Project OSCAR

1. Project OSCAR Octagonal Speech-Controlled Autonomous Robot ONGO-01

2. Client: Iowa State University Department of Electrical and Computer Engineering Faculty Advisor: Ralph E. Patterson III Presentation Date: December 6, 2005 EE Team Members Kevin Cantu EE 492 Jawad Haider EE 492 Robert Dunkin EE 491 Nicholas Hoch EE 491 CprE Team Members Jeff Parent CprE 492 Peter Gaughan CprE 491 Andrew Levisay CprE 491 Mike Mikulecky CprE 491 ME Team Members Lynn Tweed ME 466 Michael Snodgrass ME 466 David Brownmiller ME 466 Project OSCARFall 2005

3. Project OSCARPresentation Overview • Initial Information Jeff • Project Introduction Jeff • Description of Activities • Tachometer Jawad & Bob • Software Mike & Peter • End-effector construction Dave & Michael • End-effector electronics Nick • Documentation: Wiki Andy • Resources, Schedules , Summary Kevin • Closing Jeff

4. Project OSCARList of Definitions • OSCAR Octagonal Speech-Controlled Autonomous Robot • BasicX-24 Microcontroller used to interface with SONAR system • CVS Concurrent versions system • Cybot The predecessor to OSCAR • Drive train The assembly of electrically controlled motion elements, including the robot’s wheels, gears, belts, and tachometers • End effector The electrically controlled mechanical arm and gripper • GUI Graphical user interface • I/O Input and output to a device • PEEL Programmable Electrically Erasable Logic • SONAR Sound navigation and ranging • Tachometer A device for indicating speed of rotation • Wiki An internet based content management system for many users

5. Project Introduction Jeff Parent

6. Project IntroductionProblem Statement • General Problem Develop a robot and perform demonstrations to generate interest in the field and in the department. • General Solution Approach An ongoing project was started to design a modular, autonomous robot which incorporates speech control, sonar sensors, and an end effector to interact with its surroundings and audience.

7. Project IntroductionOperating Environment • Indoors • Flat surfaces, no downward stairs or drop-offs • Obstacles must be 2.5 feet high

8. Project IntroductionIntended Users and Uses • Users • Project OSCAR team members • Supervised non-technical users • Use: Demonstration to raise interest in the field and the department • Autonomous navigation of a hallway • Ability to pick up and place objects via the end effector • Ability to speak • Manual movement via wireless control software • Control via spoken commands

9. Project IntroductionAssumptions and Limitations • Assumptions • Demonstrations last less than one hour • Technical supervisors present during operation • Operators speak English and are familiar with control software • Remote PC for robot control has the appropriate software and hardware • Limitations • Software must run in Mandrake Linux • Speech commands are issued less than 15 feet away • Sonar range is 15 inches – 35 feet • Wireless Ethernet within 328 feet • Must fit through a standard 30-inch doorway • End effector must fit within top module

10. Project IntroductionEnd Product & Deliverables • A robot with working systems • Power • Drive • Sensors • Software • End effector • Documentation

11. Tachometer Jawad Haider Bob Dunkin

12. TachometerElectromechanical Design • Problem • Interface of Motor Controller and Optical Encoder • Optical encoder outputs digital pulse train • Motor controller needs analog 5V with direction • Solution • Build a Wheel Tachometer circuit and interface the motor and encoder

13. Optical Encoder TachometerElectromechanical Design Optical encoder digital output Needed analog signal

14. TachometerProposed Design

15. TachometerParts Used and Schematic • Switch: ADG419 • Frequency-to-voltage converters: LM2907 and/or AD650KN • Phase decoder: LS7184 LSI sheet/LS7184 USD sheet • Op-amps: LM324 • Charge pumps (providing negative voltage): ADM660 • Adjustable voltage regulator: LM117

16. TachometerAccomplishments Tested the phase decoder • We look at the UP/DN output • Signal flips between +5V and 0V with the change in the direction of shaft motion • Signal level stays there until direction changes again

17. TachometerTesting • Charge Pump • Two capacitors of 10uF are used for charge storage • The voltage inversion operation is obtained using ADM 660 • Voltage Regulators • Two types of voltage regulators are used (5V and 12V)

18. TachometerFrequency to Voltage • LM 2907 • Unknown chip malfunction • AD 650KN • MATLAB analysis • Ripple voltage too high • Used for higher frequency motors • Range (100Hz—1MHz)

19. TachometerAverage and Ripple Voltage

20. TachometerFuture • Need to put more research into chips • TC 9402 chips seems more feasible up to 100Hz • Design new circuit, with new chips • Create and test circuit components

