automated bridge scour inspection fsu/famu college of engineering team 7 detailed design review and...
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Automated Bridge Scour Inspection
FSU/FAMU College of EngineeringTeam 7
Detailed Design Review and Test Plan2/8/2011
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-Vertical DC motor-Motor Controller-2 SLA Batteries
-MicroController-Sonar-NiMH Battery-Tilt Servo-Circular DC Motor
Vertical Guide Rail
Circular Rail
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Vertical Motion Drive
Design Updates:
• Revised gearhead selection
• Previously a 28:1 Ratio
• Now a 26:1 Ratio
• Trade-off: Availability vs. Over-specification
• Comparable Performance:
• Slightly slower ascent
• Moderately higher percentage of motor output ability
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Vertical Motion Drive
Design Updates:
• Revised encoder selection
• Previously using Magneto-Resistant (MR)
• Now using Optical
• Trade-off: Availability vs. Cost
• Comparable Performance:
• 500 CPR vs. 512 CPR
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Vertical Motion Drive
Mechanical Test Plan:
• Part One:
• Confirm rated no-load output velocity
• Measure angular velocity with tachymeter
• Part Two:
• Prior to full integration, simulated mass lift
• Confirm loaded output torque ability
• Protect components prior to integrated test
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Circular Motion Drive
Design Updates:
• Unchanged Motor/Encoder/Gearhead
• Revised drive-surface interaction
• Previously: Geared drive-surface on guiderail
• Now: High-friction contact drive
• Trade-off: Manufacturability vs. Precision
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Circular Motion Drive
Mechanical Test Plan:
• Part One:
• Confirm rated no-load output velocity
• Measure angular velocity with tachymeter
• Part Two:
• Prior to full integration, full-speed revolution
• Confirm loaded output torque and velocity
• Protect components prior to integrated test
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SONAR Tilt Servo Drive
Design Updates:
• Unchanged Servo Motor selection
• Low risk of failure under load
• Focus on adequate positioning
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SONAR Tilt Servo Drive
Mechanical Test Plan:
• Prior to SONAR integration
• Simulate moment arm to represent transducer
• Demonstrate loaded angular range of motion
• Confirm inspection range capability
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Vertical Motion Updates
•Material
•Aluminum vs Stainless
•Rollers
•Drivers
•Idlers
•Bearings
•Size Constraint
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Bearings and Rollers
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Circumferential Motion Updates
•Material
•Design
•Driver
•Idlers
•Expectations
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Circular Guide Rail
• Changes
• Size and Shape
• Material
• Connection
• Manufacturing
• Ideas
• Simplify
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Testing
•Vertical and Circumferential Motion
• Degrees of Freedom
•Waterproofing
•Step by Step
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Electrical Design
Updated Plan- Use two Battery sources Higher-Power →Motor Controller,DC motors Lower-Power →Microcontroller,servo,
sonar
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Higher-Power Design
• Battery →Sealed Lead Acid Battery (SLA)
- Most likely will be 12 Volt, 3 Ahr SLAs
- Will need 2 of these to make 24V in series
Fuse and Switch on positive battery wire to motor controller
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High-Power Design
Why use 2 -12 Volt 3Ahr Battery? The Vert. DC motor → 24V ~3A continous
Running for < 3 minutes for a final test run. The Circular motor → 12V ~300mA cont.
Running for < 10 minutes for a final test run.
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# of Test Runs
Amps Drawn by Vert. motor Amps drawn by circ. motor Total Ahr
1 <3 min... 3/60 * 3A= .15Ahr <10min...10/60 *0.3A= .05 Ahr 0.2
2 0.3 0.1 0.4
3 0.45 0.15 0.6
4 0.6 0.2 0.8
5 0.75 0.25 1
6 0.9 0.3 1.2
7 1.05 0.35 1.4
8 1.2 0.4 1.6
9 1.35 0.45 1.8
10 1.5 0.5 2
Estimate Current Draw per Test
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Lower-Power Design
• Battery → NiMH
• MicroController needs 5V ~500mA ..Max 2A
• Voltage regulator to get constant 5V
• May need heat sink
• Power to servo and sonar sensor as well
• Battery size depends on final servo, sonar choice. Neither should be current demanding components
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The Beaglejuice
$88
4500 mAh battery
5V output
1.5A current delivery
powers a BeagleBoard for at least 6.5 hrs
on/off switch
Possible option for battery source, mounts below the microcontroller, space saver
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Microcontroller
Version: Xm Version: rev. C4
1 GHz ARM Cortex A8
600MHz ARM Cortex A8
512MB LPDDR 256MB LPDDR
4 USB 1 USB
RS-232 Serial & I2C RS-232 Serial & I2C
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Expansion Board
Zippy2
• I2C 1.8v to 5v
• 2nd RS-232 port
• 2nd SD slot
• Ethernet
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Programming – Autonomous Movement
Motor Controller & Motors Coding
• Sabertooth: In simplified Serial Mode
• RS-232 port
• Using single 8byte commands to control speed & direction of motors
• Each motor 7bits of Resolution
• Motor1: 1-127
• Motor2: 128-255
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Programming – Autonomous Movement
Encoders & Servo Coding
• I2C interface
• Encoders: Counting the leading & falling edge to determine distances
• Servo: PWM (Pulse Width Modulation)
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Testing
Autonomous Movement Program
• Program Simulations: I/O Signals
• MCU & Oscilloscope: PWM - Pulse Widths approx.: 1ms to 2ms - Period: 10ms to 2ms
• MCU & Signal Generator: Simulate encoder input (Square Waves)
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SONAR – Control Test
• Humminbird HDR 650• Transducer/Display combo• 2ft. – 600ft.• Verify data accuracy from
other transducers• ~ 1.2in. Resolution• 200kHz• Strictly handheld; will not
be connected to MCU
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SONAR Transducer
• Furuno USA• 235 kHz• 7 degrees• 0.04m – 100m• NMEA 0183 – ASCII serial
communications • Sentence structure: DDBT, DDPT
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NMEA 0183 Sentence Structure
•8 bits•4800bps•Checksum = hexadecimal; XOR of all char between $ and *
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Microcontroller 1 $170.00 $170.00
Motor Control Unit 1 $137.00 $137.00
12V DC Motor/encoder 1 $40.00 $40.00
SONAR 3 $200.00 $600.00
SLA Battery 12V 3.2Ahr 2 $12.00 $24.00
24V DC Motor/encoder 1 $431.05 $431.05
Beagle Juice (Battery) 1 $88.00 $88.00
Mounting Materials $100.00
Circular Ring 1 $300.00 $300.00
High-Friction Rollers 3 $1.20 $3.60
Ball Bearings 4 $12.00 $48.00
Shaft 1 $5.00 $5.00
Square Vertical Rail 1 $10.00 $10.00
Servo 1 $20.00 $20.00
Wires, fuses. i.e N/A N/A $5.00
Software Licenses $100.00
Test Supplies $120.00
Soldering Kit 1 $15.00 $15.00
Robot casing and fittings
$50.00
Total Cost= $2266.60
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