC602

PIK202PIU1064

PIR201PIU1025 PIR202 PIUSB103

PIR301PIU1024 PIR302PIUSB102

PIU101

PIU102

PIU103

PIU104

PIU108

PIU109

PIU1010

PIU1012

PIU1013

PIU1019

PIU1020

PIU1021

PIU1022

PIU1023 PIUSB101

PIU1031 PIY102

PIU1032

PIU1039

PIU1043

PIU1044

PIU1045

PIU1046

PIU1055

PIU1058

PIU1059

PIU1063

PIY100

PIQ102

PIR602

PIU1037

NLTWD1

PIU107

PIUSB104NLUID

PIC302

PIC2702

PIC2802PIL102

PIQ101

PIQ201

PIR101

PIR605

PIR606

PIR607

PIR608

PIU105

PIU1027

PIU1028

PIU1035

PIU1051

PIY103

PIC101PIK101PIR102

PIU1057

NLEXTINT080000

NLEXTINT0

POEXTINT080000

PIU1016

NLEXTINT080000

NLEXTINT1

POEXTINT080000

PIU1011

NLEXTINT080000

NLEXTINT2

POEXTINT080000

PIU1061

NLEXTINT080000

NLEXTINT3

POEXTINT080000

PIQ202

PIR601

PIU1038

NLEXTINT080000

NLEXTINT4 NLTWCK1

POEXTINT080000

PIU1042

NLEXTINT080000

NLEXTINT5

POEXTINT080000

PIU1060

NLEXTINT080000

NLEXTINT6

POEXTINT080000

PIU1056

NLEXTINT080000

NLEXTINT7

POEXTINT080000

PIU1062

NLEXTINT080000

NLEXTINT8

POEXTINT080000POEXTINT0POEXTINT1POEXTINT2POEXTINT3POEXTINT4POEXTINT5POEXTINT6POEXTINT7POEXTINT8POEXTINT080000

POSPI0POSPI1POSPI2POSPI3POSPI4POSPI5POSPI050000

POTWI00POTWI0010000POTWI01


POUSART0POUSART1POUSART010000

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\ext.interface.SchDoc Drawn By: Zhangxiaowen Gong

12345

P3

Header 5

12345

P4

Header 5

12345

P6

Header 5

12345

P7

Header 5

+5V+12V

GND

TWI10TWI11

TWI1[1..0] TWI1[1..0]

External interface to motor control boards

USART[1..0] USART[1..0]

USART0USART1

1 2 3

P2

Header 3

123

P5Header 3

PIP201 PIP202 PIP203

COP2

PIP301

PIP302

PIP303

PIP304

PIP305

COP3

PIP401

PIP402

PIP403

PIP404

PIP405

COP4

PIP501PIP502PIP503

COP5

PIP601

PIP602

PIP603

PIP604

PIP605

COP6

PIP701

PIP702

PIP703

PIP704

PIP705

COP7

PIP302

PIP402

PIP602

PIP702

PIP301

PIP401

PIP601

PIP701

PIP303

PIP403

PIP603

PIP703

PIP201

NLTWI1010000

NLTWI10

POTWI1010000PIP503NLTWI1010000

NLTWI11

POTWI1010000

PIP202PIP304

PIP404

PIP604

PIP704

PIP305

PIP405

PIP502

PIP605

PIP705

PIP203NLUSART010000

NLUSART0

POUSART010000

PIP501NLUSART010000

NLUSART1

POUSART010000



1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\main.board.SchDoc Drawn By:

TWI0[1..0]TWI1[1..0]

SPI[5..0]

EXTINT[8..0]

USART[1..0]

AVR32 core systemAVR32.SchDoc

SPI[5..0]

D/CRESET

OLEDOLED.SchDoc

TWI0[1..0]

INT

sensorsensor.SchDoc

power managerPM.SchDoc

SPI[5..0]

TWI0[1..0]

EXTINT5

EXTINT[8..0]

EXTINT7

CE

SPI[5..0]

IRQ

wireless2.4GHz.Wireless.SchDoc

EXTINT3EXTINT6

Zhangxiaowen Gong

TWI1[1..0]

USART[1..0]

external interfaceext.interface.SchDoc

TWI1[1..0]

Main sheet

EXTINT2NLTWI1010000NLTWI1010000NLTWI0010000NLTWI0010000

NLEXTINT080000NLEXTINT080000NLEXTINT080000

NLEXTINT2

NLEXTINT080000

NLEXTINT3

NLEXTINT080000NLEXTINT080000

NLEXTINT5

NLEXTINT080000

NLEXTINT6

NLEXTINT080000

NLEXTINT7

NLEXTINT080000

NLSPI050000NLSPI050000NLSPI050000NLSPI050000NLSPI050000NLSPI050000

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\My.PCBs\ECE445\OLED.SchDocDrawn By:

SPI[5..0]

D/C

SCKMOSI

SPI2SPI0

CSSPI4

SPI[5..0]

