Robotics Development Platform

Presented by: Michael Carr Christina Welk Advisors: Dr. K. Pashin Nikaaien Professor Gordon Jenkins Course: GE-492 Sponsor: Z-Buffer inc.

Concept

•Modular Design •300 Pound Carrying Capacity •At Least 30 Minute Battery Life •5-25 mph Speed Range •Climbs Stairs •Fits in Buildings and Cars •Onboard Mini ATX Motherboard •Local Data Acquisition •Real Time Reaction to Sensor Input •Speed Controller Interface •Wireless Connection to Laptop •Joystick Input

Six Sigma Tools

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

Risk Mitigation

Computer Hardware

• Via ME600 – Mini ATX form factor – 600mhz fan less processor – 256 MB DDR ram – One PCI Slot – Standard ATX I/O • Ituner 200 watt ATX to dc power supply • Netgear MA311 802.11b PCI wireless card • Fujitsu 20 GB hard drive • Microsoft SideWinder USB joystick

CS Progress

• All hardware components selected • Fedora Core 2 installed on via board • CVS server set up • UML design Actor/goals list – Use cases – Sequence diagrams – Domain models – Class diagrams

Domain Model

Mechanical Design

• Drive Train Design • Tank Tread Design • Batteries and Control Systems • Heat Exchanger Design • Suspension Design • Structural Analysis

Briggs and Stratton Etek DC Electric Motor • 24 – 48V • 21 Pounds • 1.14 in-lbf/A • 72 RPM/V • 89% Peak Efficiency • 15 hp Peak Power • 330 A max for 2 minutes

Drive Train Design

Tank Tread Design

Batteries and Control Systems

Concorde Sun Xtender PVX-1040T AGM Sealed Battery • 100 Ah at 20 hr rate • 66 pounds each • Group 27: 12.03” X 6.77” X 8.93” RoboteQ AX2550 Dual Channel, Electronic Speed Controller • Fully Digital, Microcomputer Design • Advanced Data Logging • 200 mA Idle Current Draw • 2.5 mW ON Resistance MOSFETs • 120A for 15 seconds, 80A Extended • 16kHz Pulse Width Modulation

Heat Exchanger Design

Heat Exchanger Design (cont.)

Heat Exchanger Design (cont.)

Suspension Design

• Studied 3 different materials • Conducted 3 experiments to determine stiffness, creep and abrasion properties • Based on these results, selected molded polyurethane straps rated to 2 times their original length

Structural Analysis

• Used the ANSYS finite element analysis software package • Examined 8 worst case scenario load cases • Also analyzed axles for structural integrity • Found and corrected all cases where the stresses exceeded half of the yield strength of steel

Classes Used

Direct Use • CM-410: Advanced Engineering Com.

• • • • • • • • • • • • • • MA-130: Calculus I MA-140: Calculus II MA-150: Calculus III MA-210: Fundamentals of Linear Algebra MA-250: Principles of Differential Equations MA-320: Numerical Analysis SC-235: Physics I SC-245: Physics II CS-190: C++ Programming CS-270: Structured Computer Organization CS-360: Advanced Program Design CS-430: Data and Computer Com. Networks CS-440: Software Engineering CS-450: Operating Systems •GE-110: Engineering Graphics •GE-201: Engineering Statics •GE-202: Engineering Dynamics •GE-203: Engineering Mechanics of Materials •GE-205: Engineering Materials •GE-290: Introduction to Engineering Design •GE-305: Electrical Circuit Analysis •ME-204: Mechanics and Materials Laboratory •ME-301: Fluid Statics and Dynamics •ME-320: Heat and Mass Transfer •ME-390: Introduction to Mechanical Design •ME-415: Kinematics and Mechanisms •ME-420: Finite Element Analysis •ME-460: Introduction to Robotics Survey Use • HM-480: Moral and Ethical Issues • • • • • • CM-100: Written and Oral Com.

CM-110: Scientific and Business Com.

MA-290: Discrete Structures MA-330: Probability and Statistics ME-350: Engineering Vibrations GE-210: Engineering Economics •SC-195: General Chemistry •CS-210: Data Structures and Algorithms •CS-291: Theory of Computation •CS-480: Computer System Architecture •EE-310: Microprocessor Systems •EE-360: Digital Circuit Design

Complete Budget Fall-Through

Updated Risk Mitigation:

Complete Budget Fall-Through

Updated Risk Mitigation:

Our Sponsorship Evaporated Now What?

• The design process went on hold • Alternate projects were researched and evaluated - Reduced design (approximately 100 pounds) - Small design (25-50 pounds) - Small hybrid/electric vehicle conversions • Opted to complete a full scale prototype with slightly modified implementation details - Single battery pack on delivery - Sensor array to be implemented as a module • This process, as well as the enduing redesigns, caused a massive schedule lapse • As a result, we have failed to make almost every single deadline set at the onset of this project.

Senior Design Project Schedule, First Phase

Senior Design Project Schedule, Second Phase

Budget

Conclusions

To date, we have: • addressed all major design issues and concerns • developed finished mechanical designs and domain models • completed the development phase and are now ready to move on to implementation “this is going to be the best prom ever”

Questions?