Final Project Plan P0820 2/5/6/7/8 – RP1 Motor Module

1. Emilien Barrault (ME) Wendy Fung (ME) Jason Kenyon (ME) Jasen Lomnick (ME) Hoainam Nguyen (ME) Final Project PlanP08202/5/6/7/8 – RP1 Motor Module

2. Project Plan • Project Name • RP1 Motor Module • Project Number • P08202/5/6/7/8 • Project Family • Robotic Platform Family • Track • Vehicle Systems Technology • Start Term • 2007-2 planned academic quarter for MSD1 • End Term • 2007-3 planned academic quarter for MSD2 • Faculty Guide • Dr. Wayne Walter (ME) • Faculty Consultant • Dr. Dan Phillips (EE) • Faculty Consultant • Dr. Hoople (TBD) • Primary Customer • Dr. Edward Hensel (ME)

3. Mission Statement Product Description A fully functional, open source, open architecture, scalable motor module subsystem for use on the 1 kg (RP1) robotic vehicular platform. Each motor module will have the ability to drive, steer, communicate with a controller, and work cooperatively with a number of motor modules in a number of configurations to drive a robotic vehicular platform capable of carrying a 1kg payload. Key Business Goals To provide an open source, open architecture design To provide an off-the-shelf motor module for the mobility of a 1 kg robot platform To provide a motor module that is scalable according to payload requirements To publish the RP1design to be used by anybody wishing to mobilize a 1kg payload. The team must provide complete documentation of the analysis, design, manufacturing, fabrication, test, and evaluation of this subsystem to a level of detail that a subsequent team can build upon their work with no more than one week of background research Primary Market Dr. Edward Hensel RP1 Platform team Future SD teams Secondary Market FIRST Robotics Faculty projects Class-based projects Stakeholders Dr. Edward Hensel Faculty members 1 kg platform team Gleason Foundation RIT Brinkman Machine Shop FIRST Robotics

4. Robotic Platform Family Overview

6. Choosing Multiple Team Structure 3 Broad Options: Option 1: All teams will be given and identical PRP and will not collaborate Option 2: All teams will be responsible for the design, fabrication and interface of a portion of the design Option 3: All teams will work collaboratively and each build a Motor Module but will focus on specific areas of the design

7. Choosing Multiple Team Structure Cont. What we chose and why: We chose Option 3 because: • Collaboration: This structure requires team cooperation • Intelligence of design: It uses student specialties by weighting teams by discipline according to a team’s task (eg. more electrical and computer engineers on a team responsible for developing a PWM motor controller) • Robustness: One team’s failure does not mean failure of the entire project family

8. Team Staffing Requirements and Responsibilities

11. Team Staffing Requirements and Responsibilities cont.

12. Team Staffing Requirements and Responsibilities cont.

13. Baseline Kit BOM 5 Baseline Kits 4 Baseline Kits

14. Target Specifications Specifications for all teams: • A single RP1 Motor Module will be capable of propelling a robotic platform which carries a payload of up to 1kg in weight: • Design is capable of variable speed from 0 to 35 inches per second • Design is capable of an acceleration of 70 in/s2 when propelling a platform carrying a 1kg weight • Design will be tested on a flat 8’ X 8’ surface • Design should fit within an 8” height X 4” length X 4” width size envelope • Motor Module design should weigh no more than 3 lbs each • Each team will deliver 3 Drive (powered) and 4 Idler (non-powered) motor modules • Design should be open source: all documents and designs will be public domain and all file types can be accessed by the public (eg. .IGES files that can be used by multiple CAD packages instead of types that can onlybe used by a single package) • Design should be open architecture: all commercial off the shelf (COTS) components are able to be purchased from multiple vendors and all manufactured components are able to be fabricated using common technologies and tools • Design should have an infinite steering angle around a vertical axis • Should be able to access any component on the module with no more than 3 minutes of disassembly

