UNDERWATER REMOTE OPERATING VElllCLE

MOHAMMAD AFIQ BIN HASlllM

This report is submitted in partial fulfillment of the requirements for the award of

Bachelor of Electronic Engineering (Telecommunication Electronics) with Honors

Faculty of Electronic and Computer Engineering

Universiti Teknikal Malaysia Melaka

May 2008

UNlVERSTI TEKNIKAL MALAYSIA MELAKA FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER

BORANG PENGE AHAN STAT S LAPORAN

PROJEK SARJANA MUDA II

TajukProjek

Sesi Pengajian

UNDERWATER REMOTE OPERATING VEHICLE

200712008

Saya MOHAMMAD AFrQ BIN HASHIM mengaku membenarkan Laporan Projek Srujana Muda ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1. Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.

2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan laporan iill sebagai bahan pertukaran antara institusi

pengajian tinggi.

4. Sila tandakan ( ..J ) :

D SULIT*

D TERHAD*

[£] TIDAX TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKT A RAHSlA RASMJ 1972)

(Mengandungi maklumat terhad yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

~ (MO~AfIri\i HASHIM) (EN. RAN BIN MOHD IBRAHIM)

Alamat Tetap: NO. 60 TMN FORTUNA FASA I JLN PENAMPANG. 88200 KOTA KJNABALU. SABAH.

Tarikh :. ~.l~. I.~~ ......

IMRAN BIN MOHO IaftAHIM Pensy.rah

F~ Kei: .E~ dan Kej. Komputer (FKEKK), Uruversitl TeI!.nikil Mala~ Melakl (UTeM).

Karung Be~ 1200. Ayer KerIh, 75450 Melaka

. (b/l/Ot Tankh: ............................ .

III

"I hereby declared this report is the result of my own work except for quotes as cited

in the references."

Signature

Author

Date

: ................. ~ .................•....... : MOHAMMAD AFIQ BIN HASHIM

: ... '.?j~.l.~.? ...................................... ... .

"I hereby declare that I have read this report and in my opinion this report is

sufficient in terms of the scope and quality for the award of Bachelor of Electronic

Engineering (felecommunication Electronics) With Honors."

Signature

Date

Supervisor Name . IMRAN BIN MOHD IBRAHIM

: ......... ~.~( .r!.~.~ ................... ............... .

IV

v

For my lovely family

VI

ACKNOWLEDGEMENT

Praise to God the Almighty for His mercy; I could finish my Industrial

Training Program successfully.

I would like to deliver my heartiest appreciation to Mr. Imran bin Mohd

Ibrahim, Vice Dean (R&D) of Faculty of Electronic and Computer Engineering for

accepting my request to be my supervisor, for his helpful thought and motivation

throughout completing this project.

I dedicate my deepest gratitude to Mr. T. L. Lee of Unipac Engineering

(Melaka) Sdn. Bhd. for his advices, guidance and his effort in helping me in

designing and developing parts for this project.

A countless appreciation dedicated to my beloved family and all my friends

for their endless support and for being there for me through thick and thin.

And again my appreciation to those already mentioned and to those who are

not mentioned. Thank you very much.

Thank you.

Vll

ABSTRACT

The remote operating vehicle (ROY) is designed to be used for an underwater

surveillance such as in ecological studies or environmental parameters survey. For

that reason, the ROV will be equipped with suitable tools such as a video camera and

robotic arm to accomplish its mission. Several limitations are made as a guideline in

designing and developing the ROV. Most ROV must be big enough to accommodate

adequate tools for surveillance. As their functions increase, the size will also increase.

Consequently the cost for producing such vehicle will also expand. Based on the

situations mentioned above, the goals for this project are to design and develop a

small and effective ROV and to produce it with expenses as low as possible. In order

to meet the objectives, research regarding to the design and developing the ROV is

mostly depends on internet resources. These resources are from an internet forum

which discuss mainly on homebuilt ROV, journals and research paper that are related

to the project. The secondary resources are from books available locally. The

outcome is expected to meet all objectives mentioned above and the limitation

should be obeyed. Constructed ROV should be reliable with the help of real-time

monitoring system to aid controller. It also should be safe to use and operated by

human as well as do not harm the environment at any cost.

