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CANDLE-SNUFFING ROBOT IEEE 2003 ENTRY “ ROBBY JR.”

Stephen Rochelle, CoE Mark Randall, EE

University of Evansville

Presented at 2003 MUPEC Student Paper Conference April 26, 2003

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I. INTRODUCTION Each year, Region 3 of the Institute of Electrical and Electronics Engineers

(IEEE), comprising the southeastern United States and the Caribbean) sponsors

a student Hardware Design Competition, usually envisioned as some sort of

autonomous robotics project. Consequently, the projects themselves are not

solely hardware but a mix of hardware and embedded software design

encompassing the skill sets of electrical, computer, and often mechanical

engineering students.

This year’s competition was fashioned after the Trinity College Fire-

Fighting Robot contest held yearly. However, though superficially similar, we

decided in April 2002 that a single robot design was unlikely to fare competitively

in both Trinity and IEEE formats. Consequently, we decided to focus our design

on the IEEE rules set, as Mark and I have both been involved in past IEEE

competitions.

The competition itself was designed as a mock-up of a robotic fire-fighting

force. Particularly in light of the destruction of the World Trade Center, there is

currently great interest in the use of robots to enter high-risk areas in lieu of

humans. Due to hostile conditions, however, even remote-control robots could

prove unusable in some environments, spurring an interest in fully-autonomous

self-contained robots. The goal of the competition, then, was to create such an

autonomous self-contained robot capable of, at the sound of a fire alarm,

traversing a floor plan, finding a light-emitting diode (LED) “fire,” dropping a paper

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cup over the LEDs to “extinguish” the fire, and exiting the floor plan within a set

amount of time.

Since the robot needed little physical capability beyond navigating the

track and dropping a cup, Mark decided to reuse the chassis of the 2001 IEEE

robot “Robby.” Our robot, being his direct descendant and requiring moderate

size reduction, was shortly christened “Robby Junior” (Fig. 1), though often still

called “Robby” for

simplicity. Further

references to Robby

herein specify the

2003 revision of the

chassis unless

otherwise noted.

Robby was outfitted

with a battery of

optical sensors to

allow him to detect lines on the ground, walls, and the candle. Additional

hardware was tested for the purpose of sensing distance and bearing, including

position encoders on the motors, ultrasonic echo sensors, an electronic

compass, and an optical mouse.

The driving idea behind Robby’s software was to maintain a precise state

of his position within the floor plan, cross-referencing that against a scale copy of

the floor plan written to firmware to determine his next course of action. Beyond

Figure 1: Robby Junior – The Fire-Fighting Robot (Development Version)

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that, Robby’s code was intended to be driven from section to section by various

interrupt triggers linked to external events. While the original design proved

unworkable with the resources at hand, significant portions of it survived through

to the final version and in fact remained the basis of Robby’s primary decision

making.

The final design proves quite workable, successfully completing around

ninety percent of runs made on our test track under the competition constraints

and regulations available in March 2003. At IEEE SoutheastCon 2003 in April,

Robby finished tied for ninth place in a field of twenty-six. Unannounced

competition conditions and rule changes, we feel, reduced our ability to compete

effectively and cost us a shot at a top-three finish.

II. PROBLEM BACKGROUND

The IEEE SoutheastCon 2003 Student Hardware Competition was

designed and overseen by the IEEE student chapter at the University of

Technology, Jamaica (Appendix A). The requirements are listed as “Final” and

dated December 1, 2002; however, they do not necessarily reflect the actual

competition, as neither clarifications by email nor rules changes at SoutheastCon

were made publicly available. For that matter, clarifications were made by email

only on a case-by-case basis and not sent to every participating school, so we

remain unconvinced that all participants had the same set of information

available.

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Generally speaking, however, the problem centered on the cup drop itself.

Teams could earn a maximum of 128 points per round (Table 1). A successful

drop itself earned 70 of those points, and without a perfect drop, no more than 20

Meet Size Requirement with Cup 10 pts

Leave Home Area 10 pts

Perfect Cup Drop 70 pts

*Return to Home Area 20 pts *Completion Time 18 – (time in seconds / 10) pts

Incorrect Drop - 20 pts

*Enter Wrong Room - 15 pts (per room)

Hit Wall - 5 pts (per round)

Overturn Candle Disqualified (per round) *Prerequisite of Cup Drop

points per run could be achieved. Maximum robot size was restricted to a 21 cm

x 21 cm footprint with a 20 cm ceiling. Additionally, the robot was required to be

autonomous and self-contained. Such restrictions naturally lend themselves (as

is usually the case with IEEE hardware competitions) to microcontroller / DC

battery solutions.