15. Target Specifications Cont. • Design should be powered by a DC power source • Design will utilize components outlined in the initial kit: • Drive Motor (steering motor from RP10 MM): Shayang Ye Industrial Co. IG320071-41F01, 24VDC 67RPM 71:1 http://www.superdroidrobots.com/shop/item.asp?itemid=717&catid=7 • Steering Motor: Hsiang Neng 175 RPM 7.2V 50:1 Gearmotorhttp://www.lynxmotion.com/Product.aspx?productID=96&CategoryID=11 • Drive Wheel: Colson Perfoma WCO2 2” diameter X 7/8” wide, ½” bore http://www.robotmarketplace.com/marketplace_colsons.html • Steering Motor Encoder: Quadrature Motor Encoder http://www.lynxmotion.com/Product.aspx?productID=448&CategoryID=11 • Designs will use encoders for information feedback of Drive and Steering Motor parameters • All team designs will use the same interfaces for attaching the Communications and Drive Electronics to the RP1 Motor Module • Physical attachment (eg. Bolt pattern) • Quick Disconnect electrical power and data connections • Design should be modular; can interchange modules on single type of platform and operate in a similar manner; All team designs will use the same interfaces for attaching the RP1 Motor Module to the RP1 Platform: • Physical attachment (eg. Bolt pattern) • Quick Disconnect electrical power and data connections

16. Target Specifications Cont. • Design will drive the Drive and Steering motors with a PWM signal • Design will physically resemble past projects (RP10 and RP100) • Design will have a professional look and feel • Design is able to fall from a 4’ tall tabletop and sustain none to minimal damage • Design will apply the principles and practices in Design for Manufacturability and Assembly (DFMA) • Utilize common components with other teams wherever possible to reduce costs and complications • Design’s manufacture and assembly time will be kept at a minimum • All component should adhere to the overall RP Project family: • Constraint Objectives • Regulatory Constraints • Academic Constraints • Safety Constraints • Resource Objectives • People Resource • Equipment Resources • Materials Costs • Labor Costs • Scope Objectives • Technology Objectives

17. Target Specifications Cont. Specific to Project P08202 • Design will adhere to the general specifications for all teams • Design will use the same COTS Motor Controller(s) as teams P08205, P08206 and P08208 • Design will use (if possible) the same Micro Controller Unit as P08206, P08205 and P08208 with an alternate communications protocol as P08206 (eg. If P08206 uses a CAN protocol, P08202 will use SPI protocol or I2C)  Specific to Project P08205 • Design will adhere to the general specifications for all teams • Design will use the same COTS Motor Controller(s) as teams P08202, P08206 and P08208 • Design will use (if possible) the same Micro Controller Unit as P08202, P08206, P08207 and P08208 but will communicate with a with a wireless device • The Wireless Micro Controller Unit used will be responsible for: • Minimum: • Receiving a wireless PWM signal and sending it to the PWM Motor Controller • Transmitting feedback information from encoders back through the wireless connection for processing • Preferred: • Receiving a wireless PWM signal and sending it to the PWM Motor Controller • Receiving feedback information from encoders and processing this signal

18. Target Specifications Cont. Specific to Project P08206 • Design will adhere to the general specifications for all teams • Design will use the same COTS Motor Controller(s) as teams P08202, P08205 and P08208 • Design will use (if possible) the same Micro Controller Unit as P08202, P08205, P08207 and P08208 with an alternate communications protocol as P08202 (eg. If P08202 uses a CAN protocol, P08206 will use SPI protocol or I2C) Specific to Project P08207 • Design will adhere to the general specifications for all teams • Design will use a custom PWM motor controller(s) developed by the team • The custom PWM Motor Controller(s) will: • Control the Drive and Steering Motors • Operate in the same manner as the COTS PWM motor controllers chosen by teams P08202, P08205, P08206 and P08208 • Use the same input and output connections as the COTS PWM Motor Controllers chosen by teams P08202, P08205, P08206 and P08208 • Design will use (if possible) the same Micro Controller Unit as P08202, P08205, P08206 and P08208 with communications protocol of the teams choosing Specific Project P08208 • Design will adhere to the general specifications for all teams • Design will use the same COTS Motor Controller(s) as team P08202, P08205, and P08206 • Design will use (if possible) the same Micro Controller Unit as P08202, P08205, P08206 and P08207 with communications protocol of the teams choosing