Vlll

ABSTRAK

Remote operating vehicle (ROY) atau kenderaan kawalan jauh yang dibina

adalah bagi memenuhi keperluan dalam membuat kajian ekologi dan tinjauan ciri­

ciri persekitaran di dalam air. Bagi mendapatkan hasil kajian yang terbaik, ROV

tersebut akan dilengkapi dengan peralatan yang sesuai seperti kamera video ataupun

lengan robotik. Beberapa had batasan telah digariskan sebagai panduan dalam proses

mereka dan membina ROV tersebut. Pertambahan bilangan peralatan yang akan

digunakan secara lazimnya akan menyebabkan saiz ROV turut bertambah dan secara

tidak langsung akan meningkatkan kos pengeluaran ROV tersebut. Oleh yang

demikian, projek ini adalah dicadangkan untuk membina ROV yang efisyen dalam

bidang tugasnya dan dihasilkan menggunakan modal serendah yang mungkin. Bagi

memenuhi objektif-objektif projek, kajian berkenaan rekabentuk dan pembikinan

ROV tersebut adalah bergantung kepada sumber daripada forum internet, jurnal dan

kertas kajian berkenaan projek ini. Surnber kedua merupakan buku-buku yang

berkaitan yang boleh diperolehi secara percuma di perpustakaan. Pada akhir semester

ke-2, adalah diharapkan supaya projek ini akan memberikan hasil yang memenuhi

objektif ini secara menyeluruh. Penggunaan ROV yang dibina diharapkan adalah

efisyen dengan bantuan sistem pengawasan secara real-time. Hasil projek ini juga

diharapkan dapat berfungsi tanpa memberikan ancaman keselarnatan kepada

pengguna dan juga kepada alam persekitarannnya.

