Electrical Engineering Department College of Engineering California State University, Long Beach Long Beach, California, 90840

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1 Electrical Engineering Department College of Engineering California State University, Long Beach Long Beach, California, EE 400D - Electrical Engineering Design Fall 2012 President: Gary Hill Track Rover Project Document November 30, 2012 Project Manager: Trish Le Systems Engineer: Rahat Moin

2 2 P a g e Contents Executive Summary... 3 Overview... 3 Level 1 Project Requirements... 3 Level 2 System Requirements... 3 Design Features... 4 Detailed Cost and Scheduling... 4 Cost Analysis... 4 Scheduling: Shows Top and Low Level Tasks... 4 System Design... 6 System Block Diagram... 6 Description of Block Diagram:... 7 Electrical Interface Definition... 7 Resource Allocations... 8 System Resource Map:... 8 Sensors and Motors pin connections:... 8 References:... 9 System Level Task Descriptions... 9 Subsystem Design Wiring: Wire Harness Solution Shell Chassis Mechanical Design Documents Measurements and Parts placement D Modeling of Parts Software Documents Project Status Scheduling: Design Side and Back View Bottom View Front View of model along with mission payload head:... 20

3 3 P a g e Cost Project Reports Future Consideration Executive Summary Overview To lower the cost, new research studies on the prices have been conducted; in addition, to keep the new model at its lowest cost, old parts will be re-used. Next, the new designs were presented for a cool-better-looking version with cleaned and organized wiring system while making it student-friendly. To make it available to the future students, a manual was added in the document. Lastly, the use of the 3D printed is needed to print parts for the new rover. Level 1 Project Requirements Lower the cost, increase scanning accuracy and directional speed of the existing EE444 Rover while meeting or exceeding the mission requirements as defined in the EE444 Syllabus. Make the Tracked Rover user friendly for future EE400D and EE444 students. Level 2 System Requirements One step in lowering the cost and increasing the accuracy of the rover will be to replacing the current bipolar NEMA-17 stepper motor with a step size of 0.8 degrees/step with a lower cost unipolar (to be operated as a bipolar stepper motor) geared stepper motor with a step size of 0.47 degrees. The speed of the rover will be increased, without additional cost, by replacing the existing DC motor gears with an M9 gear box. To make the current rover more student friendly (less likely to be broken) the design will be enclosed with pop-out panels and an integrated cable harness. To keep cost down, the chassis and shell will be fabricated using an in-house 3-D printer. Cost - Use all of the old parts from the current rover. - The cost will reduce substantially for future students due to the new 3-D printed parts. - No money will be spent on the rover. User Friendly - Rover manual: updates instruction manual, step by step how to build the rover. - Guide to edit 3D model, personalize chassis. - EE444 mission compatibility: tested to ensure rover meets all the requirements for EE 444 course. - Support the Aruduino platform. - Test the track and wheel performance.

4 4 P a g e Design Features 3D Print New Chassis design to eliminate the cost of purchasing a chassis. 3D Print slots for major components such as battery holder, mini circuit, and 9 volt battery. 3D print shell for chassis to add a new look and for better stability. Fix Clustered wiring on the rover. Detailed Cost and Scheduling Cost Analysis These are miscellaneous parts that can be found cheaper if future 400D students are interested in replacing these parts. The rover team cut the cost substantially because all of the body parts are being 3D printed. Item Cost Aluminum wire x 2 $7.50 Heat Shrink Tubing $3.50 Total $11.00 The above costs were purchased for rapid prototyping and to enhance solving clustered wiring issue. Scheduling: Shows Top and Low Level Tasks The schedule shows individual tasks done by each member of the team. The final modified explanation of the scheduling is shown in pg.22 of this document.

