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Lucky

Team 23 Enterprises Presents…. ™. Lucky. Outline of Presentation. Objectives / Parameters Robot Prototype Design Hardware Software Cost and Feasibility Prototype System Analysis Evaluation and Conclusion. Objectives.

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Lucky

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  1. Team 23 Enterprises Presents… ™ Lucky

  2. Outline of Presentation • Objectives / Parameters • Robot Prototype Design • Hardware • Software • Cost and Feasibility • Prototype System Analysis • Evaluation and Conclusion

  3. Objectives • To demonstrate the feasibility of an autonomously operated robotic retrieval system (AORRS) • To move manufactured products from specified storage locations to a centralized repository within a warehouse facility

  4. Parameters • operate within 12” wide corridor • travel to a calculated “home location” • minimum running velocity of 0.5 ft/s • total average velocity of 0.3 ft/s • travel to bins • transmit a signal at bins • return to home location.

  5. Robot Design Lucky III (Final Design)

  6. Design X No turning / locked axles Operated on 1 motor Distance based on time Lucky I 2 drive wheels plus 2 guiding wheels lifting motor to allow turning Distance and turning based on time Preliminary Hardware Design

  7. Preliminary Hardware Design (cont.) • Lucky II • 2 drive wheels plus 2 guiding wheels • More stable and accurate lift motor mechanism • Synchronizing drive wheel mechanism • Distance and turn based on time

  8. Lucky III (Final Design) • Two Chassis Design • 4 wheels per Chassis (2 drive / 2 guiding) • Light Sensor Odometer System • Lift motor for changing chassis

  9. Lucky III special features… N/S chassis Lucky III w/ 2 chassis design E/W Chassis

  10. Light Sensor Odometer Lift Mechanism / Guide Rails

  11. Accurate Turning

  12. Inputs bin information from the user Creates a C header file Outputs movement map Map is well formatted and easy to use Software Design (Fortran) Input Start Calc Home Loc. Valid Home Loc.? No Adjust Home Loc. Yes BubbleSort Output Stop

  13. User-defined functions Easy to modify Measures distance with light sensors Only runs necessary motors Software Design (C) #define NUMBINS 4#define NUMRETR { 2, 3, 2, 1}#define LOITERTIME 15.0#define XPOS { 5, 2, 3, 3}#define YPOS { 3, 7, 5, 5}#define HOMEX 4#define HOMEY 6#define FORCE 7

  14. Move to home Start Input I = 0 Is I < Number of Bins? No Incr. I Yes I2 = 0 Is I2 < Number of Retrievals? No Incr. I2 Move to bin Yes Loiter and transmit Return Home Stop

  15. Cost and Feasibility Production cost of a single robot:

  16. Man Hours

  17. Development Cost and Breaking Even • Development cost = (307) × ($17,000) = $5,219,000 • To Break even: ($250,000) × # of Robots = ($165,000) × # of Robots + ($5,219,000) ] # of Robots ≈ 62 • This is a reasonable number of robots

  18. Replacing Standard Forklifts • Cost to operate 1 forklift for 1 year • 2 operators/hr × 24 hrs/day × 349 days/yr × $18/hr = $301,536 per year/forklift • Robot = $0 • Multiplied by 62 forklifts (only break even) Almost $19 million difference.

  19. Replacing Standard Forklifts • Pros • Save money • Never get tired • Flat rate (no inflation, benefits, etc.) • Cons • Technicians require more training • Loss of jobs • Loss of human judgement

  20. Prototype System Analysis • Mechanical design (positive aspects) • Two chassis-system • Light sensor odometer system • Use of higher motor speeds and gearing-down • Reliable lifting mechanism • Programming design (positive aspects) • Use of functions for every operation (C program) • Extensive testing (both Fortran and C) • Simplistic use of language minimizes errors (Fortran) • Use of format statements to perfect movement map (Fortran) • User-Friendly (Fortran)

  21. Prototype System Analysis • Mechanical design (negative aspects) • Design was relatively frail • Incapable of turning • Room for improvement of light sensor odometer system • Slight tire slippage • Programming design (negative aspects) • Minimal error trapping (both Fortran and C)

  22. Evaluation and Conclusion • We felt that we had the correct focus for this project— eliminate or minimize error • Areas Error was eliminated or minimized: • Turning • Distance traveled • Going straight • Areas where error remains • Average velocity and time to travel to a bin

  23. Evaluation • Overall, Lucky III performed well • Earned 90 / 100 pts. • Shortcomings • Robot required redress • Some time predictions inaccurate Conclusion • Our robot prototype outperformed that of others by a significant margin. • The design we used would be successful in a real warehouse setting, with minimal modifications.

  24. Don’t be a fool, stay in school!

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