IX

CONTENTS

CHAPTER CONTENTS PAGE

PROJECT TITTLE

DECLARA TION ii

DEDICATION v

ACKNOWLEDGEMENT vi

ABSTRACT vii

ABSTRAK viii

CONTENTS ix

LIST OF TABLE xii

LIST OF FIGURE xiii

LIST OF AB BRE VIA TION xv

LIST OF APPENDIX xvi

I INTRODUCTION

1.1 Introduction

1.1.1 Micro Class 2

1.1.2 Mini Class 2

1.1.3 General Class 2

1.1.4 Light Work Class 3

1.1.5 Heavy Work Class 3

1.1.6 Trenching Burial Class 3

1.2 Objective 4

1.3 Problem Statement 5

1.4 Scope 5

x

CHAPTER CONTENTS PAGE

1.5 Methodology 6

n BACKGROUND OF STUDIES 8

2.1 Basic Components 8

2.1.1 Frame and Housing 8

2.1.2 Buoyancy 9

2.1.3 Control System 11

2.1.4 Propulsion 13

2.1.5 Tools and Equipments 16

2.2 Additional Components and Consideration 17

2.2.1 Vehicle Teleoperation Interfaces 17

2.2.2 Low Drag and Mechanical Symmetry 19

ill METHODOLOGY 21

3.1 Data Acquisition Method 21

3.1.1 Internet Forum 21

3.1.2 Articles, Journals and Reports 22

3.1.3 Books 22

3.2 Data Processing Method 23

3.2.1 Discussion 23

3.2.2 Comparison 24

3.2.3 Design, Simulate and Construct 24

3.3 Electronic Circuit Development 26

CHAYfER CONTENTS PAGE

IV

V

RESULTS AND DISCUSSION 31

4.1 Project Specification and Results 31

4.1.1 Frame and Watertight Housing 31

4.1.1.1 ROV Frame 32

4.1.1.2 Main Watertight Housing 35

4.1.1.3 Buoyancy and Stability 38

4.1.2 Main Controller and Control System 39

4.1.2.1 Main Processor 39

4.1.2.2 Motor Controller 41

4.1.2.3 Ground Controller 44

4.1.3 Propeller and Propulsion 48

4.1.3.1 Vertical Motion 48

4.1.3.2 Horizontal Motion 49

4.2 Discussion 51

CONCLUSION

5.1 Conclusion

5.2 Future Works

REFERENCE

6S

65

66

68

xi

xii

LIST OF TABLES

NO TITLE PAGE

4.1 Comparison of frame materials 33

4.2 Proto typed frame comparison 34

4.3 Comparison of control system type 39

4.4 Submerged unit and surface unit components 52

4.5 ROV final dimension 57

Xlll

LIST OF FIGURES

NO TITLE PAGE

2.1 Air pressured ballast tank 11

2.2 6-channel RF transmitter 12

2.3 DC motor with Electronic Speed Controller unit 14

2.4 6-DOF 15

2.5 Thruster configuration and allocation of RRC ROV II 16

2.6 CCD camera 17

2.7 ROV REV II user interface 19

3.1 ROV development flowchart 25

3.2 Electronic circuit development flowchart 26

3.3 Printed layout on transparency paper 28

3.4 Circuit layout on the copper side 28

3.5 Circuit arrangement in the UV exposure machine 29

3.6 Developing process 30

3.7 Developed circuit 30

4.1 First frame prototype 32

4.2 Final frame designed 34

4.3 Frame comparison 35

4.4 Watertight compartment 36

4.5 1" extension 36

4.6 Elevations 37

4.7 Drilled holes 38

4.8 The ROV system 40

4.9 The co-processing system 41

4.10 PC fan 42

XIV

4.11 MDlOA motor driver 43

4.12 Motor driver circuit schematic 44

4.13 PS2 game controller 46

4.14 PS2 - Bs-ll interface circuit 47

4.15 KYOSHO propeller 50

4.16 Propulsion unit assembly 51

4.17a Front view 53

4.17b Back view 53

4.17c Side view 54

4.17d Aerial view 54

4.17e Bottom view 55

4.18a Main watertight compartment circuit arrangement 56

4.18b Surface control box circuit arrangement 56

4.19a Weighed ROV 57

4.19b Measurement close-up 58

4.20a Output voltage 59

4.20b Input voltage 59

4.21 BS-JI output test 60

4.22a Captured video in normal light 61

4.22b Real image 61

4.23a Captured video with light assistant 62

4.23b Captured video without light assistant 62

4.23c Real image 63

4.24 Light trajectory 64

xv

LIST OF ABBREVIATION

BS-ll - Basic Stamp II

CAD - Computer Aided Design

CCTV - Closed Circuit TeleVision

CCW - Counter Clockwise

CW - Clockwise

DOF - Degree of Freedom

GUI - Graphical User Interface

hp - Horse Power

IC - Integrated Circuit

IR -Infra Red

PC - Personal Computer

PS2 - PlayStation@ 2

PSM - Projek Sarjana Muda

PVC - PolyVinylChlorida

RF - Radio Frequency

TIL - Transistor-Transistor Logic

UV - Ultra Violet

xvi

LIST OF APPENDIX

NO TITLE PAGE

A-I Frame cost 71

A-2 Electronic component cost 72

A-3 Miscellaneous item cost 73

A-4 Total cost 74

B Main processor coding 75

C MDlOA datasheet 84

D-l JAWSSROV 90

D-2 'The Hunter' by Paul Konings 91

D-3 Gearbox 91

D-4 Chain drive 92

D-5 Direct drive 92

E-l Developed ROV system 93

E-2 45° arrangement 93

E-3 Completed horizontal thruster unit 94

E-4 Vertical thruster connection 94

F BS-II datasheet 95

CHAPTER I

INTRODUCTION

1.1 Introduction

Remote operating vehicle (ROY) technology appears since early 1900's until

become widely used in 1970's [1]. Back then, the underwater ROY is mainly used in

oil industry while manned submersible vehicle is the preferred tools for underwater

scientific studies. As the technology developed, its functions have expanded to be

used in both industries and scientific studies [1][2]. ROY is defined as the

underwater robot that allows the vehicle's operator to remain in contented

environment while the piloted robot performs the work underwater.

