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Modular Motor Module Design for Robust Wireless Control System

Learn about the innovative Modular Motor Module (MM) design, a system incorporating wireless & PWM motor control for seamless integration. Explore the critical requirements, final design components, and system-level considerations for the RP1 project.

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Modular Motor Module Design for Robust Wireless Control System

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  1. RP1 20072 MSD I 1kg Motor Module, First Generation P08208 – Mechanical Design P08205 – Wireless & PWM Motor Controller

  2. WHAT IS A MOTOR MODULE ? aka “MM” MODULAR MOUNTING STEER DRIVE

  3. 100kg 10kg 1kg OFF THE SHELF MOTOR MODULES

  4. RP100( Wired ) RP10( Wired ) RP1 RP10Redesign Sister projects!

  5. Autonomous! RP10Redesign Smaller! Lighter! Wireless! RP1 Robust!

  6. Drive Andrew Anderson Matthew Benedict Platform Eric Rodems Artur Ponikiewski Yoke James Edick Eric Rodems P08205 Reid Williamson Electronics Bryan Jimenez Jonathan Maglaty P08208 Wendy Fung Steer Matthew Benedict Artur Ponikiewski Controls Brendan Hayes Philip Edwards ORGANIZATION BREAKDOWN

  7. System-Level Process Flow Motor Controller Computer Wireless Receiver RP1 Motor Module Microprocessor

  8. CRITICAL REQUIREMENTS • Transport 1kg Payload • Robust = Withstand Tabletop Drop • Wireless Communication • Power Motors with a PWM Signal • Open Source & Open Architecture • Reflect Design of the RP Family • Modular Design for Multiple End Uses

  9. Quantity 2, Fully Functional Size 12in x 6in x 6in Speed @ max efficiency 38 in/s Droptest Repair Time < 5 min Wireless Range 300 ft max Battery Life 1 hour + EXPECTATIONS 2 1

  10. FORMAT Drive & Steering • Q & A Yoke & Platform • Q & A Electronics & Controls • Q & A DFMA & MSD II Outlook • Q & A

  11. DRIVETRAIN SYSTEM • Responsibilities: • Highly dynamic range of operating speeds • An array of different operating conditions • Robustness • Seamless system integration • Risks • Difficulty obtaining different motor gearboxes • Drive Shaft Alignment (turntable wobble) • Robustness of design • Accurateness of systems modeling • Tolerances • Assembly

  12. FINAL DESIGN IG 32 Motor 27:1 Gear Reduction Axle Couplings ¼” Stainless Steel Axles Thrust Bearings ½” Aluminum Spacers 2:1 Synchronous Belt and Pulley 2” Diameter Wheel Axle Collars

  13. SYSTEM LEVEL DESIGN

  14. SYSTEM LEVEL DESIGN

  15. STEERING • Responsibilities: • Infinite Steering • Easy to assemble/disassemble • Robust • Seamless system integration • Risks • Robustness of belt tension system • Turntable • Integration with electronics and controls • Tolerances • Assembly

  16. STEERING SUBSYSTEM IG 32 Motor 71:1 Gear Reduction ¼” Stainless Steel Axles 1:3 Synchronous Belt and Pulleys Custom Centerpost Turntable

  17. STEER BELT TENSION Adjustable Steer Motor Mounting Plate Axle Couplings Adjustable Bearing Plate

  18. DRIVE & STEERING Q & A

  19. YOKE

  20. YOKE • Responsibilities: • Responsible for structural skeleton of Rp1 • Design a rigid and robust framework • House all other sub-systems within framing • Provide protection against a 36” drop to the floor • Risks • Keeping within the weight requirements • Withstand drop without any significant damage or misalignment of components • Minimizing overall cost of yoke

  21. UPPER YOKE 1/8” AL Plate ½” x ½” Al Posts AL Angle Brackets 1/8” Al Motor Mounting Plates Encoder standoff mounting plate 1/8” Al Upper Yoke to Turntable Mounting Plate

  22. LOWER YOKE 1/8” Al Upper Yoke to Turntable Mounting Plate 80/20 90° Base Connector 1”x1” AL 80/20 Quick Frame Mounted Flanged sleeve bearings

  23. Design Justification • Critical Decisions: • Frame built of aluminum instead of Lexan to improve strength • Used an open 80/20 fork design for lower yoke to provide maximum rigidity while minimizing weight • Used solid post box design in upper yoke to fully enclose drive, steering and electrical systems. Solid posts allows for easier hardware attachment • Turn table connected to mounting plates on both sides to support upper and lower yoke

  24. PLATFORM Responsibilities Platform design Mounting of modules to platform Idler module development Test fixture design Risks Design was heavily reliant on upper yoke Design of platform for drivability

  25. DRIVE PLATFORM 2 platforms (1 per team) • Holds 2 motor modules • Holds 2 idler modules • Square shape for adaptability

  26. IDLER MODULE Idler Design Past RP project experience Use of motor module parts Simplified design Caster offset (slot)

  27. TEST PLATFORM 1 test platform • Holds 1 motor module • Holds 2 idler modules • Will have quick connect adapters spec’d out from Molex

  28. YOKE & PLATFORM Q & A

  29. CONTROLS • Graphical User Interface (GUI) • Allow the user to interact with and control the robotic platform • Wireless • Responsible for the communication between the user and the platform • Microprocessor • Generate control signals and monitor sensor feedback

  30. Controls • Risks • GUI • User is unaware of current state of RP1 • User is unable to respond quickly • Wireless • Wireless interference • Insufficient data rate • Microprocessor • “Swamped” with encoder feedback

  31. GUI • Final Design Wheel Angle Battery Life Remaining Left Motor Module Drive Motor: Good Right Motor Module Drive Motor: Inefficiency Left Motor Module Steering Motor: Good Right Motor Module Steering Motor: Good

  32. MIB520 USB-Gateway MICAz 2.4 GHz Wireless Transceiver Wireless

  33. Microprocessor • Freescale MC9S12DT256 • 8 Channel PWM Module • Modular Communication • IIC • SPI • SCI • CAN

  34. ELECTRONICS • System Responsibilities • Provide components for motor control • Placement of motor control components • Supply power to electrical components • Confirm electrical components are compatible with microprocessor • Risks • Component ratings (i.e. heat, amps, etc.) • Lead time on final part selections • Compatibility between electrical components

  35. H-bridge PWM Motor Controller 3A Encoders US Digital EM5 EM1 HUBDISK Final Design

  36. Power Schematic for encoders (5V) Final Design

  37. Final Design • Simulation for Encoder Power Schematic

  38. Final Design • Battery Selection • NiMH • 24V • 3.5Ah • Rechargeable

  39. CONTROLS & ELECTRONICS Q & A

  40. Design For Manf. & Assembly • Steering assembly implementation • Degree of machining precision • Bending of motor shaft • Spacing and fasteners • Control Communication • Functional control

  41. Build RP1 prototype Test accuracy of system modeling Build test fixture Do the drop test Look into possible aesthetical improvements Optimize current design Build GUI Setup basic wireless communication Test all electrical components Full system integration and test Plans for MSD II

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