21. Software Mike Mikulecky Peter Gaughan

22. SoftwarePast Accomplishments • Design process • Software controls hardware • Software extends in all directions to all levels • Main software system

23. SoftwareSoftware Languages • All ported to Linux • Java • Pearl • C#

24. SoftwareCurrent Problems • Code • Voice recognition • Documentation of code • Computer hardware • Inconsistent power supply performance • Defective power button • Motherboard battery dead

25. SoftwareJava • Improve Java code • Reorganize • Add support for debugging

26. SoftwarePrototyping • Rapid evaluation of ideas • Wireless motion control via Xbox controller • Prototyping framework

27. SoftwarePerl • Prototyping language • Flexible and fast • Modular

28. SoftwareMiscellaneous • New brain for OSCAR • No change in voice synthesis

29. SoftwareFuture • Continue modularization of Java • Finish and extend prototyping framework • Use framework to test motion algorithms • Integrate better voice synthesis

30. End Effector Mechanical David Brownmiller Michael Snodgrass

31. 3 1 2 4 End EffectorPrevious Design • Design was only 50% Complete • Slide mechanism had binding issues • Gears and motors were not modeled to scale • Structural issues on wrist rotational motor

32. 1 2 End EffectorCurrent Design • Remodel Gears and Motors • Design rotational joint to eliminate stress on the rotation motor • A completed arm with slide and base rotation for spring 06 • Selected materials for structural integrity and aesthetics

33. End EffectorCurrent Status • Acquisition of materials • Physical manufacture of the arm • Manufacturing limitations on campus • Machine shop in Nevada

34. End EffectorControl Nick Hoch

35. End Effector ControlOverview Functionality • Computer control for five motors in the new end effector • H-bridges for power • Controlled by microcontroller(s) • Communication with the PC Goals • To fully design the system • To build the system without significant design revisions

36. End Effector ControlOriginal Technology Selection • BasicX-24 top level • Multiplexers • LM629 motorcontrollers (1 per motor) • H-bridges (1 per motor)

37. End Effector ControlQuestions • Too complex • Serial PC <-> BasicX • Serial BasicX <-> LM629 • Skills requred: Java, Basic, LM629 codes, hardware programming

38. End Effector ControlPossible Improvements • USB connection (PC <-> microprocessor) • Fewer parts (possibly only 1 microcontroller + 5 H-bridges) • More software, less hardware (faster implementation) • C instead of BASIC as a primary language (students have experience)

39. End Effector ControlPossible Solutions • LabVIEW board and software • previously discarded because of PC and Linux issues • PIC like the PIC18F4550 • USB capable • Specialized PIC or a DSP chip like the dsPIC30F4011 • 6 PWM outputs • 1 optical encoder input • FPGA with programmed logic to replace entire circuit.

40. Documentation Andy Levisay

41. DocumentationPrevious Problems • Incomplete • No central repository • Decision process not documented • Design and testing not well documented

42. DocumentationSolution: The OSCAR Wiki • Well organized • Carries from semester to semester • Easy sharing of documents and pictures • Also provides a place for making announcements and meeting times • Useful in document collaboration

43. DocumentationThe OSCAR Wiki

44. DocumentationThe OSCAR Wiki

45. DocumentationDocumentation Activities • Software • Tachometer testing • Sonar maintenance • End Effector

46. DocumentationFuture Activities • Dedicated server for the WIKI • Adding more back data to the WIKI

47. Resources and Summary Kevin Cantu

48. Resources and Schedules: Fall 2005Material Requirements • End effector • Structural materials, machining – donated • Motors – salvaged • Electronics – $99.90 • Workstation PC - donated • Software • Operating system – free • OSCAR PC – $10 • Documentation • Wiki – free, donated • Wiki PC – $10 • Projected semester cost: ~$700 • Actual semester cost: $119.90

49. Resources and Schedules: Fall 2005Personnel Effort Requirements • Visitor demonstrations • End effector control circuit design • Tachometer implementation • Software • Documentation project • Senior Design reporting • Projected total hours: 1013 • Actual hours: 622

50. Resources and Schedules: Fall 2005Financial Requirements • Fall 2005 • Projected cost of materials: $700 • Actual cost of materials: $119.90 • Projected cost of labor at $10.50 per hour: $10,636.50 • Actual cost of labor: $6,131.00 • Fall 2005 Projected Total: $11,336.50 • Fall 2005 Actual Total: $6,650.90 • Previous Semesters • Spring 2005: $6,000-9,000 • Fall 2004: $9,000-13,000 • Spring 2004: $12,000 • Fall 2003: $15,000 • Spring 2002: $10,000-16,000 • Fall 2001: $11,000-17,000 • Estimated Overall Total, Spring 2001- Fall 2006: $115 thousand