Zhangxiaowen Gong

0.9" OLED display interface

NC(GND) 1

VSS 8

C2P 2

C2N 3

C1P 4

C2N 5

NC 7

VCC 28

BS111

BS212

CS13

D/C15

R/W16

RESET14

VCOMH 27

VBAT 6

D0(SCLK/SCL)18

D1(SDIN/SDAIN)19

D2(SDAOUT)20

D321

D422

D523

D624

D725 IREF 26

NC(GND) 30BS010

VDD 9

E/RD17

VLSS 29

U2

UG-2864HSWEG01

500K

R9

Res3

GND

1uF

C8Cap Semi

1uF

C7Cap Semi

2.2uF

C9

Cap Semi2.2uF

C10Cap Semi

+5V

VCC

Res1-1 1

Res2-1 2

Res3-1 3

Res4-1 4

Res1-28

Res2-27

Res3-26

Res4-25

R8

4 Res Pack

4.7K

R7Res3

RESET

D/CD/C PIC701

PIC702 COC7

PIC801

PIC802 COC8

PIC901PIC902

COC9PIC1001

PIC1002COC10

PIR701

PIR702COR7

PIR801

PIR802

PIR803

PIR804PIR805

PIR806

PIR807

PIR808

COR8

PIR901 PIR902

COR9

PIU201

PIU202

PIU203

PIU204

PIU205

PIU206

PIU207

PIU208

PIU209

PIU2010

PIU2011

PIU2012

PIU2013

PIU2014

PIU2015

PIU2016

PIU2017

PIU2018

PIU2019

PIU2020

PIU2021

PIU2022

PIU2023

PIU2024

PIU2025

PIU2026

PIU2027

PIU2028

PIU2029

PIU2030

COU2PIU206

PIR807

NLD0CPOD0C

PIC901

PIC1002PIR902

PIU201

PIU208

PIU2010

PIU2011

PIU2012

PIU2016

PIU2017

PIU2020

PIU2021

PIU2022

PIU2023

PIU2024

PIU2025

PIU2029

PIU2030

PIC701PIU203

PIC702

PIU202

PIC801PIU205

PIC802PIU204

PIC902PIU2027PIC1001PIU2028

PIR701 PIU2014PORESET

PIR801

PIU2013

PIR802

PIU2015

PIR803 PIU2018

PIR804 PIU2019

PIR901

PIU2026

PIU207

PIR702

PIU209

NLSPI050000POSPI050000 NLSPI050000POSPI050000 NLSPI050000POSPI050000

POD0C

PORESET

POSPI0POSPI1POSPI2POSPI3POSPI4POSPI5POSPI050000

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\My.PCBs\ECE445\PM.SchDocDrawn By:

100uF

C16Cap Pol1

470uF

C15Cap Pol1

47uH

L3Inductor

D2

1N5822

100

R12Res3

VIN

GND

+5V

23

1 SW1

SW-SPDT 200

R13Res3

D3LED2

SHDN1

POL2

REF3

FB4

VCC 8

LX 7

GND 6

ISET 5

U3

MAX6290.1uF

C11Cap Semi

0.1uF

C13Cap Semi 47uH

L2Inductor

D11N5819

47K

R10Res3

4.7KR11Res3 150pF

C14Cap Semi 100uF

C12Cap Pol1

GND

+12V

+5V

Zhangxiaowen Gong

GND

15uF

C18Cap Tant

100uF

C17Cap Pol1

+5V

VCC

IN3 OUT 2

GND 1TAB4

U5

LM1117MP-3.3

12

P1

Header 2

VIN

GND

Power management providing +3.3V, +5V, and +12V

13.8V power for the power MOSFET in the H-bridges

5V power for motor controller boards

3.3V power for AVR32, 2.4GHz transceiver, sensor, OLED, etc.

FB 4

VIN1

ON/OFF5

GND3 TAB 6

OUT 2U4

LM2596S-5.0

PIC1101 PIC1102

COC11 PIC1201

PIC1202

COC12

PIC1301

PIC1302COC13

PIC1401

PIC1402COC14

PIC1501

PIC1502COC15

PIC1601

PIC1602

COC16

PIC1701

PIC1702

COC17 PIC1801

PIC1802

COC18

PID101 PID102

COD1

PID201 PID202

COD2

PID301PID302

COD3

PIL201 PIL202COL2

PIL301 PIL302

COL3

PIP101

PIP102

COP1

PIR1001

PIR1002COR10

PIR1101PIR1102

COR11

PIR1201

PIR1202COR12

PIR1301

PIR1302COR13PISW101

PISW102

PISW103

COSW1

PIU301

PIU302

PIU303

PIU304 PIU305

PIU306

PIU307

PIU308

COU3

PIU401 PIU402

PIU403

PIU404PIU405

PIU406

COU4

PIU501

PIU502PIU503

PIU504

COU5

PIC1302

PIC1501

PIC1701

PID202

PIL201

PIL302 PIR1302

PIU301

PIU305

PIU308

PIU404

PIU503

PIC1201PIC1402PID102PIR1002PIC1101

PIC1202PIC1301

PIC1502

PIC1602

PIC1702 PIC1802

PID201

PID302

PIP102

PIR1102

PISW103

PIU302

PIU306

PIU403 PIU406

PIU501

PIC1102PIU303

PIC1401

PIR1001PIR1101

PIU304

PIC1601PIR1201

PID101PIL202

PIU307

PID301PIR1301

PIL301PIU402

PISW102PIU405

PIC1801PIU502

PIU504

PIP101

PIR1202PISW101

PIU401

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\My.PCBs\ECE445\sensor.SchDocDrawn By:

GND

VCC

0.1uF

C22Cap Semi

INT

2.2nF

C23Cap Semi

0.1uF

C24Cap Semi

10nF

C21Cap Semi

TWI0[1..0]

TWI00TWI01

TWI0[1..0]

