ECE 477 Design Review ECE 477 Design Review Team 6 Team 6 Spring 2011 Spring 2011

Left to right: Kirk Iler, Brian Bentz, Stephen Wolf, Fuhe XuLeft to right: Kirk Iler, Brian Bentz, Stephen Wolf, Fuhe Xu

OutlineOutline• Project overview Project overview • Project-specific success criteriaProject-specific success criteria• Block diagramBlock diagram• Component selection rationaleComponent selection rationale• Packaging designPackaging design• Schematic and theory of operationSchematic and theory of operation• PCB layoutPCB layout• Software design/development statusSoftware design/development status• Project completion timelineProject completion timeline• Questions / discussionQuestions / discussion

Project OverviewProject Overview

Defender is a basic defense system designed to Defender is a basic defense system designed to identify and neutralize hostile targets. It combines identify and neutralize hostile targets. It combines a number of modules to create a turret-mounted a number of modules to create a turret-mounted defense system.defense system.

Modules:Modules:•CoilgunCoilgun•Motor systemMotor system•Image processingImage processing•Ethernet connectivityEthernet connectivity

Project-Specific Success CriteriaProject-Specific Success Criteria

• 1.1. An ability to fire a projectile using magnetic An ability to fire a projectile using magnetic forceforce

• 2.2. An ability to aim the projectile by controlling An ability to aim the projectile by controlling of the azimuth and elevation angles of the barrelof the azimuth and elevation angles of the barrel

• 3.3. An ability to charge a capacitor bank to a An ability to charge a capacitor bank to a variable voltage, up to 400Vvariable voltage, up to 400V

• 4.4. An ability to gather images and perform target An ability to gather images and perform target recognition and trackingrecognition and tracking

• 5.5. An ability for a user to enter commands and An ability for a user to enter commands and display the status of the turret through an external display the status of the turret through an external interfaceinterface

Block DiagramBlock Diagram

Component Selection RationaleComponent Selection Rationale

• CameraCamera– Canon VC-C50i with PTZCanon VC-C50i with PTZ

• Atom BoardAtom Board

• CapacitorsCapacitors– 39003900μμFF– 400V max electrolytics(x4). U32L400V max electrolytics(x4). U32L

MicrocontrollerMicrocontroller

• PIC24FJ64GB002PIC24FJ64GB002

– 16bit16bit

– 64KB flash/8k RAM64KB flash/8k RAM

– 16MIPS16MIPS

– 3.3V3.3V

– 44 TQFP44 TQFP

– 5 Timers5 Timers

– 1 USB OTG1 USB OTG

– 2 I2 I22CC

– 15 remappable pins 15 remappable pins

Firing Controls - IGBTFiring Controls - IGBT

• Criteria:Criteria:

– VoltageVoltage

– AmperageAmperage

– Heat dissipation, Failure modeHeat dissipation, Failure mode

– PricePrice

• Part chosen:Part chosen:

– APT200GN60JDQ4APT200GN60JDQ4

• 600V, 283/600A600V, 283/600A

• 640W, .25°C/W 640W, .25°C/W

• $42.60$42.60

• No sinkNo sink

• Step angle: Step angle: 1.8°±5%1.8°±5%• Rated voltage: Rated voltage: 12V 12V • Current per phase: Current per phase: 0.4A 0.4A • Holding torque: Holding torque: 2kg/cm2kg/cm• Mass:Mass: 0.2kg0.2kg

MotorMotor

42BYG023-R42BYG023-R

Stepper Motor Controllers

• DRV8821 from Texas Instruments

• Controls 2 stepper motors up to 1.5A each

• 8-40V stepper motors

• Microstepping modes

• Edge triggered digital stepping via PWM from Micro

Packaging Constraints

• Portability – Defender should be easily moved and installed.

• Weight – lightweight to allow for small motors• EMI resistant – To protect circuitry from strong fields

present in coil gun.• Firing range – Target over a broad area.• Keypad – Interface must be easily accessible.

Packaging Layout

• Four major physical components:

– Base: Divided metal box containing control circuitry, high voltage capacitors, and power supply.

– Rotator: Uses stepper motors to aim the Coil Gun; Mounted on top of Base.

– Coil Gun: Mounted on top of Rotator.– Camera: Mounted on top of Base.