19. Benchmarking (100kg Motor Module) • RP100 Motor Module Product Teardown • Make use of quick disconnect wiring connectors • All wiring between platform and module and all module subsystems • Avoid the need for unscrewing wiring, which will add to ease of assembly • Wing nuts are good for quick assembly/disconnect • To remove EMF cage must disconnect every electrical component before the cage can be removed. • There are several areas on the module that can not be reached without an extreme amount of disassembly • No fall resistance • Too much slop in the turntable assembly • Meshing of gears (mainly the internal ring\spur) • Accessing internal gears • No warning labels • Imperfect welds

20. P07202: RP100 Motor Module

21. Benchmarking (10 kg Motor Module) Appeal • Looks impressive with lightweight and transparent lexan sides • Shiny steel and aluminum • Exposed circuitry • Exposed drive system • Exposed "guts" lets users know how it works and is easy to diagnose problems • Use of bushings instead of bearings gives it a cheap and inaccurate feeling • Looks clunky • Could be a much more compact design • Size of turntable obviously determined overall design Operating Characteristics • Large and awkward to handle • Drive wheel is easy to spin but lots of slop in drive system • I cannot readily tell how to use the product: Where do I plug it in? What orientation do I mount it in? Product Teardown 1) Functions • Must drive wheel • Must turn wheel • Must be able to be addressed and controlled by platform • Must physically attach to platform • Must be electrically plugged into platform 2) Technology - Product employs: • Bevel Gears • Synchronous belt drive • Incremental encoders for drive and steering motors (US Digital P/N E5S-400-250-IH) • 1 24VDC Drive Motor w/integrated gearbox (Shayang Ye Industrial Co. P/N IG420017-C520) • 1 24VDC Steering Motor w/integrated gearbox (Shayang Ye Industrial Co. P/N IG320071-41F01) • Various electrical and control circuitry • Large turntable • Colson Hi-Tech Performa 5 x 1.5 Drive and Steering wheel 3)Strengths and Weaknesses • Large, clunky, homemade looking • Very big, definitely not 1/10 the size of the RP100 motor module • Visibility of "guts" is attractive and easy to diagnose problems • Incremental encoders cannot tell control system "where things are" • Had to extend motor shafts 4) Materials used • PCB's • Wires • 2 DC Motors • Encoders for Motors (Qty 2) • Turntable • Bevel gear pair • Synchronous belt drive (rubber belt, plastic drive pulley, metal driven pulley) • Shaft couplings to extend shafts • Less than 1 ft^2 of 1/8" aluminum • About 5 ft^2 of 1/4" lexan • Miscellaneous fasteners • Zip-ties • E-clips for retaining shafts • Bronze Bushings (Qty 6) • Internal gear pair • Steel driveshafts 5) Manufacturing • Cutting lexan, aluminum, and driveshafts • Drilling lexan, aluminum, turntable, internal gear pair • Machining E-clip grooves in driveshafts • Pressing bushings into lexan • Fastening all peices together • Wiring components, holding wires with zip-ties • Experience and Knowledge • Design does not seem rugged, very fragile • Design seems imprecise • If you wanted to replace a broken part you would have to disconnect quite a bit to get to the part (eg. wheel, encoder, gear pair, shaft extension couplings, motor mounting screws, etc.)

22. Technologies for SD Teams to Consider • Turntable Bearing: • Search Criteria: • Slewing Rings • Turntable Bearing • Slewing Bearing • Cross Roller Ring • Websites and Catalogs: • http://www.kaydonbearings.com/products.php • http://www.thk.com/eng/products/class/crossroller_r/index.html • Sales Contact: Tom Weibel, District Manager, THK America Inc. Phone:   585-396-2145; Canandaigua, NY • Compared to past components: + Vastly more precise + Possibility for integrated internal gear - Much more expensive • All-in-one Motor Controller and Micro Controller Unit + Less space than separate units + Simpler programming - More expensive?