In order to perform various task [1][3], suitable tools are equipped to the

underwater ROY. Generally, a camera, depth sensor [1][3] , pressure sensor and

temperature sensor are the main features of a ROY. For special task, tools such as

mechanical ann [2], radiation sensor [3] and sonar is used. As human supervision is

critically needed, the camera and sensors are interfaced using suitable graphic

interface and consoles [1][2][3][4] for monitoring purposes. In addition, various

types of method are developed to meet the needs of reliable ROY maneuvering and

ground control scheme.

2

The underwater vehicle came in various size shape and purposes. While its

ize is depended on its purposes, their shapes are made based on performance factor.

There are six classes of ROV existed which define their size and its mission.

1.1.1 Micro Class

Very small in sIze and weight as it only carry lightweight tools for

surveillance. Most Micro ROV nowadays can weight less than 3kg and used in a

place which are dangerous and too small for a diver such as pipeline, sewer or small

cavity (17] [21].

1.1.2 Mini Class

A Mini class ROV is bigger than Micro ROV with weight less than 50kg.

Mini ROV is also used as a diver replacement and could perform intervention tasks.

As its size is bigger than Micro ROV, it could be equipped with more tools and

equipment. This ROY also could be used where medium water current exists [16]

[17].

1.1.3 General Clas

Work at a depth of less than lOOOm with additional manipulator grippers

on board and may carry sonar unit for light survey applications. More tools and

complex equipment are installed for data collection purposes. The General Class

ROV usually came up with less than 5hp propulsion power [17].

3

1.1.4 Light Work Class

The Light Work Class ROY works at a depth less than 2000m and uses less

than 50hp propulsion power. It can carry more than one manipulator for its light

work missions. For its frame, polymers such as polyethylene is used rather than the

conventional stainless steel or aluminium alloys. Its weight is ranging between

1000kg to 2200kg. Typical tasks for this class are drilling support light construction

support pipeline inspection and general "call out" work [17][19].

1.1.5 Heavy Work Class

Its huge size enables the ROV to carry at least two manipulators for its heavy

work mission. This heavyweight ROV require not more than 220hp thruster power

for movement. For its size and ability the Heavy Work Class ROY usually works at

a depth up to 3500m. With new requirements to perform subsea tie-in operations on

deepwater installations and to carry very large diverless intervention systems this

class of ROV is becoming increasingly large powerful and capable of carrying and

lifting large loads thu the term "heavy work class vehicle" has been adopted by the

industry. These vehicles can weight more than ten thousand pounds and resemble a

minivan in size [17].

1.1.6 Trenching Burial Class

The trenching ROV is used for trenching burial works only. The ROV used

more than 200hp propulsion power with an ability to carry a cable lying sled and

work at depths up to 6000m. Commonly the trenchers are not a free flying ROY

instead it crawls on the seabed cutting trench for cable. Cameras lights sonars and

other sensors necessary to operate at great depths are readily available. Manipulators

capable of lifting hundreds of pounds are commonly installed on these vehicles [6].

4

1.2 Objective

The goals for this project are determined from the problem statements that are

made based on my observation and studies regarding the ROV issues.

First objective of this project is to design and develop a small and yet

effective ROV. The ROV will be in a Mini Class ROV which is designed for

observation purposes. For data collection process, the ROV will be equipped with

basic tools such as camera and compass. The operation of the ROV will be equipped

with real-time video monitoring from the camera attached to the ROV to improve the

reliability of the ROV.

The second objective determined for this project is to produce a low cost

ROV which can be obtained by almost everyone. Even though with as small

spending as possible, the first objective of the project will not be sacrificed. The

project should prove that a reliable ROV at its own class can be produced at low

pnce.

Thus, in the end the project is expected to meet all objectives mentioned

above and the limitation should be obeyed. Constructed ROV should be very reliable

with the help of real-time monitoring to aid controller. It also should be safe to be

used and operated by human as well as it do not harm the environment at any cost. In

addition, it is also expected that this project will help to improve my problem solving

skills knowledge on field other than electronic other engineering disciplines and

scientific concepts.

5

1.3 Problem Statement

The following situations stated are the major issues that usually arise among

ROV users based on studies made. There are two main issues which led to the

conception of this project.

