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Senior Design Team 5: Final Presentation May 9, 2009

Senior Design Team 5: Final Presentation May 9, 2009. Outline. Team & Project Introduction Design Process Obstacles Prototype Design Conclusion. Team Introduction. David VanKampen (EE). David VandeBunte (EE). Ryan Mejeur (EE). Matt Lubbers (EE). Inspiration. Service-oriented

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Senior Design Team 5: Final Presentation May 9, 2009

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  1. Senior Design Team 5: Final Presentation May 9, 2009

  2. Outline • Team & Project Introduction • Design Process • Obstacles • Prototype Design • Conclusion

  3. Team Introduction David VanKampen (EE) David VandeBunte (EE) Ryan Mejeur (EE) Matt Lubbers (EE)

  4. Inspiration • Service-oriented • Design automated system • Robotics/ motor control

  5. Project Overview Traditional Warehouses + Robots Automated Storage & Retrieval Systems (AS/RS) - Built w/ warehouse STORBOT

  6. Project Scope Evolution Beginning End More mechanical Limited real-time capabilities Full Business Plan Bottom-up robot system design • Implement RTOS on open core • Exhibit small amount of controls • Vastly coding oriented

  7. System Architecture

  8. Robot Workflow 10110101 Host PC sends command PC Sends Command FPGA Decodes FPGA decodes and receives command FPGA signals wheel motors to advance Robot Moves Arm Rotation At proper shelf, truck stops, rotator starts Elevator Up After rotation, the elevator raises the arm Once correct height is reached, the forearm advances Forearm Extension Upon contact with the product, a vacuum is created, and the product is pulled back Vacuum Enabled Elevator Down Once the product is over the tray, vacuum is released, and arm is lowered

  9. From Concept… … To Reality Redesigned over Spring Break Addressed specific issues Visual conception drawn in Sketch-up • New Design • Taller tower • Longer arm • Shelf Motor • Linear bearings

  10. Design Process • Task breakdown • Dave VandeBunte – FPGA • Dave VanKampen – Sensors • Matt – Elevator • Ryan – Robot Base • Working in parallel • Late nights and early mornings

  11. Testing and Performance • Performance • Tests • “Agile” development style • Incremental tests • Feature by feature • Bench tests for mechanics • Vacuum • Elevator • Arm • Wheel motors • Calibration • Setting Elevator Heights • Sizing of Suction Cups • Know when to call it quits • Wheel steppers • Turn-disc • PCBs vs. breadboards

  12. Obstacles • Elevator limitations • Small range of motion • Structure too weak • Turn-disc inaccuracy • Error magnification • Poor drive system • Stepper Controller inconsistency • Voltage stepper failure • Development board damage

  13. Solutions and Tradeoffs • Redesign elevator • Linear bearings • Improved structural design • Fix Turn-disc • Bolt in place • Loss in range of motion • Controller opto-isolation • Far too much time & too many gray hairs • No level translation necessary

  14. Prototype Design Base Design Elevator/Arm Design

  15. Base Design • Power Supplies • Stepper Motor Controllers • Wheel Stepper Motors • Turn-disc Stepper Motor • H-Bridge and Relay • Development Board • Powertrain Base Design Elevator/Arm Design

  16. Arm Design • Bearings • Rack and Pinion • Adjustability

  17. Elevator Design • Elevator Assembly • Arm Assembly • Plate Assembly • Tower Assembly • Turn-disc Assembly • Vacuum Pump • Distance Sensor

  18. Prototype -- Analog Sensors Peripheral Circuits High current H-bridges Voltage steppers Opto-isolation Transistor switches • Reflectance • Encoders • Ultrasonic Distance • IR Proximity • Vacuum

  19. Prototype -- Digital • Functional GUI • Front end for Serial Port • Inventory Management System • Successful coordination with CS student

  20. Prototype -- Digital

  21. Final Prototype

  22. Conclusions • Success • Heavier Box 15 to 30 lbs • Larger Dimensions12 “ to 18” • Lessons learned • Robotics Field • Debugging • Potential Development • Expandability • Patent follow-up • Debug turn-disc

  23. Acknowledgements • Phil Jasperse – Shop Attendant • Josh Vroom – CS Student • Chuck Holwerda – Electronics • Professor Bossemeyer & Calvin Faculty • DornerWorks • Xilinx University Program • Ben Lubbers and Jonathan Mejeur

  24. Questions?

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