23. Budget Allocation

24. Partnership RIT - INSA Design Project Management

25. Interest • RIT and INSA • Opportunity for INSA to create the first collaboration overseas, • Strengthen the relationship between RIT and INSA • First collaboration to create the common project • Opportunity to exchange experience-knowledge and challenge the idea • Have some new ideas about one topic, one project • Help students to develop a new method of working • Have and understand another way to resolve different problems • To be familiar with European method. • Help students who want to go to USA the next year to understand DPM and can continue the project in US • Working on the same project with RIT can help INSA students to practice their English,

26. The French Connection

27. Plan • Communicate with Professor in France • The first letter has been sent, we are waiting for his • Finish the initial document and presentation and send to INSA, • response after the French vacation, • Set up a conference between Dr. Hensel and Professors in France, • If the Professors accepts the idea, translate and put the package in French format • Take part in the team as observers • Understand the design • Translate the documentation into French for the next team in France.

28. Preliminary Work Breakdown Structure • During the first week of SD1, Wendy Fung, Jason Kenyon, and Jasen Lomnick will give an overview of past designs and a quick run through on what a robot is. • Current and past work will be easily referenced from each project’s web sites.

29. Preliminary WBS (continued) • Week One • Everyone • Understand assigned roles and responsibilities • Understand overall project details • Access EDGE website and add all RP1 projects • Meet with members from other teams on their respective subsystem (weekly) • Understand their respective subsystem • Research respective subsystem • Team Leader • Assign roles and responsibilities to each member • Get card access for all team members to necessary rooms • Bring team up to speed on project details • Meet with other team leaders (weekly) • Meet with each subsystem leader (weekly)

30. Preliminary WBS (continued) • Week Two • Everyone (to be repeated every week) • Meet with respective subsystem members • Ask questions on any unclear points (weekly) • Bring any concerns about any aspect of the project (weekly) • Update team with news on their respective subsystem (weekly) • Propose concept level designs • Determine components and materials needed to be ordered • Research respective subsystems • Team Leader • Address any concerns or questions (weekly) • Update on progress of other teams (weekly)

31. Preliminary WBS (continued) Week Three Everyone Finalize parts to order for the prototype Order parts Build text fixture Begin building rudimentary platform Team Leader Review interface requirements with team

32. Grading and Assessment Scheme Grading of students in this project will be fully consistent with grading policies established for the SD1 and SD2 courses. The following level describes an absolute level of expectation for the design itself, for the hardware. However, the student team must also meet all requirements related to analysis, documentation, presentations, web sites, and posters, etc. that are implicit to all projects. P08208 – Focus: Mechanical Design: Level D: The student team will deliver cost effective working motor module prototypes, capable of controlled motion. The prototypes will be fully characterized. The motor module prototypes will meet customer specifications. The prototypes developed will be 100% open architecture and open source. They will use no proprietary components, only COTS components available from multiple manufacturers. A function generator is used to send out PWM signals. Level C: The student team will deliver all elements of Level D PLUS: The motor module prototypes will show quantitative improvements over the past motor modules for the customer's application. There will also be marked improvement over the past motor modules in the areas of control and user interface. The PWM signal is controlled by a motor controller. The motor module can communicate with a platform. Level B: The student team will deliver all elements of Level D and C PLUS: The motor module prototypes will exceed the past motor modules in every aspect asked for by the customer. The team’s motor modules can be interchangeable with at least one other team’s motor module. Level A: The student team will deliver all elements of Level D, C, and B PLUS: The team’s motor modules can be interchangeable with any other team’s motor modules.

33. Grading and Assessment Scheme P08207 – Focus: RIT Motor Controller: Level D: The student team will deliver cost effective working motor module prototypes, capable of controlled motion. The prototypes will be fully characterized. The motor module prototypes will meet customer specifications. The prototypes developed will be 100% open architecture and open source. They will use no proprietary components, only COTS components available from multiple manufacturers. A function generator is used to send out PWM signals. Level C: The student team will deliver all elements of Level D PLUS: The motor module prototypes will show quantitative improvements over the past motor modules for the customer's application. There will also be marked improvement over the past motor modules in the areas of control and user interface. The motor is controlled by a RIT motor controller. Level B: The student team will deliver all elements of Level D and C PLUS: The motor module prototypes will exceed the past motor modules in every aspect asked for by the customer. The team’s motor modules can be interchangeable with at least one other team’s motor module. Level A: The student team will deliver all elements of Level D, C, and B PLUS: The team’s motor modules can be interchangeable with any other team’s motor modules.