5 5 P a g e ID Task Name User Defined Text 1 Start Finish Duration Amit, Kevin - Power Train Engineer 1 New Ideas for Cost, Chassis, Stepper Dinh, Cong Software Engineer motor, Model for rover, User Friendly Hoang, Tuyen 3D modeling Engineer 9/20/2012 9/26/2012 5d Moin, Rahat Systems Engineer Amit, Kevin Power Train Engineer Dinh, Cong Software Engineer 2 Level one Presentation Hoang, Tuyen 3D modeling Engineer 9/27/2012 9/27/2012 Moin, Rahat Systems Engineer 3 Test Motor speed Amit, Kevin Power Train Engineer Hoang, Tuyen 3D modeling Engineer 10/1/ /11/2012 9d % Complete 4 User Friendly Manual/Software Dinh, Cong Software Engineer 9/20/ /14/ d Sep 2012 Oct 2012 Nov 2012 Dec /30 10/14 10/28 10/21 11/4 9/23 10/7 11/11 11/25 12/2 11/18 12/9 Amit, Kevin Power Train Engineer Dinh, Cong Software Engineer 5 New 3-D design for Rover and Chassis Hoang, Tuyen- 3D modeling Engineer 10/1/ /10/2012 8d 6 Wiring Harness Ideas 10/9/ /10/2012 2d 7 Level One part two presentation Amit, Kevin Power Train Engineer Dinh, Cong Software Engineer Hoang, Tuyen 3D modeling Engineer 10/11/ /11/ Finalize Design With President Hill 10/16/ /16/ Working with mission payload manager 10/31/ /31/2012 Amit, Kevin Power Train Engineer Ideas on new wiring installation and Parts 10 10/17/ /1/ d placement 11 3-D Printed Chassis (melted/deformed due to being left in the car, use existing chassis) 11/2/ /2/2012 Amit, Kevin Power Train Engineer 12 Team Meeting to Discuss upcoming Dinh, Cong Software Engineer presentation 11/5/ /5/ D print new chassis 11/5/ /5/2012 Amit, Kevin Power Train Engineer 14 Finalize Frame Idea Dinh, Cong Software Engineer 11/6/ /13/2012 6d 15 Test the wiring solution 11/6/ /9/2012 4d 16 Dimensions and placement for Arduino to implement on Chassis 11/6/ /9/2012 4d 17 Dimensions and placement for the battery holder to implement on chassis 11/6/ /9/2012 4d 18 Dimensions for new chassis Amit, Kevin Power train 11/7/ /13/2012 5d Amit, Kevin Power Train Engineer 19 Conceptual Design Review Dinh, Cong Software Engineer 11/8/ /8/ Research on the magnet Dinh, Cong Software Engineer 11/9/ /9/ Replica of the shell 11/12/ /12/2012 Meeting with President Hill to discuss final Amit, Kevin Power Train 22 11/13/ /13/2012 3D designs. Amit, Kevin Power Train Meeting with 3D modeler to model the 23 11/14/ /14/2012 shell Nguyen, Andros 3D Model Dimension of the motor placements on 24 11/15/ /15/2012 chassis 25 Meeting with President Hill 11/15/ /15/ Stepper Motor measurements Amit, Kevin Power Train 11/15/ /15/2012 Create separate 3D models of each 27 Amit, Kevin Power Train 11/16/ /19/2012 2d component 28 Measurements for arduino holes 11/19/ /19/ Meeting with 3D printing Amit, Kevin Power Train 11/26/ /26/ Meeting with Andros of 3D printing Amit, Kevin Power Train 11/27/ /27/ Finalize the measurement of components Amit, Kevin Power Train and parts placement of the rover. 11/29/ /29/ Amit, Kevin Power Train Start 3D printing of Chassis, and battery slot. Nguyen, Andros 3D modeling 12/3/ /3/ Meet with mission payload team to discuss Amit, Kevin Power Train mounting of head for rover. 12/4/ /4/ Fix issues that occurred with 3D printed chassis. Amit, Kevin Power Train 12/5/ /5/ Place all components onto new 3D printed Amit, Kevin Power Train chassis. 12/6/ /6/ Place the new mission payload head onto the rover body. Mission Payload Team 12/7/ /7/ Start 3D printing the Shell for rover. 12/6/ /6/ Install new shell. 12/10/ /12/2012 3d 45%

6 6 P a g e Performance Measurement Project 38 Tasks Average = 159/38 = 4.18 days Total weight = 38*4.18 = 159 Started and Completed: Started = 1 tasks Average = 3/1 = 3days Total weight =.5*3*1= 1.5 Completed = 37 tasks Average = 156/37 = 4.2 days Total weight = 4.21*37 = (completed) + 1.5(started) = /159 =.99 = 99% completed Issues with completion: This above completion was done before some issues occurred with the body of the rover. The body was a huge part of our project but due to the printing issue, the completion percent dropped down to 85% complete. System Design System Block Diagram

7 7 P a g e Description of Block Diagram: This block diagram represents the components of the track robot. The components of the track robot are connected to the mission payload components. The stepper motor is connected to the stepper motor along with the gyroscope. DC motor 1 and DC motor 2 are connected to the motor shield. The I2C connects the Arduino uno to the Arduino pro mini. The servo (scan/tilt), camera, laser, and mid/long range IR sensors are all connected to the Arduino pro mini. Electrical Interface Definition

