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Senior Design Team 5:Final Presentation
May 9, 2009
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Outline
• Team & Project Introduction
• Design Process• Obstacles• Prototype Design• Conclusion
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Team Introduction
Ryan Mejeur (EE)
Team Project Process Obstacles Prototype Conclusion
David VanKampen (EE)
David VandeBunte (EE)
Matt Lubbers (EE)
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Inspiration
• Service-oriented• Design automated
system• Robotics/ motor
control
Team Project Process Obstacles Prototype Conclusion
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Project Overview
Traditional Warehouses+ Robots
Automated Storage & Retrieval Systems (AS/RS)
- Built w/ warehouse
STORBOT
Team Project Process Obstacles Prototype Conclusion
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Project Scope Evolution
Beginning• Implement RTOS on
open core• Exhibit small amount
of controls• Vastly coding oriented
End• More mechanical• Limited real-time
capabilities• Full Business Plan• Bottom-up robot
system design
Team Project Process Obstacles Prototype Conclusion
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System Architecture
Team Project Process Obstacles Prototype Conclusion
Wall Outlet
Robot
DC Power Supply FPGA
DC Power
Sig
nals
Amplification
Motors Sensors
Host Computer
(User Interface)
AC Power
CTRL
CTRL
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Host PC sends command
PC Sends Command
FPGA decodes and receives commandFPGA signals
wheel motors to advance
FPGA Decodes
Robot Moves
At proper shelf, truck stops,
rotator starts
Arm Rotation
After rotation, the elevator raises the
arm
Elevator Up
Once correct height is reached,
the forearm advances
Forearm ExtensionUpon contact with
the product, a vacuum is
created, and the product is pulled
back
Vacuum EnabledOnce the product is over the tray,
vacuum is released, and arm
is lowered
10110101
Elevator Down
Robot Workflow
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From Concept…
• Redesigned over Spring Break•Addressed specific issues•Visual conception drawn in Sketch-up
Team Project Process Obstacles Prototype Conclusion
… To Reality
New Design•Taller tower•Longer arm•Shelf Motor•Linear bearings
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Design Process
• Task breakdowno Dave VandeBunte – FPGAo Dave VanKampen –
Sensorso Matt – Elevatoro Ryan – Robot Base
• Working in parallel• Late nights and
early mornings
Team Project Process Obstacles Prototype Conclusion
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Team Project Process Obstacles Prototype Conclusion
Testing and Performance
• Tests• “Agile” development
style– Incremental tests– Feature by feature
• Bench tests for mechanics– Vacuum– Elevator– Arm– Wheel motors
• Performance
• Calibration– Setting Elevator
Heights– Sizing of Suction
Cups
• Know when to call it quits– Wheel steppers– Turn-disc– PCBs vs.
breadboards
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Obstacles• Elevator limitations
– Small range of motion– Structure too weak
• Turn-disc inaccuracy– Error magnification– Poor drive system
• Stepper Controller inconsistency– Voltage stepper failure– Development board damage
Team Project Process Obstacles Prototype Conclusion
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Team Project Process Obstacles Prototype Conclusion
Solutions and Tradeoffs• Redesign elevator
– Linear bearings– Improved structural design
• Fix Turn-disc– Bolt in place– Loss in range of motion
• Controller opto-isolation– Far too much time & too many gray hairs– No level translation necessary
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Prototype Design
Base Design Elevator/Arm DesignTeam Project Process Obstacles Prototype Conclusion
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Base Design
Base Design Elevator/Arm Design
•Power Supplies•Stepper Motor Controllers•Wheel Stepper Motors•Turn-disc Stepper Motor•H-Bridge and Relay•Development Board•Powertrain
Team Project Process Obstacles Prototype Conclusion
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Arm Design
• Bearings• Rack and Pinion• Adjustability
Team Project Process Obstacles Prototype Conclusion
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Elevator Design
• Elevator Assembly• Arm Assembly• Plate Assembly• Tower Assembly• Turn-disc Assembly• Vacuum Pump• Distance Sensor
Team Project Process Obstacles Prototype Conclusion
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Prototype -- Analog
Sensors• Reflectance• Encoders• Ultrasonic Distance• IR Proximity• Vacuum
Peripheral Circuits• High current H-bridges• Voltage steppers• Opto-isolation• Transistor switches
Team Project Process Obstacles Prototype Conclusion
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Prototype -- Digital
• Functional GUI• Front end for Serial
Port• Inventory
Management System
• Successful coordination with CS student
Team Project Process Obstacles Prototype Conclusion
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Prototype -- Digital
Team Project Process Obstacles Prototype Conclusion
Development Board
GUI (Java)
Hardware (VHDL)
Device Driver Wrappers (C++)
Wheel Controllers (BASIC)
Terminal (Serial)WirelessSignal
Linux Device Drivers (C)
Reflectance Sensors
Ultrasonic Sensor
Program Driver (C++)
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Final Prototype
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Conclusions
• Success• Heavier Box 15 to 30
lbs• Larger Dimensions12 “
to 18”
• Lessons learned• Robotics Field• Debugging
• Potential Development• Expandability • Patent follow-up• Debug turn-disc
Team Project Process Obstacles Prototype Conclusion
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Acknowledgements
• Phil Jasperse – Shop Attendant• Josh Vroom – CS Student• Chuck Holwerda – Electronics• Professor Bossemeyer & Calvin
Faculty• DornerWorks• Xilinx University Program• Ben Lubbers and Jonathan Mejeur
Team Project Process Obstacles Prototype Conclusion
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Questions?