Zhangxiaowen Gong

4.7K

R15Res3

4.7K

R14Res3

6-axis gryoscope and accelerometer interface

S1 4VDDIO 13

SETP8

SETC12

DRDY15

VDD 2

GND 9GND 11

C110

SCL1

SDA16

U6

HMC5883LGND

220nF

C19Cap Semi

4.7uF

C20Cap Tant

HMC5883 works as an auxiliary for MPU-6050's 9-axis sensor fusion

CLKIN1

NC 2NC 3NC 4NC 5

AUX_DA6

AUX_CL7

VLOGIC 8

AD09

REGOUT10

FSYNC11

INT12

VDD 13

NC 14

NC 15

NC 16

NC 17

GND 18

RESV 19

CPOUT20

RESV 21

CLKOUT22

SCL23

SDA24

U7

MPU-6050

0.1uF

C26Cap Semi0.1uF

C25Cap Semi

PIC1901

PIC1902

COC19

PIC2001

PIC2002COC20

PIC2101

PIC2102 COC21

PIC2201

PIC2202 COC22

PIC2301

PIC2302 COC23

PIC2401

PIC2402 COC24

PIC2501

PIC2502 COC25

PIC2601

PIC2602 COC26

PIR1401

PIR1402COR14

PIR1501

PIR1502COR15

PIU601

PIU602

PIU604PIU608

PIU609

PIU6010

PIU6011

PIU6012

PIU6013

PIU6015

PIU6016

COU6

PIU701

PIU702

PIU703

PIU704

PIU705

PIU706

PIU707

PIU708

PIU709

PIU7010

PIU7011

PIU7012

PIU7013

PIU7014

PIU7015

PIU7016

PIU7017

PIU7018

PIU7019

PIU7020

PIU7021

PIU7022

PIU7023

PIU7024

COU7

PIC2002PIC2101 PIC2201

PIC2301 PIC2401

PIC2501PIC2601

PIU609

PIU6011

PIU701

PIU709

PIU7011

PIU7018

PIU7023

NLTWI0010000

NLTWI00

POTWI0010000

PIU7024

NLTWI0010000

NLTWI01

POTWI0010000

PIC1901PIU608PIC1902 PIU6012 PIC2001

PIU6010

PIC2302PIU7020

PIC2402 PIU7010PIR1401PIU601

PIU707

PIR1501PIU6016

PIU706

PIU6015

PIU702

PIU703

PIU704

PIU705

PIU7012POINT

PIU7014

PIU7015

PIU7016

PIU7017

PIU7019

PIU7021

PIU7022 PIC2102 PIC2202PIC2502

PIC2602PIR1402 PIR1502

PIU602

PIU604

PIU6013

PIU708

PIU7013

POINTPOTWI00POTWI0010000POTWI01

PAC101 PAC102

COC1

PAC201PAC202

COC2

PAC301 PAC302

COC3

PAC401 PAC402

COC4

PAC501PAC502COC5

PAC601PAC602

COC6 PAC701PAC702

COC7PAC801PAC802 COC8

PAC901PAC902

COC9

PAC1001PAC1002

COC10

PAC1101PAC1102

COC11

PAC1201 PAC1202

COC12

PAC1301PAC1302COC13

PAC1401 PAC1402COC14

PAC1501

PAC1502

COC15

PAC1601

PAC1602

COC16

PAC1701 PAC1702

COC17

PAC1801PAC1802

COC18

PAC1901PAC1902

COC19PAC2001 PAC2002

COC20

PAC2101 PAC2102

COC21

PAC2201PAC2202

COC22



PAC2501PAC2502COC25

PAC2601PAC2602COC26

PAC2701PAC2702

COC27

PAC2801PAC2802COC28

PAD101

PAD102

COD1PAD201

PAD202

COD2

PAD302

PAD301COD3

PAK102

PAK101

COK1PAK202

PAK201

COK2

PAL102

PAL101COL1

PAL202PAL201

COL2

PAL302PAL301

COL3

PAP102PAP101

COP1

PAP203

PAP202

PAP201

COP2

PAP301PAP302PAP303PAP304PAP305

COP3PAP401PAP402PAP403PAP404PAP405

COP4

PAP503

PAP502

PAP501



COP7

PAQ103

PAQ102

PAQ101

COQ1PAQ203PAQ202

PAQ201

COQ2PAR102PAR101

COR1PAR202 PAR201

COR2

PAR302 PAR301COR3

PAR402PAR401

COR4

PAR502PAR501

COR5

PAR608PAR601PAR602PAR603PAR604

PAR607PAR606PAR605

COR6

PAR701PAR702 COR7PAR808

PAR801 PAR802PAR803 PAR804

PAR807PAR806 PAR805

COR8

PAR901PAR902

COR9

PAR1002PAR1001

COR10

PAR1102PAR1101

COR11PAR1202PAR1201

COR12

PAR1302 PAR1301COR13

PAR1401PAR1402COR14PAR1501PAR1502COR15

PARF100

PARF108

PARF107

PARF106

PARF105

PARF104

PARF103

PARF102

PARF101

CORF1

PASW101 PASW102 PASW103COSW1

PAU101PAU102PAU103PAU104PAU105PAU106PAU107PAU108PAU109PAU1010PAU1011PAU1012PAU1013PAU1014PAU1015PAU1016

PAU1017PAU1018PAU1019PAU1020PAU1021PAU1022PAU1023PAU1024PAU1025PAU1026PAU1027PAU1028PAU1029PAU1030PAU1031PAU1032PAU1033PAU1034PAU1035PAU1036PAU1037PAU1038PAU1039PAU1040PAU1041PAU1042PAU1043PAU1044PAU1045PAU1046PAU1047PAU1048

PAU1049PAU1050PAU1051PAU1052PAU1053PAU1054PAU1055PAU1056PAU1057PAU1058PAU1059PAU1060PAU1061PAU1062PAU1063PAU1064COU1

PAU2029 PAU2030PAU2027 PAU2028PAU2025 PAU2026PAU2023 PAU2024PAU2021 PAU2022PAU2019 PAU2020PAU2017 PAU2018PAU2015 PAU2016PAU2013 PAU2014PAU2011 PAU2012PAU209 PAU2010PAU207 PAU208PAU205 PAU206PAU203PAU204PAU202PAU201

