Nerc Robot Presentation PDF

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11/26/2009
SYLAR
1st Runner Up (NERC-09)
Robot Design Strategy

Sit down in your groups and start discussing. Make a plan:

What
do you want to do? How do you want to do? How much budget do you have? How much time do you have?

Listen to everyone in the group. Discuss your ideas and seek help from friends and people in your social circle.
Generated by Foxit PDF Creator Foxit Software http://www.foxitsoftware.com For evaluation only. 11/26/2009
Robot Design Strategy
Go through the score distribution scheme and choose one with the highest score. Select a path which involves minimum time to complete the task. Finalize above two points before you start designing your robot
Path Strategy
Starting Mechanical Design
Main parts of your robot will be:

Peg placement mechanism Peg loading mechanism Base (including wheels and drives)
Think on each part step by step. Go from the top to the base of the robot. Visualize every design that comes up in your mind. Make sketches of all the main parts of the robot. Stick to the most robust and reliable design. Do not indulge yourself in a very complicated design. Finalize model of your robot on any designing software
SYLAR
Material Selection

Aluminium is light in weight & relatively strong. Acrylic can also be used in some parts:
Flexible Light
Weight Easily available
Use Hard Nylon for small parts which are not bearing too much load Main drive shafts should be preferably of steel.
Dont
go for stainless steel as it is heavier then steel
Mechanical Design
The Peg Placement & Loading Mechanism:

Go
for the one giving you max. tolerance in placement. Try to minimize the placement time by extending the arm out of the base. The mechanisms should be rigid and firmly supported. Keep mechanisms as simple as possible. Discuss your purpose and ideas with your machinist.
Peg Placing Strategy
Peg Placing Mechanism
Peg Loading Mechanism
Mechanical Design
Robots Base:
Base should be strong enough to carry the load.

n
Aluminium beams are suitable in most cases
The lower the base, the stable it is. Prefer nuts & bolts on welding. Always use spring washers with the nuts. Ask your Machinist for the suitable bolt sizes. Minimize the material to minimize the weight. Try for a frame rather than a completely filled platform. Always use bearings to couple the shaft with the base. Keep in mind overall dimensions of the Robot.
Bottom View of Base
Mechanical Design
Robots Wheels:
Your robot can have:

Two powered wheels with a roller Two powered wheels with two rollers n Four powered wheels (coupled with belts, chains etc.)
n n
Minimize the distance between tires on same side for precise turning.(for four powered wheels only) Ready made wheels are available in market.
Bigger the wheels, Higher the required torque , More the speed n Bigger the wheels, More the ground clearance n Select the dia. which best fulfills your requirement
n
For custom made nylon wheels, use O`rings to avoid slippage.

n
Do not use very thick rings.
Old Base
10
Base Drive
Mechanical Design
Selecting a Motor:
Go Always
n 48V
for simple PMDC motors with matched RPM. use a gear ratio
PITMAN motors with their gear box will be an ideal selection.
Check
your motor`s torques on the turns Test motors with 100% PWM to check difference between their RPM.
n Minimum
the diff, stable the drive
Use
servos for precise operation of the mechanisms Complete and test your base along with the drives before the time limit.
11
Old Motor
Pitman 48V
12
Robot Design Flexibility
Keep in mind the time constraints. Always leave allowance in your measurements. Always keep space for modification in your design. Test your design practically before time limit.
Arm Adjustment
13
Sensors & Mountings
Types of Sensors generally used:

IR Sensors Photo Transistors LDR (Light Dependant Resistors)

n
Photo Transistors have best response & are handled easily
Mount your sensors in proper housings (prefer internally blackened

housings)
Keep your sensors covered to filter undesired lights. Keep sensors mountings adjustable in two DOF.

