VITL Interim Review 1 (IR #1)

VITL April 21, 2023

VITLInterim Review 1

(IR #1)

Friday, April 21, 2023ASEN 4028

Team Members: Ryan Hickman, Chris Homolac, Jen Krupp, Kyle Ligon,

Heather Love, Alex Paulson, Kathryn Rash, Veronica Vertucci

Vehicle for Icy Terrain Locomotion2

VITL April 21, 2023

Overview

• IR1 Checklist & Resolution of RFA• Design Summary & Updates

– Mechanical– Electrical– Software

• Current Issues• Test Plan• Schedule Progress• Budget Progress


VITL April 21, 2023

IR1 Checklist & Resolution of RFA

• 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


VITL April 21, 2023

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


VITL April 21, 2023

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

20 in24.25 in

13 in

IR Cliff Detection


VITL April 21, 2023

Design Summary


VITL April 21, 2023

Design Summary

Side View

Front View

Min FOS = 12


VITL April 21, 2023

Electronics Overview

Circuit Board

Main Switch

Receiver

IRSensors

Rover Physical Boundary

RCAccess Panel

Fuse

VoltageRegulator

Encoders

Amplifiers

Battery

Status LEDs

GND(16 AWG)

GND(16 AWG)

5V(22 AWG)

GND(16 AWG)

Motors

Chassis Mounted

GND


VITL April 21, 2023

Buffer/Signal Conditioning Circuit


VITL April 21, 2023

Wiring

• 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


VITL April 21, 2023

PCB Layout


VITL April 21, 2023

3D PCB


VITL April 21, 2023

Software Updated


VITL April 21, 2023

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


VITL April 21, 2023

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

Acceptance – Component Testing

Integration – Assembly Testing

System – Full System Testing


VITL April 21, 2023

Testing GoalsAerial View of Mission ProfileComplex/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


VITL April 21, 2023

T-100.10. Wheel Traction

• 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 traveled needs 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:1. Determine slope and initial

position.2. Drive the vehicle using remote

control for 5 ft and then stop.3. Record end position.4. Compare actual and vehicle-

measured distance traveled.5. Repeat.


VITL April 21, 2023

• 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%

T-100.20. Motors with Gear Heads Operation


position and orientation.2. Drive the vehicle using remote

control for 5 ft, turn, drive another 5 ft, and then stop.

3. Record end position and rotation angle.

4. Compare actual and vehicle-measured distance traveled.

5. Repeat.


VITL April 21, 2023

T-100.22. Motor Braking• 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

Vehicle commanded to stop

Vehicle fully stopped

Steps:1. Determine the slope and

initial position.2. Drive the vehicle using

remote control for 10 ft and stop. Time the stop period and distance.

3. Record the end position and time and distance to stop.

4. Repeat.


VITL April 21, 2023

T-100.30. Suspension Obstacle Clearance

• 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.

Steps:1. Setup the obstacle.2. Record the suspension front and rear

arm initial positions.3. Drive the vehicle using remote

control so that the suspension is half way on top of the obstacle.

4. Stop the vehicle.5. Measure the deflection of front and

rear arm relative to initial position.6. Repeat.


VITL April 21, 2023

T-200.20. IR Proximity Sensors – Cliff Detection

• 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.

Steps:1. Setup the obstacle.2. Record the suspension front and

rear arm initial positions.3. Drive the vehicle using remote

control so that the suspension is half way on top of the obstacle.

4. Stop the vehicle.5. Measure the deflection of front

and rear arm relative to initial position.

6. Repeat.

Raised Surface of Variable Height and Slope


VITL April 21, 2023

T-200.21. IR Proximity Sensors – Obstacle Detection

• 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.

Steps:1. Turn on power supply, set to 5 V, and

turn off. 2. Connect power supply and sensors.

Connect sensors to software platform.3. Turn on power supply.4. Vary distance of obstacle and record

the distance when the sensors detect too close a distance.

5. Turn off power supply.6. Repeat.


VITL April 21, 2023

T-200.60. Encoder Accuracy

• 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

Steps:1. Turn on power supply, set to 5 V and

11.1 V, and turn off. 2. Connect one power supply to amplifier

and motor. Connect other power supply to encoder and amplifier. Connect everything to the PIC.

3. Turn on power supply.4. Command motor operation at varying

speeds, recording the encoder data.5. Turn off power supply and motor.6. Compare encoder data.7. Repeat.

Motor

Amplifier

Encoder 1 Encoder 2


VITL April 21, 2023

T-2.3. Mission Life• 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

Step:1. For any system vehicle

test during which it is driven, the test must be timed and recorded.


VITL April 21, 2023

T-3.4. Temperature

• 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

Steps:1. Record the temperature.2. Perform any of the system tests

for terrain crossing, level movement, or inclination in a 0º C environment.


VITL April 21, 2023

T-3.6. Efficiency/Accuracy• 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)


position.2. Drive the vehicle in pre-turn-

determined paths. 3. Record end position.4. Compare actual and vehicle-

measured distance traveled.5. Repeat for the remaining

paths.