COU2

PAU305

PAU306

PAU307

PAU308

PAU304

PAU303

PAU302

PAU301

COU3PAU406PAU405PAU404PAU403PAU402PAU401

COU4

PAU504PAU503

PAU502

PAU501

COU5

PAU601PAU602PAU603PAU604PAU605PAU606PAU607PAU608

PAU609PAU6010PAU6011PAU6012PAU6013PAU6014PAU6015PAU6016COU6

PAU701PAU702PAU703PAU704PAU705PAU706

PAU707PAU708PAU709PAU7010PAU7011PAU7012PAU7013PAU7014PAU7015PAU7016PAU7017PAU7018

PAU7019PAU7020PAU7021PAU7022PAU7023PAU7024

PAU7025

COU7

PAUSB100

PAUSB105PAUSB104

PAUSB103

PAUSB102PAUSB101

COUSB1

PAY101

PAY102PAY103

PAY100

COY1

PAC1302

PAC1501

PAC1701

PAD202

PAL201PAL302

PAP302

PAP402

PAP602

PAP702

PAR402

PAR502

PAR1302

PAU206

PAU301

PAU305

PAU308

PAU404

PAU503

PAC1201

PAC1402

PAD102

PAP301

PAP401

PAP601

PAP701

PAR1002

PAC202

PAL101PAU1014

PAU1018

PAC101PAK101

PAR102

PAU1057

PAU1016

PAR701

PAU1011

PAU2014

PARF103

PAU1061PAQ202

PAR601PAU1038

PAU1042

PAU7012

PARF108

PAU1060

PAR807

PAU1056PAU1062

PAC102

PAC201

PAC301

PAC401PAC502

PAC601

PAC901 PAC1002

PAC1101

PAC1202

PAC1301

PAC1502

PAC1602

PAC1702

PAC1802

PAC2002

PAC2101

PAC2201

PAC2301PAC2401

PAC2501

PAC2601PAC2701

PAC2801

PAD201 PAD302

PAK102

PAK201

PAP102

PAP303

PAP403

PAP603

PAP703

PAR902

PAR1102

PARF101

PASW103

PAU106

PAU1015

PAU1017 PAU1026 PAU1030

PAU1036

PAU1052

PAU201 PAU208 PAU2010 PAU2011 PAU2012 PAU2016 PAU2017 PAU2020 PAU2021 PAU2022 PAU2023 PAU2024 PAU2025 PAU2029 PAU2030

PAU302

PAU306

PAU403

PAU406

PAU501

PAU609PAU6011

PAU701

PAU709 PAU7011

PAU7018

PAUSB100

PAUSB105

PAY101

PAC402PAC501

PAU1029

PAC602

PAK202

PAU1064

PAC701

PAU203

PAC702

PAU202

PAC801

PAU205

PAC802

PAU204

PAC902

PAU2027

PAC1001

PAU2028

PAC1102 PAU303

PAC1401PAR1001

PAR1101

PAU304PAC1601 PAR1201

PAC1901PAU608

PAC1902PAU6012 PAC2001PAU6010

PAC2302

PAU7020

PAC2402

PAU7010

PAD101PAL202

PAU307 PAD301PAR1301

PAL301

PAU402

PAP202

PAP304

PAP404

PAP604

PAP704

PAP305

PAP405

PAP502

PAP605

PAP705

PAR201

PAU1025

PAR202PAUSB103

PAR301

PAU1024

PAR302PAUSB102

PAR801

PAU2013

PAR802

PAU2015

PAR803

PAU2018

PAR804

PAU2019

PAR901

PAU2026

PAR1401 PAU601

PAU707

PAR1501PAU6016

PAU706

PASW102

PAU405

PAU1023

PAUSB101

PAU1031

PAY102

PAR805PARF106

PAU1047

PARF107

PAU1048

PAR806

PARF105

PAU1049

PARF104

PAU1050

PAR808

PAU1040PAU1041

PAR603PAU1034

PAU7024

PAR604PAU1033

PAU7023

PAQ102

PAR602PAU1037

PAP201

PAQ103 PAR501

PAP503

PAQ203 PAR401

PAU107

PAUSB104

PAP203PAU1053

PAP501

PAU1054

PAC302

PAC1801

PAC2102

PAC2202

PAC2502

PAC2602

PAC2702

PAC2802

PAL102

PAQ101

PAQ201

PAR101

PAR605PAR606PAR607PAR608

PAR702

PAR1402PAR1502

PARF102

PAU105

PAU1027PAU1028

PAU1035

PAU1051

PAU209

PAU502PAU504

PAU602 PAU604

PAU6013

PAU708PAU7013

PAY103

PAP101

PAR1202

PASW101

PAU401

B.2 The Slave Controllers

35

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\AVR8.SchDoc Drawn By:

PWM1

0.1uF

C2Cap Semi

VCC

0.1uF

C3Cap Semi

ADDR0ADDR1ADDR2ADDR3

NCGNDOUTVDD

Y1

Osc

XIN

XIN

GND

VCC

PWM0

PWM2

K1SW

0.1uF

C1Cap Semi

4.7K

R2

Res3

VCC

GND

SDASCL

TWI0TWI1

TWI[1..0]TWI[1..0]

INT0INT1

INT[1..0] INT[1..0] DIR0DIR1

DIR3

PWM[2..0] PWM[2..0]

DIR2

DIR3

DIR[3..0] DIR[3..0]

1234

8765

S1

SW DIP-4

ADDR[3..0]

ADDR0ADDR1ADDR2ADDR3

ADDR[3..0]GND

LED0

LED1

VM

200

R4

Res3

200

R3

Res3

D2

LED2

D1

LED2

LED0

LED1

ADC

Zhangxiaowen Gong

AVR8 microcontroller core system

DIP switch that determines the low bits of the TWI address

MISOMOSISCK

RST

VCC

GND

SCK

RST

MISO

PWM2

USART[1..0]

USART0USART1

USART[1..0]