Most ROV must be big enough to accommodate tools for surveillance. For

basic observations and data collections, for instance, an observation of environmental

parameters, sets of sensor such as pH sensor, temperature sensor, and salinity sensor

are equipped to the ROV. As data collecting tools increased, so do the frame area or

platform size to accommodate the tools must be sufficiently enough thus increasing

the size of the ROV itself. In returns, much higher propulsion power needed to

mobilize the ROV and thus increasing the total power needed by the vehicle [7].

As the functions increase, the size will also increase. Consequently, every

aspect of producing the ROV also increases. This includes the factor of reliability of

the ROV itself as most tools and equipments that come with high quality and great

performance will be very costly to acquire. It also involves the cost of obtaining

small yet has very outstanding performance equipment. Thus, to produce a very

reliable ROV will be too expensive even though producing a micro ROV class [20].

This scenario can be observed from the production of ROV for educational purposes

which are hardly affordable prices.

1.4 Scope

Limitations below are created based on several purposes. Firstly, it is used to

determine on how reliable the ROV was when operated [5]. Secondly, the limitation

is used as a barrier to avoid materials wasting and unnecessary parts of the ROV

which consequently will reduce the cost of production.

6

First limitation determined is the operating depth. The Mini Class ROV

should be operating in shallow water which the depth is below than 30m. This is due

to the pressure issues that will always appear along the ROV construction process.

As we going deeper underwater, the pressure applied on us will increase. If the ROV

hull cannot withstand the pressure, it will eventually break and water will flood the

hull and consequently destroy all electronic equipments.

Secondly, the ROV is set to be maneuvered inside calm water or with low

current. For an area with such current, the ROV should be able to maneuver free and

easily without a huge drag forces introduced. Even if operating inside calm water,

attention upon current that might exist should be considered during the development

of ROV.

Thirdly, the ROV must have its own clear and defined jobs. Due to lack of

time given to complete the project, the ROV is limited to perform basic data

collection and light observation task. The jobs defined will acquire the ROV to be

equipped with general observation tools or payloads such as video camera, digital

compass and pressure sensor. Additional tools will be equipped if there are ample

times to do so.

Lastly, the ROV developed is small enough to operate inside a test tank. This

is due to the PSM II Seminar that will be held inside Faculty's laboratory which did

not permit a large test area for the ROV.

1.5 Methodology

In this project, methodology can be divided into two parts. The first part

introduced the methodology used for data collecting while the second part describes

the methodology used for data processing.

7

For data collection, there are three main methods used. The flIst method is by

collecting data from internet groups that are dedicated on building their own ROY

and anything related to the project such as sensors and microcontroller. Secondary

method used in order to gather data is from journal, articles and reports of subject

associated with the project obtained from various online database portals such as

IEEE website. This source provides data based on professional analysis and test that

is valid for citation in this report and most importantly can be used for developing the

ROY along with data obtained from the first method. Last method used in order to

complete this project is by referencing to the books that must be related to the project.

Data processing methods also comprise of three techniques. The first

technique is through discussion among experienced person with matters related.

Then, comparison technique is used mainly to choose the best from available choices

of material, tools or modus operandi. The third method is through design, simulation

and constructs the data obtained in order to achieve desired results.

The following part of the report is organized as follows. Chapter IT will

describe the literature review done for this project. Chapter ill is an extended

discussion of methodology used in this project. Chapter IV contains results and

discussions, which mainly describe the project progress and lastly Chapter Y, the

conclusion of the progress report of Underwater ROY project including suggestion

for further improvement of this project.

CHAPTERll

BACKGROUND OF STUDIES

Despite their size and functions, all ROV shares generic building blocks

which consist of major common components. The difference is only how the

manufacturers manipulate these components in designing their own ROV. Usually,

work class ROV are constructed using a same design while smaller ROV are freely

designed to fit its mission.

2.1 Basic Components

Despite their classes and mission objectives, all ROV are build with

consideration of the following matters. These followings matters can be describe as

the basic component of a ROV.

2.1.1 Frame and Housing

This is the most important part of the ROV, the frame provides a solid

platfonn for attaching necessary mechanical, electrical, data acquisition and

propulsion components. The concept of choosing the best material for the frame is to

give maximum strength to the structure with minimum weight. It is very important

for the weight to be offset with buoyancy of the ROV which will keep it balanced