III. DESIGN APPROACH

III.1. HARDWARE DESIGN

Due to a combination of project budget constraints and size restrictions,

we decided to base the entry off the 2001 robot “Robby.” Budget was a concern

primarily because, in addition to hardware expenses, travel costs necessitated

airfare. By reusing the Robby chassis, no additional expenses were incurred for

Table 1: Scoring System

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the motor / encoder assembly, and it was hoped that the motors would not

require remounting.

The electronics hardware design centered around the LEGO7A single-

board computer (Fig. 2) developed within the department for various projects.

Powered by a Philips P89C51RD2, an Intel 8052 microcontroller variant, the 8-bit

system runs at 2MHz with 256 bytes of RAM and 64 kilobytes of Flash ROM.

Additionally, the SBC assembly provides for in-system programming via serial

link cable to PC, an 8-bit eight-channel analog-to-digital converter, four high-

current H-drivers for motors, two 8-bit D-latches, and miscellaneous processor

pins brought to external connections. Besides providing a robust feature set, the

SBC is an already-verified circuit layout, eliminating a potentially major source of

development errors.

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For navigation, an array of four infrared detectors interspersed with three

infrared emitters (Fig. 3) was mounted on the bottom of Robby, facing downward,

Figure 2: The Lego7A Board schematic. Robby-specific alterations are noted in red.

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orthogonal to the axis of motion. Of the four detectors, the center two track tape

lines in hallways, providing Robby with feedback to avoid traveling at odd angles.

The outer two detectors search for hallway corners and doorways, and their

relatively large separation allows Robby to correct his alignment. All four

detectors are coupled to the ADC present on the Lego board. The emitters are

used to ensure a relatively constant amount of detectable IR radiation

underneath Robby, helping counter external conditions and prevent interference

from cameras and the

like. Additionally, Robby

was equipped with a pair

of position encoders

providing 512 pulses per

revolution. Coupled with

a 40:1 gear ratio on the

motors, these sensors

put out a whopping

20480 pulses per

revolution, a resolution of approximately ten micrometers per pulse!

Three other infrared detectors were retrofitted with red optical filters and

biconvex lenses to look for the fire (red LED assembly). One, mounted on a

servo swiveling across the front 180° arc, determines an approximate bearing to

the LED candle. The remaining two, mounted above the motors facing aft,

provide stereo feedback to allow Robby to back towards the candle making

Figure 3: Robby’s line following hardware consists of 4 IR detectors (green) and 3 IR emitters (Yellow).

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needed corrections. Like the floor IR detectors, these three also feed into the

ADC. A final IR emitter / detector pair is mounted on the aftermost portion of

Robby’s base to create an “electric eye” across the U-shaped indention. When

the candle is reached, it interrupts the IR beam, providing hardware confirmation

that the objective has been reached without physically contacting the candle and

risking disqualification. Rather than feeding into the ADC, this detector’s output

goes to a Schmitt trigger for direct digital interpretation.

Various options were considered for providing Robby with reliable position

data within rooms, including outfitting him with an optical mouse and IR distance

sensors. Finally, a digital compass module, outputting either an I2C serial signal

or a PWM waveform, was selected to provide bearing data to be trigonometrically

analyzed against linear position encoder data. Proximity to severe

electromagnetic interference from the motors, solenoid, processor, and timing

crystal, however, precluded reliable compass readings, relegating intra-room

navigation to a software solution.

III.2. SOFTWARE DESIGN

Robby’s code was initially envisioned as operating almost entirely out of

interrupt service routines. However, by the time I began formally laying out

Robby’s code, I settled on a design primarily triggered by interrupts but executed

in the main code sequence (Fig. 4). The design relied heavily on the features of

the P89C51RD2 microcontroller that stretch beyond Intel’s original 8051

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specification such as a programmable counter array, extended RAM, and the

maximum addressable Flash ROM. From the beginning, the inclusion of a servo

motor required a PCA channel plus two timers: Timer 0 to clock the PCA

appropriately and another using an interrupt to update the servo’s position in the

background. The drive motors required two more PCA channels and had no

problems using the clock provided for the servo. The digital filter needed to

detect the start signal needed a timer and interrupt routine to maintain a constant

input rate. Moving to the Lego board as a whole, the two drive motors and

solenoid each needed motor drivers, and ADC channels were filled by the four

floor sensors, three candle sensors, and microphone.

