Semester Wrap-up

1. Semester Wrap-up Michael D. Vaughan Fall 2008 4 December 2008

2. Outline • ECE573 – Practical (Physical) • Ranger system • Building new system • System characterization • Software used • Future work • ECE574 – Theoretical (Research) • Proposal work • Conceptual research

3. ECE573 – Ranger system • Pros • Robust (Heavy, Stable) • Accurate (μm scale) • Cons • Small work area • Designed for high-resolution scanning • Works best at very low speeds

4. ECE573 – New system • Address issues with Ranger system • Larger work space • Designed for motion control • Accurate at higher speeds

5. ECE573 – System characterization • Position error vs. speed at 21.2m/s2

6. ECE573 – System characterization • Position error vs. speed at 31.8m/s2

7. ECE573 – System characterization • Position error vs. speed at 42.4m/s2

8. ECE573 – System characterization • Position error vs. speed at 53.0m/s2

9. ECE573 – System Characterization • Position error vs. speed

10. ECE573 – System characterization • Position error vs. acceleration at 65.8mm/s

11. ECE573 – System characterization • Position error vs. acceleration at 98.7mm/s

12. ECE573 – System characterization • Position error vs. acceleration at 131.7mm/s

13. ECE573 – System characterization • Position error vs. acceleration at 164.6mm/s

14. ECE573 – System Characterization • Position error vs. acceleration

15. ECE573 – Software Used • Ranger control code • Manual entry of moves

16. ECE573 – Software Used • Virtual joystick • Visual movement

17. ECE573 – Future Work • Additional degree of freedom • Two-way directional control • May be accomplished now with current software • Will need additional belt and pulleys • Write additional software • Tailored to the task of visual servoing • More automated

18. Outline • ECE573 – Practical (Physical) • Ranger system • Building new system • System characterization • Software used • Future work • ECE574 – Theoretical (Research) • Proposal work • Conceptual research

19. ECE574 – Proposal Work • MURI2009 – T03 • Bio-Inspired Signal Sensing and Classification in Uncertain Environments • Survey of the state of the art • Tracking (blur and noise) • Navigation (scale, view point, illumination) • Documents written • Proposal • Relevance to sponsor

20. ECE574 – Conceptual Research • Survey of equipment with recommendations • Motors • Cameras • Belts • Wear analysis of machining tools

21. ECE574 – Survey of Motors • Servo • Motor • Gearheads • Power Supply • Cables • Stepper • Motor • Gearheads • Power Supply • Cables

22. ECE574 – Survey of Cameras • Combination • Most flexible • Smallest diameter • Large focal depth • USB-based • Autofocus • Direct digital video output • Possible compatibility issues • RCA-based • Cheapest • Autofocus • Direction correction needed • Largest shaft

23. ECE574 - Combination • Purchase Camera and Scope Separately • Camera • Sony CCD Borescope Camera $799 • Scope • FS312 General Purpose Fiberscope $1075 • 24” shaft length • 7.9mm shaft diameter • 10,000 element fiber imaging bundle • 5-75mm focal depth

24. ECE574 - USB-based • USB Video Borescope $1350 • 36” shaft length • 10mm shaft diameter • 1.1MP resolution • 15 frames/s at 640x480

25. ECE574 - RCA-based • Intraoral Camera $395 • 4” shaft length • 15mm shaft diameter • .9MP resolution • 5-30mm focal depth

26. ECE574 – Survey of Belts • Belt Types • Polyurethane • Metal Chain • Perforated Metal Belt • Tension Measurement • Sonic • Pencil

27. Belt Types • Polyurethane • Lighter, lower inertia • Deformation depends on load and speed • High precision under lower loads and speeds • Metal Chain • Heavier, potential problem with tracking and sagging • Little to no deformation • High precision • Perforated Metal Belt • Lighter than chain, lower inertia • High precision

28. Polyurethane Belt • Self-tracking • BAT10 • Curved teeth • Equal power transmission • Reduced noise • SFAT10 • Displaced by ½ tooth • Reduced noise • Reduced polygonal effect

29. Metal Chain • Solid Bush Chain • High precision solid bushes • Longer wear (1.2-4X) • Sintered Bush Chain • High precision solid bushes • Longer wear (1.2-4X) • Infrequent lubrication

30. Perforated Metal Belt • No lubrication required • Perforated holes fit over ball bearings for timing • Positioning accuracy of between 13-25 μm for timing belt • Repeatability accuracy from 51-127μm for smooth belt • Belt sag not handled by tensioning but by stationary support to maximize belt life, able to function at lower tension • Almost no deformation (some elongation depending on operating temperature, no appreciable elongation for our application)

31. Tension Measurement • Sonic type • Transdev TSM4 • 7Hz to 400Hz • ±5% Accurate • $1000± • Gates 507C • 10Hz to 5000Hz • $800±

32. Tension Measurement • Pencil type • A14Z 6-740176 • 30 lb load limit • $16±

33. ECE574 – Wear analysis • Drill bit wears as it is used • How much does it wear? • Can we model the wear? • Model developed will help toward servoing from visual inspection as the wear occurs and automatic adjustment can be made to ensure consistent manufacturing.

34. Questions?