VITL April 21, 2023

Spring Semester ScheduleMotors Shipping

Motors Shipping

Shipping Materials,Batteries and electronics

Shipping Sensors

Acquisition of Electronics and Sensors

Acquisition of raw Materials

Manufacture Suspension and Frame

Manufacture Suspension and Frame

Manufacture Wheels

Manufacture Wheels

Power board

Power testing

Battery Testing

IR 1 2/5

Preliminary Algorithms

Complete PCB

Manufacture Component Boxes

Integration of Mechanisms

Electronics and Sensor Testing

IR 2 3/5

Maunfacture Testing Structure

Full System Integration

Final Algorithms

Manufacture Margin

Last Machining Day 3/16

Outdoor Testing

Spring Break (margin)

Incline/Obstacle Testing

Testing Margin

Final Review

11/19 12/3 12/17 12/31 1/14 1/28 2/11 2/25 3/11 3/25 4/8 4/22 5/6 5/20 6/3 6/17November December January February March April May June

Final Review

Poster Due 4/23

Report Draft Due 4/23

Design Exposition 4/28

Finalize Final Report

Final Report 5/3


VITL April 21, 2023

Cost Expenditures

ElementsExpected

CostActualCost

CostDifference

Drive Subsystem $1,224 $1,965 $741

Wheels $400 $217 -$183

Motors (w/ Gear Heads) $674 $1,359 $684

Suspension (Includes Large Fasteners) $150 $389.78 $240

Sensors & Software $882 $50 -$832

Laser $780 $0 -$780

Servo $89 $0 -$89

IR Proximity Sensors $13 $50 $38

C&DH/COMM $1,148 $618 -$530

CPU $38 $0 -$38

Amplifiers $645 $322.40 -$323

Encoders $230 $212 -$18

RF RX & Crystal $85 $64.98 -$20

Misc. Parts $150 $18.56 -$131

ElementsExpected

CostActualCost

CostDifference

Structures $99 $211 $112

Frame $54 $148.52 $95

Cables $20 $62.50 $43

Component boxes $25 $0 -$25

Power $45 $5 -$40

Battery Charger $45 $5 -$40

Dummy Mass $20 $12 -$8

Shipping $300 $172 -$128

Management $500 $91.06 -$409

Total $4,217 $3,124 -$1,642


VITL April 21, 2023

Cost ExpectationsElements Expected Cost

Drive Subsystem $77

Suspension $76.50

Sensors & Software $12

Accelerometer $12

C&DH/COMM $166

Data Storage $6

PCB/Assembly $110

Misc Parts $50

Structures $50

Connecters $50

Obstacle Detection Material $30

Thermal $25

Insulation $25

Elements Expected Cost

Testing $95

Obstacle Material - Wood $45

Tape Measure $50

Miscellaneous Parts $100

Shipping $50

Management $250

Total $824

Expenditures $3124

Expected $824

Outreach $500

Subtotal $4448

25% Margin $1112

Total $5560


VITL April 21, 2023

Additional Slides


VITL April 21, 2023 Tasks Status Planned Start Planned End Actual Start Actual End Expected Start Expected End

Motors Shipping In Progress 12/08/06 02/15/07 01/08/07 02/21/07

Shipping Materials Complete 12/22/06 01/16/07 01/16/07 01/22/07

Manufacture Suspension and Frame 50% 01/16/07 01/22/07 01/29/07 02/12/07

Shipping Electronics/Sensors Complete 01/22/07 02/09/07 01/16/07 02/05/07

Preliminary Battery Testing Complete 02/05/07 02/09/07 01/26/07 01/31/07

Preliminary Algorithms 50% 01/19/07 02/15/07 01/19/07 02/15/07

IR 1 Complete 02/05/07 02/05/07

Preliminary Board layout/testing 01/30/07 02/12/07

Complete PCB 02/12/07 02/16/07

Manufacture Wheels Spikes 75% complete 02/05/07 03/02/07 01/26/07 02/12/07

Manufacture Component Boxes Removed 02/12/07 02/16/07

Integration of Mechanisms 01/22/07 02/16/07 02/12/07 02/23/07

Electronics and Sensor Testing 02/19/07 02/23/07

IR 2 03/05/07 03/05/07

Maunfacture Testing Structure Removed 02/27/07 03/12/07

Full System Integration 03/05/07 03/23/07

Final Algorithms 02/16/07 03/09/07

Manufacture Margin 03/12/07 03/16/07

Last Machining Day 03/16/07 03/16/07

Outdoor Testing 03/19/07 03/23/07

Spring Break (margin) 03/26/07 03/30/07

Incline/Obstacle Testing 04/02/07 04/13/07

Testing Margin 04/16/07 04/20/07

Final Review 04/16/07 04/17/07

Poster Due 04/23/07 04/23/07

Report Draft Due 04/23/07 04/23/07

Design Exposition 04/28/07 04/28/07

Finalize Final Report 04/23/07 04/27/07

Final Report 05/03/07 05/03/07


VITL April 21, 2023

EDMU Internal Layout: Top View

Batteries

Laser Range

Proximity Sensor

Gyroscope & Accelerometer

Motor Controller

Science Payload

C&DH board &

Receiver


VITL April 21, 2023

EDMU System Architecture

Motor Controller

C&DH board & Receiver

Suspension & Drive Train

Science Payload exploded

Science electronics

Radiation Sensor

Magnetometer

Pan Cam

Sonar


VITL April 21, 2023

EDMU System Architecture: Front View

Science Payload

Batteries

Sonar sensor

Laser Range

Motor Controller

Motors

C&DH Board and Receiver

Proximity sensor

VITL Interim Review 1 (IR #1)

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Transcript of VITL Interim Review 1 (IR #1)