Humanoid Robot Head: May 09-11

Team:Dan Potratz

Cody GenkingerTim Meer

Jason PollardAndrew Taylor

Client/Advisor: Alex Stoytchev

Planning and System Design

Problem/Need Statement Concepts & Renderings Requirements User Interface Market Survey Risks Schedule Work Breakdown Deliverables

Problem/Need

Problem – At the beginning of the project there was a robotic frame with two mobile robotic arms, but a static shell for the head.

Need – The head needs to be capable of showing human-like facial emotions and movements.› Smile, frown, frustration, etc;› Tilt and pan the head, eyes.

Concept Renderings

Provided by Isaak Moody

CAD Renderings

System Requirements F Req#001 – The head shall move front to back within a 90°

arc of motion with a velocity that will be equivalent to 90° per second

F Req#002 – The head shall move left to right within a 90° arc of motion with a velocity that will be equivalent to 90° per second.

F Req#003 – Mouth motions shall be handled by two servos, with a 180 degree arc of motion.

F Req#004 – Eyebrows shall be handled by a single servo, with a 180 degree arc of motion.

F Req#005 – A camera shall be implemented within the head or body to provide visual feedback for

processing by the operator. F Req#006 – The eyes shall be able to move on two axes,

with a 30 degree arc in each direction.

System Requirements

NF Req#001 – The head shall look clean and nonthreatening, while retaining human-like attributes.

NF Req#002 – API shall be done within C#. Interfaces will be done in C#.

NF Req#003 – Movement of the head shall be smooth and well transitioned.

NF Req#004 – Motors shall be quiet and not distracting. NF Req#005 – API shall follow format of existing arm API. NF Req#006 – The microcontroller board shall be

connected to our PC via serial or USB. NF Req#007 – Servo wiring shall be twisted pair to

maintain low noise emission.

User Interface Specification:

Overview User-directed scripting for robot

animations.› Record and playback scripts

Manually adjust each facial and neck part.

Adjust hardware related options.

User Interface Specification:

Goals To create animations for head To create a clean, easy to understand

interface To create a stable interface with:

› Proper error reporting› Feedback for the user› Crash acknowledgement

Risks

Technical:› Servo controller/motor malfunction.› Difficulties integrating serial interface.

Financial:› Parts may exceed small budget.› Loss/denied funding for project/parts.

Schedule:› Shipping delays› Course work delays project tasks

Customer Acceptance› Not pleased with result/design and documentation› Solution might exceed budget

Schedule

Work Breakdown

CAD

Coding

Parts Selection

Prototype Construction

Testing

Documentation

Redesign

Final Report

Planning Report

Design Report

Market Survey

Specific to the design of our head, there are few similar projects.› MIT

Mobile/Dexterous/Social “MDS” Nexi Leonardo Kismet

› Philips Research iCat

› University of Hertfordshire KASPAR

Deliverables

System Design

Functional Decomposition Specifications Testing Prototyping Documents

Functional Decomposition

Hardware Specification: Neck – Pitch & Pan

Two servos 0-180º < 1 second Two degrees of

freedom Fits inside space

provided on the chassis

Supports up to 4kg Price: $299.88

Hardware Specification: Neck – Rotating Servomotor

Operating Voltage: 4.8-6.0 Volts

Operating Speed (6.0V): 0.16sec/60° at no load

Stall Torque (6.0V): 56.93 oz/in. (4.1kg.cm)

Current Drain (6.0V): 8.8mA/idle and 180mA no load operating

Dead Band Width: 8usec Motor Type: 3 Pole Ferrite Bearing Type: Dual Ball Bearing Gear Type: Nylon

Weight: 1.6oz (45.5g)) Price: $15.00

Hardware Specification: Neck – Tilting Servomotor

Operating Voltage Range: 4.8-6.0 Volts

Operating Speed (6.0V): 0.15 sec/60° at no load

Stall Torque (6.0V): 333oz/in. (24kg.cm)