PC6 (RESET) 29PD0 (RXD)30

PD1 (TXD)31

PD2 (INT0)32

PD3 (INT1)1

PD4 (XCK/T0)2

VCC 6

GND 5

PB6 (XTAL1/TOSC1)7

PB7 (XTAL2/TOSC2)8

PD5 (T1)9

PD6 (AIN0)10

PD7 (AIN1)11

PB0 (ICP)12

PB1 (OC1A)13

PB2 (SS/OC1B)14

PB3 (MOSI/OC2)15

PB4 (MISO)16

PB5 (SCK)17

AVCC 18

AREF 20

GND 21

PC0 (ADC0) 23

PC1 (ADC1) 24

PC2 (ADC2) 25

PC3 (ADC3) 26

PC4 (ADC4/SDA) 27

PC5 (ADC5/SCL) 28

GND 3

VCC 4

ADC6 19

ADC7 22

U1

ATmega8-16AI

VM

4.7K

R1

Res3

1 23 45 6

P1

Header 3X2

PIC101

PIC102COC1

PIC201

PIC202COC2

PIC301

PIC302COC3

PID101 PID102

COD1

PID201 PID202

COD2

PIK101

PIK102

COK1

PIP101 PIP102

PIP103 PIP104

PIP105 PIP106

COP1

PIR101 PIR102

COR1

PIR201 PIR202

COR2

PIR301PIR302COR3

PIR401PIR402

COR4

PIS101

PIS102

PIS103

PIS104PIS105

PIS106

PIS107

PIS108

COS1

PIU101

PIU102

PIU103

PIU104

PIU105

PIU106

PIU107

PIU108

PIU109

PIU1010

PIU1011

PIU1012

PIU1013

PIU1014

PIU1015

PIU1016

PIU1017

PIU1018

PIU1019

PIU1020

PIU1021

PIU1022

PIU1023

PIU1024

PIU1025

PIU1026

PIU1027

PIU1028

PIU1029PIU1030

PIU1031

PIU1032

COU1

PIY100PIY101

PIY102PIY103

COY1

PIC102

PIC201PIC301

PIK102

PIP106

PIS101

PIS102

PIS103

PIS104

PIU103

PIU105

PIU1021

PIY101

PID102

PIU108

NLLED0

PID202

PIU102

NLLED1

PIP101

PIU1016

NLMISO

PID101PIR301

PID201PIR401

PIR101PIU1022

PIU1019 POADC

PIY100

PIC101PIK101

PIP105

PIR201PIU1029

NLRSTPIP103

PIU1017

NLSCK

PIC202PIC302

PIP102

PIR202

PIU104

PIU106

PIU1018

PIU1020

PIY103

PIR102

PIR302

PIR402

PIU107

PIY102NLXIN

PIS108

PIU1023

NLADDR030000

NLADDR0

PIS107

PIU1024

NLADDR030000

NLADDR1

PIS106

PIU1025

NLADDR030000

NLADDR2

PIS105

PIU1026

NLADDR030000

NLADDR3

PIU109

NLDIR030000

NLDIR0

PODIR030000

PIU1010

NLDIR030000

NLDIR1

PODIR030000

PIU1011

NLDIR030000

NLDIR2

PODIR030000

PIU1012

NLDIR030000

NLDIR3

PODIR030000

PIU1032

NLINT010000

NLINT0

POINT010000

PIU101

NLINT010000

NLINT1

POINT010000

PIU1013

NLPWM020000

NLPWM0

POPWM020000

PIU1014

NLPWM020000

NLPWM1

POPWM020000

PIU1030

NLUSART010000

NLUSART0

POUSART010000

PIU1031

NLUSART010000

NLUSART1

POUSART010000

POADC

PODIR0PODIR1PODIR2PODIR3PODIR030000

POINT0POINT1POINT010000

POPWM0POPWM1POPWM2POPWM020000



1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\H-bridge.SchDoc Drawn By:

VCC1

COM4

VB 8HO 7

VS 6

LO 5

IN2

SD3

U2

IR2104S

VCC 1

COM 4

VB8 HO7

VS6

LO5

IN 2

SD 3

U3

IR2104S

M

B1

Motor

Q1IRF3205S

Q3IRF3205S

Q2IRF3205S

Q4IRF3205S

GND

D8D Schottky

D10D Schottky

D7D Schottky

D9D Schottky

1K

R9

Res3

1K

R11

Res3

1K

R10

Res3

1K

R12

Res3

1K

R7

Res3

1K

R14

Res31K

R13

Res3

1K

R6

Res3

D3

Diode 1K

R5

Res3

D4

Diode1K

R8

Res3

100pF

C10Cap Semi

100pF

C9Cap Semi

VIN

89 10

U4CMC74HC00AD

1112

13

U4D

MC74HC00AD

56

4U4B

MC74HC00AD

1

23

U4A

MC74HC00ADGND

+12V D6D Schottky

D5D Schottky

D11D Schottky

D12D Schottky

100pF

C7Cap Tant

+12V

VIN

GND

100pF

C11

Cap Semi

1000uF

C6Cap Pol1

100pF

C8Cap Tant

1000uF

C4Cap Pol1

1000uF

C5Cap Pol1

DIR0PWM

DIR1

Zhangxiaowen Gong

H-bridge DC motor driver

VCC VDD

PIB101 PIB102

COB1

PIC401

PIC402

COC4 PIC501

PIC502

COC5 PIC601

PIC602

COC6

PIC701 PIC702COC7

PIC801PIC802COC8

PIC901

PIC902COC9

PIC1001

PIC1002 COC10

PIC1101PIC1102

COC11

PID301 PID302

COD3

PID401PID402

COD4

PID501PID502

COD5

PID601PID602

COD6

PID701PID702

COD7

PID801 PID802

COD8

PID901PID902

COD9

PID1001 PID1002

COD10

PID1101PID1102

COD11

PID1201PID1202

COD12

PIQ101

PIQ102

PIQ103

COQ1

PIQ201

PIQ202

PIQ203

COQ2

PIQ301

PIQ302

PIQ303COQ3

PIQ401

PIQ402

PIQ403 COQ4

PIR501 PIR502COR5

PIR601 PIR602COR6

PIR701 PIR702COR7

PIR801 PIR802COR8

PIR901 PIR902

COR9PIR1001 PIR1002

COR10

PIR1101 PIR1102

COR11PIR1201 PIR1202

COR12

PIR1301 PIR1302

COR13PIR1401 PIR1402

COR14

PIU201

PIU202

PIU203

PIU204 PIU205

PIU206

PIU207

PIU208

COU2

PIU301

PIU302

PIU303

PIU304PIU305

PIU306

PIU307

PIU308

COU3

PIU401

PIU402

PIU403

COU4A

PIU404

PIU405

PIU406

COU4B

PIU408

PIU409 PIU4010

COU4C

PIU4011

PIU4012

PIU4013

COU4D

PIC902 PIC1002

PID301 PID401

PIU201 PIU301

PIC402 PIC502 PIC602

PIC901 PIC1001

PID1101 PID1201

PIQ303 PIQ403

PIU204 PIU304

PIU401

PIU402

PIU407

PIB101

PIC702

PIC1102

PID501

PID1102

PIQ103PIQ302PIU206 PIB102

PIC802

PIC1101

PID601

PID1202

PIQ203PIQ402 PIU306

PIC701

PIR502

PIU208 PIC801

PIR801

PIU308

PID302PIR501 PID402PIR802

PID701PIR901PID702

PIR601

PIU207

PID801PIR1002 PID802

PIR702

PIU307

PID901PIR1101PID902

PIR1301

PIU205

PID1001PIR1202 PID1002

PIR1402

PIU305

PIQ101

PIR602

PIR902 PIQ201

PIR701

PIR1001

PIQ301PIR1102

PIR1302

PIQ401PIR1201

PIR1401

PIU202

PIU404PIU408

PIU203 PIU303

PIU406

PIU302

PIU405

PIU4011

PIU403

PIU409PODIR0

PIU4010PIU4012POPWM

PIU4013PODIR1

PIU4014


PID502 PID602PIQ102 PIQ202

PODIR0

PODIR1

POPWM

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\Interface.SchDoc Drawn By:

12345

P5

Header 5

VCC +12V

GND

123456

P7

Header 6

1234

P8

Header 4

123

P10

Header 3GND

SERVO

DIR1DIR0

PWM

VM

GND GND

ENCODER

Zhangxiaowen Gong

Interface with motor, servo, and main controller

VM

5V RC servo interface

feedback from DC motor

DC motor with intrgrated H-bridge

interface with the main controller

TWI0TWI1

TWI[1..0] TWI[1..0]

