Actively Stabilized Hand Held Laser Pointer

May 8, 2014

• Kaitlin Peranski

• Spencer Wasilewski

• Kyle Lasher

• Kyle Jensen

• Chris Caporale

• Jeremy Berke

Agenda• Layout/CAD Models

• System Diagrams

• Test Bench

• Test Results

• BOM/Purchase List

• Future Development

• Technical Manual

Prototype Layout

Housing

Main Power (Forward-on)

Turns Correction On (Forward-on)

NST Controller Access

Processor USB/ Charging

Port

Processor LED (On When

Correcting)

Charging LED (Yellow-

ChargingGreen-

Charged)

Push Button to turn on laser (Hold down

to turn laser on)

CAD Models

Use Instructions

• Gyroscope Calibration:

– Turn module on, and leave on a stable surface until the processor led blinks. Moving the module during this process will cause the module to not calibrate properly, resulting in possible drift.

• Battery Charging:

– Turn module on– Plug in micro USB Cable– Yellow light on charging module will turn green

when the battery is fully charged

Logic Flow ChartStart

Initialize PI constants and speed

settingsCalibrate the gyro Button Pressed?

Correction On?Turn laser onWait half a second

Turn laser off

Get gyro dataGet elapsed timeIntegrate and invertSend updated

positionSet time stamp for

integration

No

Yes

Yes

No

Wiring Diagram

Test Bench

• Approximates a sine wave from 4 to 20 Hz

• Solid state relay triggering system for solenoid actuators

• Adjustable amplitude using duty cycle

• Integrated gyroscope DAQ• Thermistor DAQ

Test Results

• Accelerometers versus Gyroscopes

• Extended Runtime

• Response Time

• Effectiveness using Test Bench

• Effectiveness using Target

• Survey

Engineering Requirements with Results

Accelerometers VS Gyroscopes

Beyond 80 cm, or 31.5 in, gyroscopes begin to out sense over accelerometers.

Extended Runtime Testing

Time (hours) Battery Voltage0.0 4.18

0.5 4.13

1.0 4.07

1.5 4.05

2.0 4.00

2.5 3.96

3.0 3.92

3.5 3.89

4.0 3.86

4.5 3.82

5.0 3.81

5.5 3.79

6.0 3.78

6.5 3.76

7.0 3.74

7.5 3.72

8.0 3.71

8.5 3.69

9.0 3.67

9.5 3.64

10.0 3.47

10.5 N/A

Total Runtime: 10.1 Hours

Extended Runtime TestingTemperature Min (C) Max (C) Average (C) Limits (C)

TCase1 22.51 26.05 24.48 32.22

TCase2 23.15 27.34 25.48 32.22

Tproc 24.44 28.63 27.03 85

TNST 25.41 29.60 27.88 60

Tgyro 24.12 28.63 26.73 85

Tbatt 22.51 27.99 25.89 60

Tamb 21.22 25.41 23.27 N/A

Response Time

Prototype:

• The code was run for 10 seconds

• The average time it took to run through the code was 1.4 ms

NST Module:

• The Pathways performance logger was used to determine response time to a step response

• Before update – 300 ms forward, 70 ms reverse

• After update – 40 ms forward, 20 ms reverse

Response Time

NST Module:

• While the teensy was sending commands to simulate a sine wave the performance logger was run

• Response time – 3.4 ms

Effectiveness using Test BenchWithout Firmware Update

0 5 10 15 20 25

-100

-80

-60

-40

-20

0

20

40

60

80

Amplitude Reduction vs Frequency

Frequency (Hz)

