VITL Interim Review 1 (IR #1)

1. VITLInterim Review 1 (IR #1) Thursday, September 25, 2014 ASEN 4028 Team Members: Ryan Hickman, Chris Homolac, Jen Krupp, Kyle Ligon, Heather Love, Alex Paulson, Kathryn Rash, Veronica Vertucci

2. Overview • IR1 Checklist & Resolution of RFA • Design Summary & Updates • Mechanical • Electrical • Software • Current Issues • Test Plan • Schedule Progress • Budget Progress Vehicle for Icy Terrain Locomotion 2

3. RFA resolved Signal Condition and Buffering added to circuit Main switch and fuse added to design IR1 Checklist Completed Electronics package overview with Trudy Schwartz Completed Mechanical Drawing package overview with Matt Rhode Completed Software package overview with Scott Palo IR1 Checklist & Resolution of RFA Vehicle for Icy Terrain Locomotion 3

4. Design Summary: Major Design Changes • Reduced design to single PIC architecture • Replaced Laser sensor with bumpers and IR sensors to detect obstacles and removed Gyro • Structure made of folded sheet metal with Al 60601-T6 Cross beams • New motor & gearhead • Maxon EC 40 & GP 52 C • Better obstacle climbing and shock absorption • Resized suspension motor mounts to allow for new motor & gearhead Vehicle for Icy Terrain Locomotion 4

5. Design Summary • RC controlled • Rocker-Boogie suspension • Center spiked wheels are motorized • IR sensors for obstacle and cliff detection • Accelerometer for slope detection • Minimal internal layout changes since CDR • Dummy payload and power supply mass included IR Cliff Detection 13 in 24.25 in 20 in Vehicle for Icy Terrain Locomotion 5

6. Design Summary Vehicle for Icy Terrain Locomotion 6

7. Design Summary Side View Min FOS = 12 Front View Vehicle for Icy Terrain Locomotion 7

8. Electronics Overview Vehicle for Icy Terrain Locomotion 8

9. Buffer/Signal Conditioning Circuit Vehicle for Icy Terrain Locomotion 9

10. Each device will have its own connection to board Twisted wiring with shield wrap will be used Adhesive mounts placed along base of rover Cable ties to secure wire Wiring Vehicle for Icy Terrain Locomotion 10

11. PCB Layout Vehicle for Icy Terrain Locomotion 11

12. 3D PCB Vehicle for Icy Terrain Locomotion 12

13. Software Updated Vehicle for Icy Terrain Locomotion 13

14. Current Issues • Accuracy of fabrication time estimates • Overestimated time and still have margin • Will improve as more machining is done • Holes for wiring • Have excess wire so holes can be more accessible • Software processing time to stop • Time each algorithm and motor breaking before integration • Extend bumpers and cliff detector further • Drive at minimum speed to allow for more processing time • Time/Labor intensive encoding software for motors • Allocated more time from margin for software development Vehicle for Icy Terrain Locomotion 14

15. Testing Basics • Types: • Inspection • Demonstration • Analysis • Interface • Two sets: • Component and assembly function testing • Requirement verification testing • Number of Tests: 34 • Total testing time: ~100 hours Vehicle for Icy Terrain Locomotion 15

16. Testing Goals Aerial View of Mission Profile Complex/Critical Tests • Functional Tests • Wheel Traction • Motor-Gear Head Operation • Motor Breaking • Suspension Obstacle Clearance • IR Proximity Sensor Cliff and Obstacle Detection • Encoder Accuracy • Requirement Verification • Obstacle Detection (Performed with Suspension Obstacle Clearance) • Mission Life • Temperature • Efficiency/Accuracy Vehicle for Icy Terrain Locomotion 16

17. Purpose: Make sure the wheels provide traction with minimal slipping on a ground surface of concrete Main Equipment: 0º, 5º, 10º, 15º, and 20º sloped concrete at least 5 feet in length Integrated vehicle Remote control Level Tape measure Timer Expected Duration: 4-6 hours Expected Location: CU Parking Garage, Folsom Hill, Colorado Ave., Handicap ramps near Engineering Center Metric for Success: Vehicle-measured distance traveledneeds to be within 0.37 inches from the actual distance traveled. This is assuming the track is 5 feet long and the rover travels the whole distance. Steps: Determine slope and initial position. Drive the vehicle using remote control for 5 ft and then stop. Record end position. Compare actual and vehicle-measured distance traveled. Repeat. T-100.10. Wheel Traction Vehicle for Icy Terrain Locomotion 17