8 8 P a g e Pin Diagram Shows the Pin diagram of the components that are connected to the motorshield, Arduino uno, and arduino pro mini. Resource Allocations System Resource Map: ATmega328P Arduino Motor Shield Motor Shield DIR (SPI Interface Motor Shield PWM Rover PD0 (RXD) J1-1 Digital Pin 0 PD1 (TXD) J1-2 Digital Pin 1 PD2 (INT0) J1-3 Digital Pin 2 JP3 Pin 1 PD3 (INT1, OC2B) J1-4 Digital Pin 3 PWM PWM2B IC1 Pin 9 PD4 (T0) J1-5 Digital Pin 4 DIR_CLK IC3 Pin 11 PD5 (T1, OC0B) J1-6 Digital Pin 5 PWM PWM0B IC2 Pin 1 PD6 (OC0A, AIN0) J1-7 Digital Pin 6 PWM PWM0A IC2 Pin 9 PD7 (AIN1) J1-8 Digital Pin 7 DIR_EN IC3 Pin 13 PC0 (ADC0) J2-1 Analog Pin 0 JP5-1 PC1 (ADC1) J2-2 Analog Pin 1 JP5-2 PC2 (ADC2) J2-3 Analog Pin 2 JP5-3 PC3 (ADC 3) J2-4 Analog Pin 3 JP5-4 PC4 (ADC 4, SDA) J2-5 Analog Pin 4 JP5-5 PC5 (ADC 5, SCL) J2-6 Analog Pin 5 JP5-6 PB0 (ICP1) J3-1 Digital Pin 8 DIR_SER PB1 (OC1A) J3-2 Digital Pin 9 PWM PWM1A PB2 (SS, OC1A) J3-3 Digital Pin 10 PWM PWM1B PB3 (MOSI, OC2A) J3-4 Digital Pin 11 PWM PWM2A IC3 Pin 12 PB4 (MISO) J3-5 Digital Pin 12 DIR_Latch IC3 Pin 12 PB5 (SCK) J3-6 Digital Pin 13 GND J3-7 GND GND AREF J3-8 AREF These pin connections are from the motor shield, motor shield DIR, motor shield PWM and rover to the ATmega328P and the arduino. Sensors and Motors pin connections: Arduino Pro ATmega328P Arduino MotorShield Mini Stepper Motor Servo IR Sensors Laser Camera PD0 (RXD) J1-1 Digital Pin 0 PD1 (TXD) J1-2 Digital Pin 1 PD2 (INT0) J1-3 Digital Pin 2 Output J1-4 Digital Pin 3 PD3 (INT1, OC2B) PWM M2 PD4 (T0) J1-5 Digital Pin 4 PD5 (T1, OC0B) J1-6 Digital Pin 5 M4 Output

9 9 P a g e PWM PD6 (OC0A, AIN0) J1-7 Digital Pin 6 PWM M3 Output PD7 (AIN1) J1-8 Digital Pin 7 PC0 (ADC0) J2-1 Analog Pin 0 LR PC1 (ADC1) J2-2 Analog Pin 1 MR PC2 (ADC2) J2-3 Analog Pin 2 PC3 (ADC 3) J2-4 Analog Pin 3 PC4 (ADC 4, SDA) J2-5 Analog Pin 4 AD4 PC5 (ADC 5, SCL) J2-6 Analog Pin 5 AD5 PB0 (ICP1) J3-1 Digital Pin 8 J3-2 Digital Pin 9 PB1 (OC1A) PWM PB2 (SS, OC1A) J3-3 Digital Pin 10 PWM Output PB3 (MOSI, J3-4 Digital Pin 11 OC2A) PWM M1 PB4 (MISO) J3-5 Digital Pin 12 PB5 (SCK) J3-6 Digital Pin 13 Output GND J3-7 GND GND GND GND GND GND GND AREF J3-8 AREF +5V Vcc Vcc Vcc Vcc Vcc Vcc +3.3V References: These documents were from President Hill s EE444 course site. erface%20design%20part%201.pdf System Level Task Descriptions Trish Le (Project Manager): - Design of shell. - Design of chassis. - Weekly project manager documents. Rahat Moin (System Engineer): - Weekly systems engineering documents. - Parts placements. - Measurements. - Design of new chassis. - Design of new shell. - Rapid prototyping of parts. Kevin Amit (Power Train): - Work on stepper motor. - Design of chassis for rover. - Design of shell for rover.

10 10 P a g e - 3D modeling for rover parts. - 3D printing of rover parts. - Measurement and placements of parts. Cong Dinh (Software Engineer): - In charge of user friendliness of rover. - Rover manual for future 400D students. - Making sure rover meets 400D standard. Tony Hoang (3D Modeling): - 3D modeling for the rover parts. - 3D printing of the rover parts. Andros Nguyen (3D Modeling): - Modeled track rover parts. - Printing track rover parts. Subsystem Design Wiring: Wire Harness Solution Rapid prototyping was done to get rid of the clustered wiring on the track robot. Product used: Heat sink tubes

11 11 P a g e Dimensions: they come in different lengths and diameters. The 3inch with a ¼ inch diameter was used. Reasoning: The tubing s are inexpensive and come in different diameters. They fit several wires and minimize the cluster on the rover. They can be cut and are flexible. Concern: The main concern was heat did research on how much heat it takes to shrink the tubes it is 158 degrees F. This is obviously impossible to come across. Was not able to test the wiring underneath the chassis because they are soldered to the motors of the track rover but we will definitely be able to minimize the cluster when we implement the tubes. The idea is simple and effective due to our limited time frame this should be the final solution. Shell This is a prototype of the frame the team wants to 3D print. This cardboard prototype gave us an understanding of the sizing and dimensions for the shell. The 3D modeling and printing team used this prototype as a visual for the shell. The two prototype frames also gave us an idea of where to place all of the components on the rover s chassis.