% R

ed

uct

ion

Frequency (Hz) % Reduction

1 56.89

2 61.07

3 57.87

4 39.5

5 15.32

6 42.34

7 42.86

8 -12.89

9 6.73

10 24.25

11 -14.7

12 -11.89

13 -28.6

14 -34.02

15 -26.87

16 -35.61

17 -44.92

18 -7.57

19 2.49

20 -81.78

Effectiveness using TargetWithout Firmware Update

Data Sets:• No Drift = {69.75, 20.06, 24.39, 47.06, 56.74, 44.64}• Possible Drift = {-13.95, 9.65, 36.18, 25.76, 43.98}• Extreme Drift = {-145.65}Averages:• ND&PD&ED = 16.85%• ND&PD = 33.11%• ND = 45.60%

No Drift Possible Drift**

**Drift in image is due to incorrect calibration of gyroscope

Ease of Use/Ergonomics Survey

Ease of Use/Ergonomics Survey

Comments:• Module is hard to aim when the correction algorithm activated at the same

time as the button press. • This led us to add a slight delay from when the button is pressed to

when the correction activates• User did not know when the correction was turned on without looking at the

switch• Led to us adding an LED light on the Teensy processor

1 2 3 4 50

0.5

1

1.5

2

2.5

3

3.5

4

4.5

Average Response

Question

Ave

rag

e R

esp

on

se

Final Prototype BOM

Quantity Component Cost Per Part Cost Per 1 Unit Cost Per 100 Units1 Teensy 3.1 Processor 19.99 19.99 1696.001 NST Module 1000.00 1000.00 100000.001 Adafruit Micro LiPo Charger 5.00 5.95 476.001 Sparkfun ITG-3200 Gyroscope Breakout 5.95 24.95 1996.001 Sparkfun Mini-USB Breakout 1.95 1.95 156.002 1000 mAh LiPo Cell 8.95 17.90 1790.002 Slide Switches 0.58 1.16 94.001 Momentary Push-Button Switch 7.14 7.14 592.005 Wire (1ft) 0.12 16.95 67.80

24 Plastic Washers 0.03 2.76 69.0010 2mm Hex Head Screws 0.16 7.82 156.408 .050" Hex Head Taper Screws 0.26 6.42 214.004 .050" Hex Head Button Screws 0.87 8.67 346.801 Lexan Material 3.64 3.64 364.001 Aluminum Material 11.08 11.08 110.80

0.33 Manual Machine Time (Hrs) 35.00 11.55 115.500.33 CNC Machine Time (Hrs) 70.00 23.10 231.00

1 Assembly and Soldering (Hrs) 35.00 17.50 175.001188.53 108650.301185.92 1083.89185.92 83.89

TOTALTOTAL PER UNITTOTAL W/O NST

Final Purchase List

• Started with a $1,000 budget

• Propose to spend remaining money on practical items

# Qty Part # Detailed Description Use Vendor Unit Price Extended Price1 1 95610a530 m3 plastic washers 100ct. Housing Hardware McMaster-Carr $2.76 $2.762 15 98952A207 M2.5 x 8 standoffs Housing Hardware McMaster-Carr $1.13 $16.953 1 91290A101 M2.5x6 SHCS 50ct Housing Hardware McMaster-Carr $7.82 $7.824 1 91294A004 M2x6 Flat Head SHCS 25ct Housing Hardware McMaster-Carr $6.42 $6.425 1 91239A703 M2x4 Button Head 10ct Housing Hardware McMaster-Carr $8.67 $8.676 1 85995K19 0.030" Latex Sheet (1 Yard) Housing Hardware McMaster-Carr $6.75 $6.757 1 8975K311 1.5"x2" 6061 (12 " long) Housing Material McMaster-Carr $22.16 $22.168 1 6023K271 1/8"x2" 6061 (12" long) Housing Material McMaster-Carr $16.18 $16.189 2 8940A26 3x25mm 2 flute endmill Tooling McMaster-Carr $20.84 $41.68