18. T-100.20. Motors with Gear Heads Operation • Purpose: • Verify that the motors and gear heads can drive the vehicle system on inclined surfaces in all directions with use of the PIC • Main Equipment: • 0º, 5º, 10º, 15º, and 20º sloped concrete at least 5 feet in length • Integrated vehicle • Remote control • Level • Tape measure • Timer • Protractor • Expected Duration:4-6 hours • Expected Location:CU Parking Garage, Folsom Hill, Colorado Ave., Handicap ramps near Engineering Center • Metric for Success: The vehicle shall be observed to turn an angle no less than 180º and move up the slopes with a speed that does not deviate by more than 5% Steps: • Determine slope and initial position and orientation. • Drive the vehicle using remote control for 5 ft, turn, drive another 5 ft, and then stop. • Record end position and rotation angle. • Compare actual and vehicle-measured distance traveled. • Repeat. Vehicle for Icy Terrain Locomotion 18

19. Purpose: Ensure that the motors stop the vehicle on inclined surfaces under a full load in a reasonable distance (~1 inch) Main Equipment: Integrated vehicle Remote control Tape measure Level Timers 0º, 5º, 10º, 15º, and 20º sloped concrete at least 10 feet in length Expected Duration: 4-6 hours Expected Location: CU Parking Garage, Folsom Hill, Colorado Ave., Handicap ramps near Engineering Center Metric for Success: Stop in ~1 in to avoid the obstacle detection device hitting the front wheels and assuming the wheels are moving at 1 rpm, the vehicle needs to stop in a maximum of 8 seconds T-100.22. Motor Braking Steps: • Determine the slope and initial position. • Drive the vehicle using remote control for 10 ft and stop. Time the stop period and distance. • Record the end position and time and distance to stop. • Repeat. Vehicle commanded to stop Vehicle fully stopped Vehicle for Icy Terrain Locomotion 19

20. Purpose: Prove that the vehicle and suspension allow for obstacle clearance Main Equipment: Integrated vehicle 1 in x 3 ft obstacles Level Tape measure Protractor 0º, 5º, 10º, 15º, and 20º sloped concrete at least 5 feet in length Expected Duration: 2-4 hours Expected Location: CU Parking Garage, Folsom Hill, Colorado Ave., Handicap ramps near Engineering Center Metric for Success: Suspension arm deflection angle = the slope being traversed, suspension arm deflection distance = the height of the obstacle. T-100.30. Suspension Obstacle Clearance Steps: • Setup the obstacle. • Record the suspension front and rear arm initial positions. • Drive the vehicle using remote control so that the suspension is half way on top of the obstacle. • Stop the vehicle. • Measure the deflection of front and rear arm relative to initial position. • Repeat. Vehicle for Icy Terrain Locomotion 20

21. Purpose: Verify that the IR proximity sensor detects the presence of cliffs (drop-offs greater than 3 inches) and steep downward slopes Main Equipment: IR proximity sensor Power supply Computer Obstacle detection software Surface of variable height and slope (cardboard boxes) Calibration material (Paper with various shades of black and white) Wiring Expected Duration: 1 hour Expected Location: ITLL or Space Grant Metric for Success: Software response when the “ground” gets farther than 3 inches away. T-200.20. IR Proximity Sensors – Cliff Detection Steps: • Setup the obstacle. • Record the suspension front and rear arm initial positions. • Drive the vehicle using remote control so that the suspension is half way on top of the obstacle. • Stop the vehicle. • Measure the deflection of front and rear arm relative to initial position. • Repeat. Raised Surface of Variable Height and Slope Vehicle for Icy Terrain Locomotion 21