12 12 P a g e Chassis This chassis was printed and damaged after being printed. The team benefited from this mistake and came up with more ideas to make improvements for the final model. This is the first 3D printed chassis that the rover team came up with. The chassis came out completely opposite from what we wanted. The design did not look appealing at all it showed that we were not professional at 3D modeling and printing. The next step we took was to come up with a more detailed chassis design.

13 13 P a g e Mechanical Design Documents Measurements and Parts placement Arduino The team decided to rotate the Arduino to make use of the left over space that will be available on the new chassis. The measurements were also made for the 3D modeling team. The length of the Arduino is 2.6 inches and the width is 2.1 inches. Battery Slot This is the dimension and placement for the new battery slot for the 12volt battery. The holder will be placed underneath the arduino. This eliminates the current strap that holds the battery in place. It will be a snug fit and will not allow the battery to fall out. The length is 3.9 inches and the width is 1.75 inches.

14 14 P a g e Mini Breadboard and Small Battery Pack These measurements are for the mini breadboard and the small battery pack. The two components will remain in the same position, but slots will be printed for them. The length and width of the mini bread board are 1.85 inches and 1.4 inches. The length and the width of the small battery pack are 2.65 inches and 1.2 inches. Chassis The final Chassis measurements are shown above. The length of the chassis will be 5.5 inches and the width will be 4.5 inches. The diameters of the holes were also determined for the motor screws and the screws to hold the arduino in place.

15 15 P a g e 3D Modeling of Parts Chassis Back View The back view of the 3D model shows the new battery slot for the 12 volt battery pack. Chassis Side View The side view of the 3D modeled chassis shows the placement of the motors and the holes for screws. Chassis Ariel View

16 16 P a g e Battery Holder After speaking with the 3D printing team, we have decided it would be much easier to print the battery holder separately and then attach it to the chassis. The 3D model of the battery holder was made and sent for printing. Mini Breadboard and Small Battery Pack The slots for the mini breadboard and the small battery pack were modeled separately and sent for printing. Bottom of Chassis The chassis was modeled facing bottom up and sent for printing.

17 17 P a g e Turret The turret was 3D modeled and sent for printing this turret was designed to meet requirements for mission payload team. A decision was made to print the parts separately for convenience. The only downside is the amount of time it will take to print each part. After printing the parts we will glue them on together and make sure they are stable for all of the components. Motor Placement The Motors will be placed in the same position.

18 18 P a g e Parts Placement: Parts placement on top of Chassis For the parts placement we decided to use as much spacing as we can on the chassis so we do not waste any free space. We rotated the Arduino on the chassis so we can use the most of the width available. The battery 12 volt battery slot was modeled under the Arduino and the mini breadboard along with the small battery pack remains in the same location with printed slots. Software Documents Software Documents can be found in the companies Track Robot file. The document is called User Manual which was done by Cong Dinh.

19 19 P a g e Project Status Scheduling: Project has had some major issues with the printing of the body so it dropped our completion to about 85% with a week left. Design Side and Back View Assembling the parts together was a challenge because some of the components did not fit. To fix the issue some modification had to be done. The Dremel was used to make the width of battery placement wider. The battery holder itself was not the correct size so the 3D printing group had to print a brand new one. The stability is a concern but there are some ideas such as printing rods on the bottom of the chassis for better support. Bottom View

20 20 P a g e The bottom of the new design is much neater then previous model. The bottom wring is hidden because most of the wiring is run through the 3D printed holes. Front View of model along with mission payload head: By working with the mission payload team the rovers head was placed on the new body. The new body was strong enough to hold all of the components without braking or showing any signs of malfunction. Cost The cost was under budget. Everything was 3D printed and assembled. Project Reports Individual project reports are provided in the Progress Reports Folder. See The Robot Here: Future Consideration 9v to power all digital electronics was inadequate Cabling simplification never adequately addressed or implemented. Scan platform electronics still does not travel down hollow turret. Chassis design flexes and breaks under load.

21 21 P a g e Design vertical components so layers build strength and not fracture lines. See printed chassis to see how layer direction directly contributed to failure. A cautionary tale. This project team was totally focused on the design of the chassis and shell to the exclusion of everything else. Most notably the powertrain and all the electrical subsystems. This shows a failure of the group members from these divisions.