USART[1..0] USART[1..0]

USART0USART1

1 2 3

P4

Header 3

123

P6Header 3

123

P9

Header 3

ADC

VCC

GND

PIP401 PIP402 PIP403

COP4

PIP501

PIP502

PIP503

PIP504

PIP505

COP5

PIP601PIP602PIP603

COP6

PIP701

PIP702

PIP703

PIP704

PIP705

PIP706

COP7

PIP801

PIP802

PIP803

PIP804

COP8

PIP901

PIP902

PIP903

COP9

PIP1001

PIP1002

PIP1003

COP10

PIP501

PIP503

PIP706 PIP804

PIP903

PIP1003

NLGNDPIP402PIP504

PIP505

PIP602

PIP703PODIR0PIP704PODIR1PIP705POPWM

PIP801 POENCODERPIP802

PIP803

PIP902POADC

PIP1001POSERVO

PIP502

PIP901

PIP701

PIP702

PIP1002NLVM

PIP401

NLTWI010000

NLTWI0

POTWI010000PIP603NLTWI010000

NLTWI1

POTWI010000

PIP403NLUSART010000

NLUSART0

POUSART010000

PIP601NLUSART010000

NLUSART1

POUSART010000

POADC

PODIR0PODIR1

POENCODER

POPWM

POSERVO



1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\motor.controller.SchDoc Drawn By:

TWI[1..0]

PWM[2..0]

ADC

DIR[3..0]INT[1..0]

USART[1..0]

AVR8 core systemAVR8.SchDoc

DIR0DIR1PWM

H-bridgeH-bridge.SchDoc

Power managementPM.SchDoc

Zhangxiaowen Gong

Main sheet

DIR0DIR1PWM0

DIR[3..0]PWM[2..0]

TWI[1..0]

PWMDIR0DIR1ENCODER

SERVO

USART[1..0]ADC

InterfaceInterface.SchDoc

TWI[1..0]

INT0

PWM1

DIR2DIR3

PWM2

INT[1..0]

USART[1..0]

NLDIR030000

NLDIR0

NLDIR030000

NLDIR1

NLDIR030000

NLDIR2

NLDIR030000

NLDIR3

NLINT010000

NLINT0

NLINT010000

NLPWM020000

NLPWM0

NLPWM020000

NLPWM1

NLPWM020000

NLPWM2

NLTWI010000NLTWI010000

NLUSART010000NLUSART010000

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

Letter

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\PM.SchDoc Drawn By:

100uF

C13Cap Pol1

470uF

C12Cap Pol1

47uH

L1Inductor

D13

1N5822

100

R15Res3

VIN

GND

23

1 SW1

SW-SPDT 200

R16Res3

D14LED2

Zhangxiaowen Gong

12

P3

Header 2

VIN

GND

Power management providing +5V

FB 4

VIN1

ON/OFF5

GND3 TAB 6

OUT 2U5

LM2596S-5.0

VM

5V 3A power for both servo and DC motor

12

P2

Header 2

VIN

GND

PIC1201

PIC1202

COC12

PIC1301

PIC1302

COC13

PID1301 PID1302

COD13

PID1401PID1402

COD14

PIL101 PIL102

COL1

PIP201

PIP202

COP2PIP301

PIP302

COP3

PIR1501

PIR1502COR15

PIR1601

PIR1602COR16PISW101

PISW102

PISW103

COSW1 PIU501 PIU502

PIU503

PIU504PIU505

PIU506

COU5

PIC1202

PIC1302

PID1301

PID1402

PIP202 PIP302

PISW103

PIU503 PIU506

PIC1301PIR1501

PID1401PIR1601

PIL101PIU502

PISW102PIU505

PIP201 PIP301

PIR1502PISW101

PIU501

PIC1201

PID1302

PIL102 PIR1602PIU504

PAB102

PAB101

COB1

PAC101PAC102

COC1

PAC202PAC201COC2

PAC302PAC301COC3

PAC401

PAC402

COC4

PAC501

PAC502

COC5

PAC601

PAC602

COC6

PAC701 PAC702COC7

PAC801 PAC802COC8

PAC901 PAC902

COC9



PAC1202

PAC1201COC12 PAC1301

PAC1302

COC13

PAD102

PAD101

COD1PAD202

PAD201

COD2

PAD301 PAD302COD3

PAD401 PAD402COD4

PAD502

PAD501

COD5PAD602

PAD601

COD6

PAD701PAD702COD7

PAD801PAD802COD8

PAD901PAD902

COD9

PAD1001PAD1002COD10

PAD1102

PAD1101COD11

PAD1202

PAD1201COD12

PAD1301

PAD1302

COD13

PAD1402PAD1401COD14

PAK102 PAK101

COK1

PAL102 PAL101COL1

PAP101PAP102

PAP103PAP104

PAP105PAP106

COP1

PAP201

PAP202COP2

PAP302

PAP301

COP3

PAP403

PAP402

PAP401


COP5

PAP603

PAP602

PAP601

COP6

PAP706

PAP705

PAP704

PAP703

PAP702

PAP701

COP7

PAP801

PAP802

PAP803

PAP804

COP8PAP903

PAP902

PAP901

COP9

PAP1003

PAP1002

PAP1001

COP10

PAQ101

PAQ102PAQ103

COQ1

PAQ201

PAQ202PAQ203

COQ2PAQ301

PAQ302PAQ303

COQ3

PAQ401

PAQ402PAQ403

COQ4

PAR101 PAR102

COR1

PAR202PAR201

COR2

PAR302 PAR301COR3

PAR402PAR401

COR4

PAR502PAR501

COR5

PAR602PAR601COR6

PAR702 PAR701

COR7PAR802 PAR801

COR8

PAR902PAR901COR9

PAR1002 PAR1001

COR10

PAR1102PAR1101COR11

PAR1202 PAR1201

COR12

PAR1302PAR1301COR13

PAR1402 PAR1401

COR14

PAR1502PAR1501

COR15

PAR1602

PAR1601COR16

PAS105

PAS106

PAS107

PAS108

PAS104

PAS103

PAS102

PAS101

COS1

PASW101 PASW102 PASW103COSW1

PAU1032PAU1031PAU1030PAU1029PAU1028PAU1027PAU1026PAU1025

PAU1024PAU1023PAU1022 PAU1021 PAU1020PAU1019PAU1018PAU1017PAU1016PAU1015PAU1014PAU1013PAU1012PAU1011PAU1010PAU109

PAU108PAU107PAU106PAU105PAU104PAU103PAU102PAU101COU1 PAU201

PAU202

PAU203

PAU204

PAU208

PAU207

PAU206

PAU205

COU2

PAU301

PAU302

PAU303

PAU304

PAU308

PAU307

PAU306

PAU305

COU3

PAU401

PAU402

PAU403

PAU404

PAU405

PAU406

PAU407

PAU4014

PAU4013

PAU4012

PAU4011

PAU4010

PAU409

PAU408

COU4

PAU506PAU505 PAU504 PAU503 PAU502 PAU501

COU5

PAY101

PAY102PAY103

PAY100

COY1PAC902

PAC1002

PAD301

PAD401

PAP501

PAU201

PAU301

PAS108

PAU1023PAS107 PAU1024PAS106 PAU1025

PAS105PAU1026

PAU109

PAU409

PAU1010PAU4013

PAP703

PAU1011

PAP704

PAU1012

PAC102

PAC201

PAC301

PAC402 PAC502 PAC602

PAC901

PAC1001

PAC1202

PAC1302PAD1101 PAD1201

PAD1301

PAD1402

PAK102PAP106

PAP202

PAP302

PAP503

PAP706

PAP804

PAP903

PAP1003

PAQ303 PAQ403

PAS101

PAS102

PAS103

PAS104

PASW103

PAU103 PAU105

PAU1021

PAU204

PAU304

PAU401

PAU402

PAU407

PAU503

PAU506

PAY101

PAP801

PAU1032

PAU101

PAD102

PAU108

PAD202

PAU102

PAP101PAU1016

PAB101PAC702

PAC1102

PAD501PAD1102

PAQ103

PAQ302

PAU206

PAB102

PAC802

PAC1101

PAD601 PAD1202

PAQ203

PAQ402PAU306

PAC701PAR502

PAU208

PAC801PAR801

PAU308

PAC1301PAR1501

PAD101PAR301

PAD201PAR401

PAD302PAR501

PAD402PAR802

PAD701PAR901PAD702PAR601

PAU207


PAU307


PAU205


PAU305

PAD1401PAR1601

PAL101

PAU502

PAP402

PAP504PAP505

PAP602

PAP902

PAU1019

PAQ101

PAR602PAR902

PAQ201

PAR701PAR1001

PAQ301

PAR1102

PAR1302

PAQ401

PAR1201PAR1401

PAR101

PAU1022

PASW102

PAU505

PAU202

PAU404

PAU408PAU203

PAU303

PAU406

PAU302

PAU405

PAU4011

PAU1013

PAU4010

PAU4012

PAP1001

PAU1014

PAP104

PAP705

PAU1015

PAC101PAK101PAP105

PAR201

PAU1029

PAP103PAU1017

PAP401

PAU1027

PAP603PAU1028

PAP403

PAU1030

PAP601

PAU1031

PAC202

PAC302

PAP102

PAP502

PAP901

PAR202

PAU104 PAU106

PAU1018PAU1020

PAU4014

PAY103

PAC401 PAC501 PAC601

PAD502 PAD602

PAP201

PAP301

PAQ102 PAQ202

PAR1502

PASW101

PAU501PAC1201

PAD1302

PAL102

PAP701

PAP702 PAP1002

PAR102

PAR302PAR402

PAR1602

PAU504

PAU107

PAY102

B.3 The PC Receiver

36

1

1

2

2

3

3

4

4

D D

C C

B B

A A

Title

Number RevisionSize

A4

Date: 5/2/2012 Sheet ofFile: F:\Dropbox\..\Main.Sheet.SchDoc Drawn By:

PE6(INT.6/AIN0)1

UVcc2

D-3

D+4

UGnd5

UCap6

VBus7

PB0(SS/PCINT0)8

PB1(PCINT1/SCK)9

PB2(PDI/PCINT2/MOSI)10

PB3(PDO/PCINT3/MISO)11

PB7(PCINT7/OC0A/OC1C/RTS)12 RESET 13

VCC14

GND 15

XTAL2 16XTAL1 17

PD0(OC0B/SCL/INT0)18

PD1(SDA/INT1)19

PD2(RXD1/INT2)20

PD3(TXD1/INT3)21

PD5(XCK1/CTS)22

GND 23

AVCC24

PD4(ICP1/ADC8) 25PD6(T1/OC4D/ADC9) 26PD7(T0/OC4D/ADC10) 27PB4(PCINT4/ADC11) 28PB5(PCINT5/OC1A/OC4B/ADC12) 29PB6(PCINT6/OC1B/OC4B/ADC13) 30PC6(OC3A/OC4A) 31PC7(ICP3/CLK0/OC4A) 32PE2(HWB) 33