Schematic/Theory of OperationSchematic/Theory of Operation

Subsections:

High voltage Control microcontroller

Capacitor bank Atom processor

Motors

Power SuppliesPower Supplies

• 3.3 V low drop out linear regulator

• Provides power to the control microcontroller

• Supplied by rectifier from high voltage system

• Switching 12 V power supply (4 Amps)

• Supplies power to the Atom and the motors

• Supplied by second transformer on Power PCB

Motor MicrocontrollerMotor Microcontroller

• Controls 2 direct drive stepper motors with two coils each• 10 heat sink grounds to copper heat sink• Dedicated I2C port expander• Commands include reset, direction, decay mode, step mode • 1/8th microsteps• Sense resistors and voltage reference limit current to 400 mA

Control MicrocontrollerControl Microcontroller

• Receives commands from Atom• Communicates information to

and from circuitry• I2C communication bus (400 kHz)• USB connection to atom• Bypass capacitors• Reset circuit

Other ComponentsOther Components

• The photogates will function by creating a logic high when an object passes through.

• These will be directly interfaced to general purpose I/O pins.

• Sends an interrupt directly to the microcontroller to signal available information

• Microcontroller collects information over I2C

Keypad Encoder

• Performs image processing and system command• Communicates with control microcontroller over USB• Communicates with user interface over Ethernet.

Atom processorAtom processor

Power PCB SchematicPower PCB Schematic

High Voltage PowerHigh Voltage Power

• Changed to Changed to TRIAC circuit TRIAC circuit to switch to switch power.power.

• Measure DC Measure DC voltage using voltage using ADC.ADC.

Rectifiers and I2CRectifiers and I2C

• 12V transformer and bridge rectifier 12V transformer and bridge rectifier connects to Communication Control connects to Communication Control PCB.PCB.

• 3.3V bridge rectifier.3.3V bridge rectifier.

ADC, LED switch, Coil ADC, LED switch, Coil Protection DiodesProtection Diodes

• Capacitor bleed Capacitor bleed circuit connects to circuit connects to capacitor bank.capacitor bank.

• ADC measures ADC measures current through a current through a voltage divider.voltage divider.

• Protection diodes Protection diodes anti-parallel to coil.anti-parallel to coil.

Power PCB LayoutPower PCB Layout

Communication PCB LayoutCommunication PCB Layout

Software Design/Development StatusSoftware Design/Development Status

• ComputerComputer– Single Executable:Single Executable:

• GUI - implementedGUI - implemented• Java.swing componentsJava.swing components

• Ethernet - testingEthernet - testing• Wrapped in to GUI componentsWrapped in to GUI components• Jnetpcap libraryJnetpcap library

Software Design/GUI PrototypeSoftware Design/GUI Prototype

Software Design/Development StatusSoftware Design/Development Status

• MicrocontrollerMicrocontroller• USB interface- not yet begunUSB interface- not yet begun

• Communicates with atom boardCommunicates with atom board• I2C bus to interface to:I2C bus to interface to:

• Motor microcontrollerMotor microcontroller• Charging controlsCharging controls

Software Design/Development StatusSoftware Design/Development Status

• Atom BoardAtom Board– Single Executable:Single Executable:

• Ethernet libraries- testingEthernet libraries- testing• Winpcap libraryWinpcap library

• USB libraries- not yet begunUSB libraries- not yet begun• PIC family librariesPIC family libraries

Camera statusCamera status

• Microsoft Visual Studio 2008 configuredMicrosoft Visual Studio 2008 configured• OpenCV image recognition libraries and OpenCV image recognition libraries and

camera motor libraries installedcamera motor libraries installed• Drivers installed for S-Video frame grabber Drivers installed for S-Video frame grabber

and motor USB to serial cablesand motor USB to serial cables• Image capture functioning on computer Image capture functioning on computer

intended for compilingintended for compiling• Minor configurations still needed on Atom, Minor configurations still needed on Atom,

which will be running the executableswhich will be running the executables

Project Completion TimelineProject Completion Timeline

• 3/11 3/11 PCB submissionPCB submission• 3/213/21 Atom board Ethernet communicationAtom board Ethernet communication

Image processing recognizing stationary Image processing recognizing stationary targetstargets

Start populating PCBs and testingStart populating PCBs and testing• 3/283/28 Start programming microcontrollerStart programming microcontroller

Begin physical packagingBegin physical packaging• 4/104/10 Completed packaging and testingCompleted packaging and testing• 4/114/11 Start system integrationStart system integration• 4/184/18 Documentation and paperworkDocumentation and paperwork• 4/274/27 PSSC DemosPSSC Demos

Questions / DiscussionQuestions / Discussion