Real software design began from this point. My first decision was to

create and maintain a file of #define directives and declarations to map standard

8051 addressing schemes to meaningful Robby-specific names (defines.h). For

example, CCAP2H was renamed MOTOR_STBD_HREG, the high-byte register holding

the speed of the starboard motor. Additional defines were made for ADC

channels, external memory addresses, and common function arguments. These

allowed for far more readable code such as ReadADC(MICROPHONE),

XBYTE[MOTOR_CONTROL], and Turn(PORT), respectively. This file allowed for more

readable code throughout (particularly for those other than me) as well as easier

modification when hardware changed. For example, when Robby had to be

disassembled for major work, his microphone might or might not be plugged back

into the same channel. Once the new channel was known, though, changing the

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Room Select

Find Room

Scan & Enter Room

Find Candle

Escape Room

Return Home

Poll Microphone

Track Distance

Control Servo

Real-Time Clock

Candle Sensor

Real-Time Clock

Track Distance

T0

EX0

T2

T2

T1

PCA

PCA

Start Signal

Cup Drop

Make Turn

Circle-Seek

Probable Bearing

Position Updates

Position Updates

Find Doorway

U-Turn Complete

Room Reached

Find Home Area

STOP

MAIN CODE INTERRUPTS

Figure 4: Software Flowchart

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single #define MICROPHONE directive in defines.h reflected the new configuration

throughout the rest of the code.

Armed with this reasonably inflexible list of hardware interface needs, I

began mapping out resource allocation (Table 2). I realized early that Timer 0

could be used for both the digital filter interrupt and the PCA clock, as they had

no overlap in execution and no interrupt need be generated when clocking the

PCA. I then decided to tie servo position control to Timer 1. Since Timer 2 is

used to generate a baud rate clock, which we wanted available for debugging

output via HyperTerminal, I decided to leave it otherwise unallocated for as long

as possible.

Three PCA channels were quickly allocated for the two drive motors and the

servo. Once the encoders were examined, we realized that the two remaining

PCA channels, 3 and 4, were ideal for use as 16-bit counters for the motor

encoders. The Lego board defaults those channels to use on motor drivers,

however, which led to our first board alteration – cutting the traces connecting

those processor port pins to their NOR gates and re-routing them to the

encoders. The two least significant bits on the output D-latch were then attached

to the chip select signals for the two disconnected motors, allowing their use in

simple on-off or software PWM modes. LEDs were then attached to the

remaining output bits for human feedback and debugging purposes.

Remaining allocations involved choices of little practical consequence.

The eight analog sensors were connected arbitrarily to the ADC. The solenoid

was placed on motor driver 3, its on-off use complementing the lack of

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Processor: RAM: 82 bytes of data plus stack space (256 bytes available) ROM: 5KB code (64KB available) Interrupts: 5 used (7 available) – EX0, T0, T1, T2, PCA PCA Channels: 5 used (5 available) – port motor, starboard motor, port encoder,

starboard encoder, servo I/O Ports: P0: Address/Data Bus P1: Pin 0 – pin 2: sirens Pin 3 & 4: motors (PCA channels 1 & 2) Pin 5 & 6: encoders (PCA channels 3 & 4) Pin 7: servo (PCA channel 5) P2: Address Bus P3: Pin 0 & 1: RXD / TXD for in-system programming Pin 2: candle-detecting interrupt Pin 3 & 4: unused Pin 5: ADC conversion finished flag Pin 6 & 7: Read / Write lines for Address/Data bus system Peripheral Board: ADC: Channel 1 – 4: floor sensors Channel 5 – 6: rear light sensors Channel 7: servo sensor Channel 8: microphone Input D-Latch: Pin 0: room select button Pin 1 – 7: unused Output D-Latch: Pin 0 & 1: enable for motors 3 & 4 Pin 2 – 7: diagnostic LEDs H-Drivers: Motor 1: port motor Motor 2: starboard motor Motor 3: solenoid Motor 4: unused

Table 2: Resource Allocation

hardware PWM on the driver. The output from the electric eye went to an

external interrupt pin. A room select button was placed on an input D-latch pin,

and the three fire truck siren toggles went on unused processor port pins.