10 2 8940A25 3x15mm 2 flute endmill Tooling McMaster-Carr $9.63 $19.2611 1 8305A51 M2.5 Bottoming Tap Tooling McMaster-Carr $9.21 $9.2112 2 8305A79 M2 Bottoming Tap Tooling McMaster-Carr $15.76 $31.5213 1 91290A332 M6x30 SHCS 50ct Test Bench Hardware McMaster-Carr $7.50 $7.5014 1 91166A250 M6 zinc washers 100ct Test Bench Hardware McMaster-Carr $2.42 $2.4215 1 91294A196 M2x20 flat head SHCS 100ct Test Bench Hardware McMaster-Carr $6.55 $6.5516 1 9246K23 3/8"x12" 6061 (12" long) Test Bench Material McMaster-Carr $36.92 $36.9217 1 N/A 3D Printed Housing V1 Housing Prototype Brinkmann Lab $59.10 $59.1018 1 N/A 3D Printed Housing V2 Housing Prototype Brinkmann Lab $59.10 $59.1019 3 1625 Teensy 3.1 Processor Device Processor Adafruit $19.99 $59.9720 6 DEV-11520 Sparkfun FIO Processor Test Bench Processor Sparkfun $34.95 $209.7021 3 1304 Adafruit LiPo Charger Device LiPo Charger Adafruit $5.95 $17.8522 3 SEN-11977 Sparkfun Gyro Breakout Device Gyro Sparkfun $24.95 $74.8523 2 PRT-00339 LiPo Cell Device Power Source Sparkfun $8.95 $17.9024 2 BOB-09966 USB Breakout Board Device Component Sparkfun $1.95 $3.9025 3 CAB-10215 Micro USB Cable Cabling Sparkfun $4.95 $14.8526 3 CAB-11301 Mini USB Cable Cabling Sparkfun $3.95 $11.8527 2 EG1901-ND Slide Switch Device Switch Digikey $0.58 $1.1628 2 GH1348-ND Push Button Switch Device Switch Digikey $7.14 $14.2829 1 1749K97 2x12x0.078" Polycarbonate Housing Material McMaster-Carr $3.64 $3.6430 1 PRT-11367 Assorted Wire Cabling Sparkfun $16.95 $16.9531 4 PRT-00116 Break Away Headers Prototyping Hardware Sparkfun $1.50 $6.0032 10 SEN-10988 Thermistor Sensors Test Bench Sensors Sparkfun $1.35 $13.5033 1 B00406ITIA Universal AC Adapter Test Bench Power Amazon $15.29 $15.2934 2 B009EQG1UY Solid State Relay Test Bench Controls Amazon $9.85 $19.7035 1 PRT-11487 Quick Disconnects Test Bench Hardware Sparkfun $7.95 $7.9536 1 N/A NCEES Poster Printing NCEES Materials RIT Print Hub $76.28 $76.28

$946.59TOTAL

Additional Items to Purchase**:

• Total: $101

• Micro USB Cable

• Sparkfun: $5

• Mini USB Cable

• Sparkfun: $4

• Universal Laptop AC Power Adapter

• Amazon: $15

• Triple Axis Digital Output Gyroscope

• Sparkfun: $25

• Micro Lipo USB LiPoly Charger X 2

• Adafruit: $12

• Teensy 3.1 + Header X 2

• Adafruit: $40

**These items have already been accounted for in our purchase list.

Future Development• Improve Packaging

• Component layout• More ergonomic

• Better Quality Gyroscope• Easier calibration• Less drift• More accurate

• Integration of Processors• Add gyroscope onto NST module• Use single processor• Continuous data and corrections• Reduce overall response time

• Improve response of NST’s mechanical system to meet a target of 2.6 ms• Add damping to test bench• Better method to image process when using test bench• Investigate setting of limits (calibration algorithm)• Ignore any jitters below 2 Hz and focus on canceling between 2 and 20 Hz

Technical Manual

• Drawing Package

• Wiring Diagram

• Processor Code with Notes

• Current Related Patents

• Use Instructions

• Final BOM and Purchase List

• Testing Results and Data