Download - RP1
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02.22.08
RP1
1kg Motor Module, First Generation
P08208 – Mechanical DesignP08205 – Wireless & PWM Motor Controller
MSD I
20072
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02.22.08
WHAT IS A MOTOR MODULE ?
DRIVE
MODULAR MOUNTING
STEER
aka “MM”
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1kg
10kg
100kg
OFF THE SHELF MOTOR MODULES
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RP100( Wired )
RP10( Wired )
RP1Sister projects!
RP10Redesig
n
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RP10Redesig
n
RP1
Wireless!
Robust!
Autonomous!
Smaller! Lighter!
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ORGANIZATION BREAKDOWN
P08208Wendy Fung
P08205Reid Williamson
SteerMatthew BenedictArtur Ponikiewski
DriveAndrew AndersonMatthew BenedictPlatform
Eric RodemsArtur Ponikiewski
YokeJames EdickEric Rodems
ElectronicsBryan Jimenez
Jonathan Maglaty
ControlsBrendan HayesPhilip Edwards
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System-Level Process Flow
Computer
Wireless Receiver
Microprocessor
Motor Controller
RP1 Motor Module
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CRITICAL REQUIREMENTS
• Transport 1kg Payload• Robust = Withstand Tabletop Drop• Wireless Communication• Power Motors with a PWM Signal• Open Source & Open Architecture• Reflect Design of the RP Family• Modular Design for Multiple End Uses
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EXPECTATIONSo Quantity
2, Fully Functional
o Size12in x 6in x 6in
o Speed @ max efficiency 38 in/s
o Droptest Repair Time < 5 min
o Wireless Range 300 ft max
o Battery Life 1 hour +
1
2
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FORMAT
Drive & Steering• Q & A
Yoke & Platform• Q & A
Electronics & Controls• Q & A
DFMA & MSD II Outlook• Q & A
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• Responsibilities: – Highly dynamic range of operating speeds– An array of different operating conditions– Robustness– Seamless system integration
• Risks– Difficulty obtaining different motor gearboxes– Drive Shaft Alignment (turntable wobble)– Robustness of design– Accurateness of systems modeling– Tolerances– Assembly
DRIVETRAIN SYSTEM
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IG 32 Motor
27:1 Gear Reduction
¼” Stainless Steel Axles
½” Aluminum Spacers
2” Diameter Wheel
Axle Couplings
Thrust Bearings
2:1 Synchronous Belt and Pulley
Axle Collars
FINAL DESIGN
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Efficiency vs. Torque
52
53
54
55
56
57
58
59
60
61
0 2 4 6 8 10 12
Torque (lb*in)
Eff
icie
ncy
(%
)
5:1
14:1
19:1
27:1
51:1
71:1
100:1
139:1
189:1
SYSTEM LEVEL DESIGN
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Power vs. Torque
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0 5 10 15 20 25
Torque (lb*in)
Po
wer
(W
)
5:1
14:1
19:1
27:1
51:1
71:1
100:1
139:1
189:1
SYSTEM LEVEL DESIGN
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STEERING
• Responsibilities: – Infinite Steering– Easy to assemble/disassemble– Robust– Seamless system integration
• Risks– Robustness of belt tension system– Turntable – Integration with electronics and controls– Tolerances– Assembly
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IG 32 Motor
71:1 Gear Reduction
¼” Stainless Steel Axles
Turntable
Custom Centerpost
1:3 Synchronous Belt and Pulleys
STEERING SUBSYSTEM
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STEER BELT TENSION
Axle Couplings
Adjustable Steer Motor Mounting Plate
Adjustable Bearing Plate
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DRIVE & STEERING
Q & A
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YOKE
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YOKE
• Responsibilities: – Responsible for structural skeleton of Rp1– Design a rigid and robust framework– House all other sub-systems within framing – Provide protection against a 36” drop to the floor
• Risks– Keeping within the weight requirements– Withstand drop without any significant damage or
misalignment of components – Minimizing overall cost of yoke
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UPPER YOKE
1/8” AL Plate
½” x ½” Al Posts
AL Angle Brackets
1/8” Al Upper Yoke to Turntable Mounting Plate
Encoder standoff mounting plate
1/8” Al Motor Mounting Plates
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LOWER YOKE
1/8” Al Upper Yoke to Turntable Mounting Plate
80/20 90° Base Connector
1”x1” AL 80/20 Quick Frame
Mounted Flanged sleeve bearings
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Design Justification
• Critical Decisions:– Frame built of aluminum instead of Lexan to
improve strength– Used an open 80/20 fork design for lower yoke
to provide maximum rigidity while minimizing weight
– Used solid post box design in upper yoke to fully enclose drive, steering and electrical systems. Solid posts allows for easier hardware attachment
– Turn table connected to mounting plates on both sides to support upper and lower yoke
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PLATFORM
• Responsibilities– Platform design– Mounting of modules to platform– Idler module development– Test fixture design
• Risks– Design was heavily reliant on upper
yoke– Design of platform for drivability
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DRIVE PLATFORM
2 platforms (1 per team)
– Holds 2 motor modules
– Holds 2 idler modules
– Square shape for adaptability
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IDLER MODULE
Idler Design– Past RP project
experience– Use of motor
module parts– Simplified design– Caster offset
(slot)
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TEST PLATFORM
1 test platform– Holds 1 motor
module– Holds 2 idler
modules– Will have quick
connect adapters spec’d out from Molex
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YOKE & PLATFORM
Q & A
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CONTROLS
• Graphical User Interface (GUI)– Allow the user to interact with and
control the robotic platform• Wireless
– Responsible for the communication between the user and the platform
• Microprocessor– Generate control signals and monitor
sensor feedback
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Controls
• Risks– GUI
• User is unaware of current state of RP1• User is unable to respond quickly
– Wireless• Wireless interference• Insufficient data rate
– Microprocessor• “Swamped” with encoder feedback
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• Final Design
GUI
Left Motor Module Drive Motor: Good
Wheel Angle
Battery Life Remaining
Left Motor Module Steering Motor: Good Right Motor Module Drive Motor: InefficiencyRight Motor Module Steering Motor: Good
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Wireless
• MIB520 USB-Gateway
• MICAz 2.4 GHz Wireless Transceiver
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• Freescale MC9S12DT256– 8 Channel PWM Module– Modular Communication
• IIC• SPI• SCI• CAN
Microprocessor
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ELECTRONICS
• System Responsibilities– Provide components for motor control– Placement of motor control components – Supply power to electrical components– Confirm electrical components are compatible
with microprocessor
• Risks– Component ratings (i.e. heat, amps, etc.)– Lead time on final part selections– Compatibility between electrical components
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Final Design
• H-bridge – PWM Motor
Controller 3A
• Encoders– US Digital
•EM5•EM1•HUBDISK
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Final Design
• Power Schematic for encoders (5V)
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Final Design
• Simulation for Encoder Power Schematic
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Final Design
• Battery Selection– NiMH– 24V– 3.5Ah– Rechargeable
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CONTROLS & ELECTRONICS
Q & A
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Design For Manf. & Assembly
• Steering assembly implementation
• Degree of machining precision• Bending of motor shaft• Spacing and fasteners• Control Communication• Functional control
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Plans for MSD II
• Build RP1 prototype• Test accuracy of
system modeling• Build test fixture• Do the drop test• Look into possible
aesthetical improvements
• Optimize current design
• Build GUI• Setup basic
wireless communication
• Test all electrical components
• Full system integration and test