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Finally, once the rest of the system was reasonably debugged, Timer 2 was

changed to use as a real-time clock for driving in-room events.

The first developed application for Robby was his line-following code. The

final version is a near-identical copy of Mark’s prototype code. Robby polls his

floor IR detectors on initialization and saves those readings as ambient values.

From that point on, the difference in current and ambient (checked for possible

negative overflow) is multiplied by a gain factor (checked for possible positive

overflow) to produce a motor drive value. This method has two potential

shortfalls. First, Robby must be turned on or reset while resting on a black

surface to accurately measure an ambient value. Second, that ambient value will

not change to adjust to a potentially different ambient value elsewhere on the

course. The obvious solution is to poll the sensors occasionally and maintain a

running average of ambient value. However, with this method, a naturally line-

following routine will saturate the ambient value with non-ambient data. If the

rate of average is accelerated, this compromises line-following even more

quickly. If slowed, the change in average will accrue too gradually to be of

benefit. Faced with this, we decided to stick with a one-time ambient check and

hope for the best, as it worked consistently in the lab.

Navigation within the room was designed from the ground up to use a

code-space memory map compared against a hardware source of positioning

data. As noted, however, such hardware solutions proved unworkable, leaving

just the position encoders as a means of navigation. Tracking to the candle was

never a serious issue – Robby simply applied his line-following algorithm to the

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twin optical sensors astride the cup drop area and homed in on the candle.

Finding the door to exit the room, however, was far trickier. We first attempted to

scan with the servo for a distinct signal from the gap in the wall, reasoning that

the extra space, additional lighting, and white tape would register the highest light

readings. Candle reflections off nearby walls, however, rendered this unreliable.

We then tried putting an LED astride the servo to illuminate walls and then find

the dimmest spot, as a doorway had no surface to reflect light from. Again

readings were inconsistent, as distant walls remained darker than the doorway

per the unaided lighting conditions. Additional attempts were made to record

encoder data while entering to retrace our steps out. We were unable, however,

to duplicate the proper turns at the proper times, and missed doorways more

than we hit them.

The solution, it seemed, was to find a distinct feature of doors

unmistakable from the rest of the room. We then settled on an algorithm

whereby, upon dropping the cup, Robby activated a real-time clock and started

driving directly forward at high speed. We hoped that, in the best case, he would

proceed fast enough to bank off his outboard rollers and reach the doorway. If

the tape line was not detected after five seconds, however, Robby reversed and

made a 40° turn, reset his clock, and proceeded forward again. This drive-and-

turn repeated a 40° - 40° - 180° pattern until the doorway was reached. For each

room Robby was programmed with the likely direction of the doorway for his

turns, though if missing, he nearly always escaped eventually. Tests even

showed he was capable of ramming a cup-covered candle without upsetting it, a

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condition allowed by the rules, while escaping. This algorithm was then

retrofitted to the cup search routine – if the cup was not dropped within 12

seconds of room entry, Robby assumed he had missed the cup and jammed

against a wall. He then pulled forward and began circling, looking for the first

bright light source before resuming his homing routine.

Robby’s position encoders were rigged to provide a variety of functions.

Under normal line-following conditions, they recorded 900-pulse increments

roughly equivalent to one centimeter, updating his stored (x,y) position as

necessary. In turns the (x,y) updates were disabled and the encoders switched

over to measure the distance turned, with options for either a zero-radius or line-

following turn – Robby’s line-following turns shifted him approximately 2 cm in

both his original and final direction. In those cases his (x,y) position was updated

accordingly. Finally, in-room, both of the above uses were disabled, and in the

final implementation, encoder data was ignored. Robby’s stored (x,y) position

remains unchanged from room entry to room exit, as only one door per room

means that he must effectively return to where he came in. While not completely

accurate, the approximation is sufficient for general navigation purposes.