VCC34

GND 35

PF7(ADC7/TDI) 36PF6(ADC6/TDO) 37PF5(ADC5/TMS) 38PF4(ADC4/TCK) 39PF1(ADC1) 40PF0(ADC0) 41

AREF42

GND 43

AVCC44

U1

ATmega32U4

VBUS 1

D- 2

D+ 3

ID 4

GND 5

GND 0

USB1

Mini USB

IN3 OUT 2

GND 1TAB4

U2

LM1117IMP-3.3GND

15uF

C6Cap Tant

3.3V

VBUS

1uF

C4

Cap Tant

GND

22

R1

Res3

22

R2

Res3

10uF

C2Cap Pol1

F1

Fuse 1

VCC

GNDVBUS

VCC

VCC

10uF

C1Cap Pol1

NC GNDOUT VDD

Y1

Osc

VCC

GND

RST

IRQ

MOSI

CSNCE

SCK

MISO

3.3V

MISOMOSISCK

CSNCEIRQ

K1SW

10K

R4Res3

VCC

0.1uF

C7Cap Semi

RST

HWB

HWB

K2SW

10K

R5Res3

VCC

0.1uF

C8Cap Semi

123456

P1

Header 6

MISOMOSI

SCK

RST

VCC

GNDLED0

200

R3Res3

D1LED2

VCC

CE3

CSN4

SCK5

MOSI6

MISO7

IRQ8

GND1

VCC2RF1

nRF24L01+ boardGND

LED0

0.1uF

C5Cap Semi

0.1uF

C3Cap Semi

Zhangxiaowen Gong

USB interfaced 2.4GHz transceiverreset and bootloader activator

3.3V power for 2.4GHz transceiver

8-bit AVR with USB 2.0 controller

PIC101

PIC102COC1 PIC201

PIC202COC2

PIC301

PIC302COC3

PIC401PIC402

COC4

PIC501

PIC502COC5

PIC601

PIC602COC6

PIC701

PIC702COC7

PIC801

PIC802COC8

PID101PID102

COD1

PIF101 PIF102

COF1

PIK101

PIK102

COK1PIK201

PIK202

COK2

PIP101

PIP102

PIP103

PIP104

PIP105

PIP106

COP1

PIR101 PIR102

COR1

PIR201 PIR202

COR2

PIR301

PIR302COR3

PIR401

PIR402COR4

PIR501

PIR502COR5

PIRF101

PIRF102

PIRF103

PIRF104

PIRF105

PIRF106

PIRF107

PIRF108

CORF1

PIU101

PIU102

PIU103

PIU104

PIU105

PIU106

PIU107

PIU108

PIU109

PIU1010

PIU1011PIU1012 PIU1013

PIU1014

PIU1015

PIU1016

PIU1017

PIU1018

PIU1019

PIU1020

PIU1021

PIU1022

PIU1023

PIU1024

PIU1025

PIU1026

PIU1027

PIU1028

PIU1029

PIU1030

PIU1031

PIU1032

PIU1033

PIU1034

PIU1035

PIU1036

PIU1037

PIU1038

PIU1039

PIU1040

PIU1041

PIU1042

PIU1043

PIU1044

COU1

PIU201

PIU202PIU203

PIU204

COU2

PIUSB100

PIUSB101

PIUSB102

PIUSB103

PIUSB104

PIUSB105

COUSB1

PIY100 PIY101

PIY102 PIY103

COY1

PIC601

PIRF102

PIU202

PIU204

PIRF103

PIU1018NLCE

PIRF104

PIU1012NLCSN


PIC402

PIC501PIC602

PIC701 PIC801PIK102 PIK202

PIP106PIRF101

PIU105

PIU1015

PIU1023

PIU1035

PIU1043

PIU201

PIUSB100

PIUSB105

PIY101

PIC802PIK201

PIR501

PIU1033

NLHWB

PIRF108

PIU1019NLIRQ

PID102

PIU108

NLLED0

PIP103

PIRF107

PIU1011NLMISO

PIP104

PIRF106

PIU1010NLMOSI PIY100

PIUSB104 PIU1041

PIU1040

PIU1039

PIU1038

PIU1037

PIU1036

PIU1032

PIU1031

PIU1030

PIU1029

PIU1028

PIU1027

PIU1026

PIU1025

PIU1022

PIU1021

PIU1020

PIU1017 PIY102

PIU1016

PIU101

PIR202 PIU104PIR201PIUSB103

PIR102 PIU103PIR101PIUSB102

PID101PIR301

PIC401PIU106

PIC702PIK101

PIP105

PIR401

PIU1013

NLRST

PIP102PIRF105

PIU109NLSCK

PIC101PIF101

PIUSB101

PIC201 PIC302

PIC502

PIF102

PIP101

PIR302PIR402 PIR502

PIU102

PIU107

PIU1014

PIU1024

PIU1034

PIU1042

PIU1044

PIU203

PIY103

PAC102 PAC101

COC1

PAC202

PAC201COC2

PAC301 PAC302COC3

PAC402PAC401

COC4 PAC501 PAC502COC5

PAC602PAC601

COC6PAC702PAC701

COC7

PAC802PAC801

COC8

PAD101

PAD102

COD1

PAF102

PAF101

COF1

PAK101

PAK102

COK1

PAK201

PAK202COK2

PAP101PAP102PAP103PAP104PAP105PAP106

COP1

PAR101PAR102

COR1

PAR201PAR202

COR2

PAR301 PAR302COR3

PAR401 PAR402

COR4

PAR501PAR502COR5

PARF101

PARF102

PARF103

PARF104

PARF105

PARF106

PARF107

PARF108

PARF100

CORF1

PAU101PAU102PAU103PAU104PAU105PAU106PAU107PAU108PAU109PAU1010PAU1011

PAU1012PAU1013 PAU1014 PAU1015 PAU1016 PAU1017PAU1018PAU1019PAU1020 PAU1021 PAU1022PAU1023PAU1024PAU1025PAU1026PAU1027PAU1028PAU1029PAU1030PAU1031PAU1032PAU1033

PAU1034PAU1035PAU1036PAU1037PAU1038PAU1039PAU1040PAU1041PAU1042PAU1043PAU1044

COU1

PAU201

PAU202

PAU203

PAU204

COU2

PAUSB101

PAUSB102

PAUSB103

PAUSB104

PAUSB100

PAUSB105

COUSB1

PAY101

PAY102 PAY103

PAY100

COY1

PAC601PARF102

PAU202PAU204

PARF103

PAU1018

PARF104

PAU1012

PAC102

PAC202

PAC301

PAC402PAC501

PAC602

PAC701

PAC801

PAK102

PAK202

PAP106

PARF101

PAU105

PAU1015PAU1023

PAU1035PAU1043

PAU201

PAUSB100

PAUSB105

PAY101

PAC802PAK201PAR501

PAU1033

PARF108

PAU1019

PAD102 PAU108

PAP103

PARF107

PAU1011

PAP104

PARF106

PAU1010

PAC401 PAU106

PAD101PAR301

PAR101 PAUSB102PAR102

PAU103

PAR201PAUSB103

PAR202

PAU104

PAU1017

PAY102

PAC702

PAK101PAP105PAR401

PAU1013

PAP102

PARF105

PAU109

PAC101PAF101

PAUSB101

PAC201

PAC302

PAC502

PAF102

PAP101

PAR302

PAR402

PAR502

PAU102

PAU107

PAU1014

PAU1024

PAU1034PAU1042PAU1044

PAU203

PAY103

special vehicle for transporting unstable chemicals

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