Senior Design Team 5:Final Presentation

May 9, 2009

Outline• Team & Project

Introduction• Design Process• Obstacles• Prototype Design• Conclusion

Team Introduction

Ryan Mejeur (EE)

Team Project Process Obstacles Prototype Conclusion

David VanKampen (EE)

David VandeBunte (EE)

Matt Lubbers (EE)

Inspiration• Service-oriented• Design automated

system• Robotics/ motor

control

Team Project Process Obstacles Prototype Conclusion

Project Overview

Traditional Warehouses+ Robots

Automated Storage & Retrieval Systems (AS/RS)

- Built w/ warehouse

STORBOT

Team Project Process Obstacles Prototype Conclusion

Project Scope EvolutionBeginning• Implement RTOS on

open core• Exhibit small amount

of controls• Vastly coding oriented

End• More mechanical• Limited real-time

capabilities• Full Business Plan• Bottom-up robot

system design

Team Project Process Obstacles Prototype Conclusion

System Architecture

Team Project Process Obstacles Prototype Conclusion

Wall Outlet

Robot

DC Power Supply FPGA

DC Power

Sig

nals

Amplification

Motors Sensors

Host Computer

(User Interface)

AC Power

CTRL

CTRL

Host PC sends command

PC Sends Command

FPGA decodes and receives commandFPGA signals

wheel motors to advance

FPGA DecodesRobot Moves

At proper shelf, truck stops,

rotator starts

Arm Rotation

After rotation, the elevator raises the

arm

Elevator UpOnce correct

height is reached, the forearm advances

Forearm ExtensionUpon contact with

the product, a vacuum is

created, and the product is pulled

back

Vacuum EnabledOnce the product is over the tray,

vacuum is released, and arm

is lowered

10110101

Elevator Down

Robot Workflow

From Concept…• Redesigned over Spring Break•Addressed specific issues•Visual conception drawn in Sketch-up

Team Project Process Obstacles Prototype Conclusion

… To RealityNew Design•Taller tower•Longer arm•Shelf Motor•Linear bearings

Design Process• Task breakdowno Dave VandeBunte – FPGAo Dave VanKampen –

Sensorso Matt – Elevatoro Ryan – Robot Base• Working in parallel• Late nights and

early mornings

Team Project Process Obstacles Prototype Conclusion

Team Project Process Obstacles Prototype Conclusion

Testing and Performance• Tests• “Agile” development

style– Incremental tests– Feature by feature

• Bench tests for mechanics– Vacuum– Elevator– Arm– Wheel motors

• Performance• Calibration

– Setting Elevator Heights

– Sizing of Suction Cups

• Know when to call it quits– Wheel steppers– Turn-disc– PCBs vs.

breadboards

Obstacles• Elevator limitations

– Small range of motion– Structure too weak

• Turn-disc inaccuracy– Error magnification– Poor drive system

• Stepper Controller inconsistency– Voltage stepper failure– Development board damage

Team Project Process Obstacles Prototype Conclusion

Team Project Process Obstacles Prototype Conclusion

Solutions and Tradeoffs• Redesign elevator

– Linear bearings– Improved structural design

• Fix Turn-disc– Bolt in place– Loss in range of motion

• Controller opto-isolation– Far too much time & too many gray hairs– No level translation necessary

Prototype Design

Base Design Elevator/Arm DesignTeam Project Process Obstacles Prototype Conclusion

Base Design

Base Design Elevator/Arm Design

•Power Supplies•Stepper Motor Controllers•Wheel Stepper Motors•Turn-disc Stepper Motor•H-Bridge and Relay•Development Board•Powertrain

Team Project Process Obstacles Prototype Conclusion

Arm Design

• Bearings• Rack and Pinion• Adjustability

Team Project Process Obstacles Prototype Conclusion

Elevator Design• Elevator Assembly• Arm Assembly• Plate Assembly• Tower Assembly• Turn-disc Assembly• Vacuum Pump• Distance Sensor

Team Project Process Obstacles Prototype Conclusion

Prototype -- Analog

Sensors• Reflectance• Encoders• Ultrasonic Distance• IR Proximity• Vacuum

Peripheral Circuits• High current H-bridges• Voltage steppers• Opto-isolation• Transistor switches

Team Project Process Obstacles Prototype Conclusion

Prototype -- Digital• Functional GUI• Front end for Serial

Port• Inventory

Management System

• Successful coordination with CS student

Team Project Process Obstacles Prototype Conclusion

Prototype -- Digital

Team Project Process Obstacles Prototype Conclusion

Development Board

GUI (Java)

Hardware (VHDL)

Device Driver Wrappers (C++)

Wheel Controllers (BASIC)

Terminal (Serial) WirelessSignal

Linux Device Drivers (C)

Reflectance Sensors

Ultrasonic Sensor

Program Driver (C++)

Final Prototype

Conclusions• Success

• Heavier Box 15 to 30 lbs

• Larger Dimensions12 “ to 18”

• Lessons learned• Robotics Field• Debugging

• Potential Development• Expandability • Patent follow-up• Debug turn-disc

Team Project Process Obstacles Prototype Conclusion

Acknowledgements

• Phil Jasperse – Shop Attendant• Josh Vroom – CS Student• Chuck Holwerda – Electronics• Professor Bossemeyer & Calvin

Faculty• DornerWorks• Xilinx University Program• Ben Lubbers and Jonathan Mejeur

Team Project Process Obstacles Prototype Conclusion

Questions?