Idle Current Drain (6.0V): 3mA at stop

Current Drain (6.0V): 240mA/idle and 3.0 amps at lock/stall

Dead Band Width: 2usec Motor Type: Coreless Carbon Brush Bearing Type: Dual Ball Bearing MR106 Gear Type: Titanium Gears

Dimensions: 40 x 20 x 37mm Weight: 2.29oz (65g) Price: $115.00

Hardware Specification: Eye – Tilting Servomotor

Operating Voltage Range: 4.8V to 6.0V

Operating Speed (6.0V): 0.11sec / 60 deg

Stall Torque (6.0V): 7.4kg / 112oz

Bearing Type: Dual Ball Bearing

Gear Type: Metal

Dimensions: 42.0 x 21.5 x 22 Weight: 32.0g / 1.12oz Price: $20.00

Hardware Specification: Face – Servomotors

Operating Voltage: 4.8-6.0 Volts

Operating Speed (6.0V): 0.09sec/60° at no load

Stall Torque (6.0V): 23.5 oz/in. (1.7kg.cm)

Motor Type: 3 Pole Ferrite

Bearing Type: Top Ball Bearing Gear Type: All Nylon Gears

Dimensions: 21.8 x 11 x 19.8mm

Weight: .27oz. (7.8g) Price: $14.00 each

Hardware Specification: Head – Microcontroller

Max packet size: 59 bytes Max control rate: 15

instructions / second 74% available bandwidth

used worst case

1 to 8 servos per board with 8-bit resolution

<1° of servo position precision resolution

Servo port can be reconfigured for digital output to drive on/off devices.  

Dimensions: 1.4 in X 1.7 in  Price: $80.00

Hardware Specification: Head – Cameras

Video capture: › Up to 640 x 480 pixels

(VGA CCD) Still image capture:

› Up to 1280 x 960 pixels, 1.3 megapixels

Frame rate: › Up to 30 frames per

second Price: $50.00

Hardware Specification: Testing

Servos› Function Generator› Oscilloscope› Bench-Top DC Power Supply

Microcontroller Board› Oscilloscope› Computer with serial connection› HyperTerminal Communication Software› Bench-Top DC Power Supply

Power Supply› Bench-Top Multimeter› Bench-Top DC Power Supply

User Interface

Software Specification: Overview

Software tools to allow for interaction with robotic head› RS-232 Instructions

Broad library› Easy to develop scripts› Implementation

Written in C#

Software Specification: Goals

Broad functions that allow for full movement control› Each servo is controlled and receives feedback

from microcontroller. Descriptive functions

› Anticipate future changes› Easy to read and use

Command hierarchy› Reduce redundant code› Stable functions› Easy to create new functions.

Software Specification:Library

Robot Head class› Provides functions for controlling each servo

(face, eyes, neck) Graphical User Interface

› Allow script building Listbox – easy to manage and build scripts Building facial positions (eyebrows and mouth)

› Interface with controller Allow for direct control of head Mapping buttons to face emotions

Software Specification: Testing

Software Specification: Testing

Unit Testing:› Test each software component.› Ensure each component works to design.

Software System Testing:› Manual test using HyperTerminal› Ensure system works to design.

User Validation› Ensures design overall correctness.

Simulation & Prototyping

Simulations run as head was constructed

Several prototype versions› Plastic pieces not built to spec› Client’s desire to change final details

Test Results

Head can operated for 4+ hours No program crashing in 4+ hours of

continuous use No overheating during 4+ hours Some jitter still present in the eye tray When head reaches outer bounds,

servos start to rubberband

Electrical CAD:Connections

Mechanical CAD:Helmet

Implementation

Final Builds Complications & Conclusions Future Work

Robot Head:Final Build CAD

Robot Head:Final Build CAD

Robot Head:Final Build CAD

Robot Head:Final Build CAD

Complications

Servos› Overheating› Stalling out› Jumping gears

Plastic› Not printed to spec

Software› Cross-communication between microcontrollers› Communication blocking during transmission to

serial board

Future Work

Cameras Microphones

Demonstration

Questions