22. Purpose: To verify that the IR proximity sensors and detection mechanism can detect obstacles greater than 3 inches in height. Main Equipment: IR proximity sensors (3) Power supply Computer Obstacle detection software Obstacle (cardboard boxes) Calibration material (Paper with various shades of black and white) Wiring Expected Duration: 1 hour Expected Location: ITLL or Space Grant Metric for Success: Software response when the obstacle detection mechanism gets closer than 3 inches away. T-200.21. IR Proximity Sensors – Obstacle Detection Steps: • Turn on power supply, set to 5 V, and turn off. • Connect power supply and sensors. Connect sensors to software platform. • Turn on power supply. • Vary distance of obstacle and record the distance when the sensors detect too close a distance. • Turn off power supply. • Repeat. Vehicle for Icy Terrain Locomotion 22

23. T-200.60. Encoder Accuracy Steps: • Turn on power supply, set to 5 V and 11.1 V, and turn off. • Connect one power supply to amplifier and motor. Connect other power supply to encoder and amplifier. Connect everything to the PIC. • Turn on power supply. • Command motor operation at varying speeds, recording the encoder data. • Turn off power supply and motor. • Compare encoder data. • Repeat. • Purpose: • Verify correct pulse counts from the encoder for motor rotations. • Main Equipment: • Encoders • Amplifier • Motor • Duel power supply • PIC/PIC programmer • Computer/Software • Expected Duration: 2 hours • Expected Location: ITLL, Senior Projects room, or Space Grant • Metric for Success: Encoder data matches each other within 5 pulse counts Vehicle for Icy Terrain Locomotion 23

24. Purpose: Make sure that all components do not fatigue or degrade significantly during 3.5 days of operation Main Equipment: Integrated vehicle Timer Backup timer for redundancy/preventative measures Misc. testing equipment for other integrated vehicle tests Expected Duration: 84 hours Expected Location: CU Parking Garage, Frozen lake, Concrete sidewalks, Handicap ramps, etc. Metric for Success: Vehicle operation at 75% initial performance values (measured at the beginning of testing) at the end of 84 hours of testing T-2.3. Mission Life Step: • For any system vehicle test during which it is driven, the test must be timed and recorded. Vehicle for Icy Terrain Locomotion 24

25. Purpose: Make sure that the drive system can still drive the vehicle in a 0ºC environment, even if performance is degraded Main Equipment: Thermometer Integrated vehicle Remote Control Level surface (ice or concrete) Expected Duration: 1 hour Expected Location: CU Parking Garage or frozen lake Metric for Success: In a 0ºC environment, component operation at 75% their performance value at room temperature T-3.4. Temperature Steps: • Record the temperature. • Perform any of the system tests for terrain crossing, level movement, or inclination in a 0º C environment. Vehicle for Icy Terrain Locomotion 25

26. Purpose: Make sure the onboard software and encoders accurately report the position of the vehicle after traveling any distance. The accuracy required is equal to of the total distance traveled. Main Equipment: Integrated vehicle Remote control Tape measure, String Surveying equipment (if available) Chalk or ink Concrete or ice surface of considerable length Expected Duration: 7 hours Expected Location: CU Parking Garage, sidewalks, frozen lake Metric for success: Accuracy of the sensors and software ≥ 0.62%  Difference ≤ (total distance traveled)*(0.0062) T-3.6. Efficiency/Accuracy Steps: • Determine slope and initial position. • Drive the vehicle in pre-turn- determined paths. • Record end position. • Compare actual and vehicle-measured distance traveled. • Repeat for the remaining paths. Vehicle for Icy Terrain Locomotion 26

27. Spring Semester Schedule Vehicle for Icy Terrain Locomotion 27

28. Cost Expenditures Vehicle for Icy Terrain Locomotion 28

29. Cost Expectations Vehicle for Icy Terrain Locomotion 29

30. Additional Slides Vehicle for Icy Terrain Locomotion 30

31. Vehicle for Icy Terrain Locomotion 31

32. EDMU Internal Layout: Top View C&DH board & Receiver Proximity Sensor Gyroscope & Accelerometer Motor Controller Batteries Science Payload Vehicle for Icy Terrain Locomotion 32 Laser Range

33. EDMU System Architecture Magnetometer C&DH board & Receiver Science electronics Pan Cam Radiation Sensor Science Payload exploded Motor Controller Sonar Suspension & Drive Train Vehicle for Icy Terrain Locomotion 33

34. EDMU System Architecture: Front View C&DH Board and Receiver Science Payload Sonar sensor Batteries Proximity sensor Motor Controller Laser Range Motors Vehicle for Icy Terrain Locomotion 34