The digital filter for starting Robby was the final piece of software to be

designed. Since the 1500 Hz signal was in the middle of the audible range,

Jamaica conceded that it would be virtually impossible to fairly penalize an

improper start and so through testing Robby could be started by any sufficiently

loud noise. Once the rest of the system worked satisfactorily, however, we

decided to tighten Robby’s starting constraints. Measurements demonstrated

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that Robby could sample at 5000 Hz while retaining about 300 computational

cycles between samples. With a 16-bit multiplication time of 23 cycles, Robby

had enough speed to run a second-order elliptic bandpass filter. Problems with

microphone voltage levels, however, prevented us from using this solution.

Instead, we coded a single-order lowpass filter. While passing many frequencies

besides the target 1500 Hz, the filter code requires consistency – without 5000

consecutive hits, one second’s worth, Robby will not accept a signal as valid.

Consequently, he ignores normal room noise like conversation but starts

accurately on application of a 1500 Hz tone.

IV. RESULTS

The biggest disappointment from the original design was our inability to

use the compass successfully. We believe the problem stemmed from

electromagnetic interference generated by the microcontroller and crystal,

mounted only an inch from the magnetic sensors. When we moved the compass

from its mount to a position six to eight inches above the microcontroller,

interference subsided and Robby was able to determine his bearing with a

reasonable degree of precision. Unfortunately, the size constraints did not allow

us to mount the compass that far off board, leading to our decision to eliminate

the compass from the final design.

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V. CONCLUSIONS

Competition results were far less than we hoped for (Appendix B).

Frankly, rules were changed upon arrival, several factors were inadequately

defined, and portions of the competition were poorly envisioned. For example,

despite explicit assurance to the contrary, teams were not permitted to see

candle placement prior to hands-off being declared. This torpedoed the

strategies of nearly every competitor. Additionally, the competition was held

outdoors in sunlight. While the rules did state that designs ought to be capable

of dealing with varied and unspecified light conditions, almost no one designed

anticipating a solar barrage of IR and red wavelengths. Our line-following, for

example, was nearly useless under the circumstances. Also, neither specific cup

dimensions nor vendors were specified, leaving us to guess at size. Robby was

tested at UE with a slightly smaller cup than at Jamaica, resulting in one run

where (despite perfect placement) the cup didn’t fall. Another run saw the cup

fall prematurely due to poor fit on the solenoid release mechanism. This one

missing piece of information, even with the other changes, cost us a third if not

second place finish. Finally, the scoring system resulted in preposterous

rankings. With no points accrued from leaving the home area until a cup drop,

three teams finished ahead of us by traveling five inches and then stopping.

Since we continued and bumped walls, we lost points on each run in entering the

correct room.

In spite of these issues, we are pleased with an 8th place finish, and the

traveling engineers are particularly grateful for the chance to visit Jamaica for

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conference purposes. While not finishing with stellar scores, UE’s participants

still placed higher than many prominent southeastern universities.

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APPENDIX A OFFICIAL RULES

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APPENDIX B COMPETITION RESULTS

School Trial Trial Trial Total Mississippi State University 15 125.2 124.9 265.1 Virginia Commonwealth University 80 123.4 15.0 218.4 Tennessee Technical University 20 10.0 85.0 115.0 Florida International University 15 10.0 85.0 110.0 Clemson University -5 15.0 80.0 90.0 University of Memphis 20 20.0 20.0 60.0 Chattahoochee Technical College 20 20.0 15.0 55.0 University of Alabama, Huntsville 15 20.0 20.0 55.0 University of Evansville 20 15.0 15.0 50.0 N. Carolina A&T State University 20 15.0 15.0 50.0 Florida Institute of Technology 20 15.0 15.0 50.0 University of Tennessee 10 20.0 20.0 50.0 Old Dominion University 20 15.0 10.0 45.0 University of Southern Indiana 20 10.0 15.0 45.0 S. Carolina State University 15 15.0 15.0 45.0 Virginia Tech 20 10.0 10.0 40.0 University of Florida 10 15.0 15.0 40.0 Western Kentucky University 5 15.0 20.0 40.0 Florida Atlantic University 10 5.0 20.0 35.0 University of Tennessee at Martin 10 10.0 10.0 30.0 S.Polytechnic State University 10 10.0 10.0 30.0 University of Kentucky Disq. 15.0 15.0 30.0 Guilford Tech Community College 10 5.0 15.0 30.0 Georgia Southern University 10 Disq. 10.0 20.0 Virginia Military Institute 5 5.0 -5.0 5.0