Up-Down Left Right
Max. Distance between front sensors and Pivot Point.
IR Reflection Sensor (Focused and Daylight Filtered)..
14
Photo Transistors
Front Sensors Mounting
15
Peg handling

Dont depend on clock for Peg Handling. Place pegs in a closed loop. Load pegs while moving from one stand to the other. Use IR sensors, Limit switches as feedback sensors. Minimize the chances of pegs getting stuck in the mechanism.
Peg Handling
16
ELECTRONICS
Basically electronics of an autonomous machine comprises following circuitry Power Distribution Card Motors and Actuators Drive Cards Sensors and signal conditioning Cards Control Card
ELECTRONICS
In SYLAR, we used a modular approach; it had three major boards:

Control and Power distribution board Sensors and their distributor board Motor drives
17
CONTROL & POWER DISTRIBUTION BOARD
Traditionally both are kept separate but in Sylar, we combined them on one. Advantage:
Reduced
the clutter of multiple boards. Simplified wiring.
18
Sensors Junction Board
19
MOTOR DRIVES

A real critical decision to take Reliable and Efficient Motor Drives

Relay-Mosfet
based vs. Conventional H-bridge Response time Acceleration and Deceleration Protection against Surge Currents Fuse Protected
MOTOR DRIVES
Sylar initially used motor drive IC; LMD 18201.

Shortcomings:
n IC
kept on short circuiting due to design fault.
Relay-Mosfet based Motor Drives were used latter on.

Shortcomings:
n This
motor drive did not provide perfect sq wave required for PWM control.
20
Wiring Strategy & Noise Reduction
We managed to get rid of heavy wiring

Simplify wiring by designing modules Implementing hardware in software; ADCs vs. Comparators Combining Power Board and Control Board
We managed to minimize electronics noise

Good PCB-designs Use of Ground Planes Use of Capacitors with Voltage Regulators Use of 0.1uF Capacitors with sensor signal lines Preferably use In-circuit Programming
Controller Selection
Major Criterian
Sensors
n ADCs n Other
Interfacing
interfaces
Actuators
n PWM
and Motors interfacing
requirement n Other techniques

Processing
Speed
21
Programming Strategy

Start with planned initial settings Efficient & reliable Low-level Programming
Use
of functions work a lot easier in debugging
Use of Multiple Files

Makes
Use of LCD or a COM link

Helpful
Multiple Files; Easier Programming
22

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Robot Design Strategy

Sit down in your groups and start discussing. Make a plan:

Robot Design Strategy

Starting Mechanical Design

Main parts of your robot will be:

Weight Easily available

go for stainless steel as it is heavier then steel

The Peg Placement & Loading Mechanism:

Peg Placing Strategy

Peg Placing Mechanism

Peg Placing Mechanism

Peg Placing Mechanism

Peg Placing Mechanism

Peg Loading Mechanism

Peg Loading Mechanism

Peg Loading Mechanism

Base should be strong enough to carry the load.

Aluminium beams are suitable in most cases

Bottom View of Base

Your robot can have:

For custom made nylon wheels, use O`rings to avoid slippage.

Do not use very thick rings.

PITMAN motors with their gear box will be an ideal selection.

the diff, stable the drive

Robot Design Flexibility

Sensors & Mountings

Types of Sensors generally used:

IR Sensors Photo Transistors LDR (Light Dependant Resistors)

Photo Transistors have best response & are handled easily

Mount your sensors in proper housings (prefer internally blackened

Up-Down Left Right

Max. Distance between front sensors and Pivot Point.

IR Reflection Sensor (Focused and Daylight Filtered)..

Front Sensors Mounting

CONTROL & POWER DISTRIBUTION BOARD

the clutter of multiple boards. Simplified wiring.

CONTROL & POWER DISTRIBUTION BOARD

CONTROL & POWER DISTRIBUTION BOARD

Sensors Junction Board

A real critical decision to take Reliable and Efficient Motor Drives

Sylar initially used motor drive IC; LMD 18201.

kept on short circuiting due to design fault.

Relay-Mosfet based Motor Drives were used latter on.

Wiring Strategy & Noise Reduction

We managed to get rid of heavy wiring

We managed to minimize electronics noise

and Motors interfacing

requirement n Other techniques

of functions work a lot easier in debugging

Use of Multiple Files

Use of LCD or a COM link

Multiple Files; Easier Programming

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