34. Grading and Assessment Scheme P08205- Focus: Wireless Communication: Level D: The student team will deliver cost effective working motor module prototypes, capable of controlled motion. The prototypes will be fully characterized. The motor module prototypes will meet customer specifications. The prototypes developed will be 100% open architecture and open source. They will use no proprietary components, only COTS components available from multiple manufacturers. A function generator is used to send out PWM signals. Level C: The student team will deliver all elements of Level D PLUS: The motor module prototypes will show quantitative improvements over the past motor modules for the customer's application. There will also be marked improvement over the past motor modules in the areas of control and user interface. The PWM signal is controlled by a wireless signal. Level B: The student team will deliver all elements of Level D and C PLUS: The motor module prototypes will exceed the past motor modules in every aspect asked for by the customer. The team’s motor modules can be interchangeable with at least one other team’s motor module. Level A: The student team will deliver all elements of Level D, C, and B PLUS: The team’s motor modules can be interchangeable with any other team’s motor modules.

35. Grading and Assessment Scheme • P08202 / P08206 – Focus: CAN/SPI/I2C Communications Protocols: • Level D: The student team will deliver cost effective working motor module prototypes, capable of controlled motion. The prototypes will be fully characterized. The motor module prototypes will meet customer specifications. The prototypes developed will be 100% open architecture and open source. They will use no proprietary components, only COTS components available from multiple manufacturers. A function generator is used to send out PWM signals. • Level C: The student team will deliver all elements of Level D PLUS: The motor module prototypes will show quantitative improvements over the past motor modules for the customer's application. There will also be marked improvement over the past motor modules in the areas of control and user interface. The PWM signal is controlled by a CAN protocol. • Level B: The student team will deliver all elements of Level D and C PLUS: The motor module prototypes will exceed the past motor modules in every aspect asked for by the customer. The team’s motor modules can be interchangeable with at least one other team’s motor module. • Level A: The student team will deliver all elements of Level D, C, and B PLUS: The team’s motor modules can be interchangeable with any other team’s motor modules.

36. Team Values and Norms • Each team member and every team must participate in collaboration to accomplish the goals of the RP1 Motor Module Project • All students are expected to follow meeting guidelines including bringing all necessary documentation, pre-agenda and personal work expected to be done by meeting date. • Punctual - Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict comes up, the absent team member will notify at least one team-mate prior to the expected absence. An absent team-member should confirm that a team-mate has received their message (in person, voice mail, email, etc). • Thorough - Each team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person. • Accurate - Each team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow. • Professional and Ethical - Each team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers. • Demonstrates the core RIT values of SPIRIT. • Committed - Each team member will contribute an equal share to the success of the project. • Team success depends on the success of each other • As a team we expect to get the most productivity with the least resistance • Lack of contribution will not be tolerated • Escalation to higher authority will be considered on a case by case basis • Design to requirements not to the budget • Document any changes in Schedule • Anticipate questions, before presenting information and answer during presentation • Have details behind decisions available during discussions/presentations • Technical integration • Measure twice Cut once • Each value is broken down to four levels of performance: Unsatisfactory, Needs Improvements, Meets Expectations, or Exceeds Expectations

37. Intellectual Property Considerations • Everything associated with this project is public domain. • The final result of the RP1 Motor Module design will be published for any party to access. • The intent of publication is for any party to use the design to build their own Motor Module for their own use.

38. Required Resources

39. Issues & Risk • Taking on too much design responsibility – “biting off more than you can chew” • Budget Constraints – staying within budget, underestimating cost • Efficient use of resources (coordination) – machine shops, people’s schedules • Packaging envelope – teams must design within constraints • Scaled down version of previous designs – desired design should look like a miniature version of previous designs • Customer expectations – miscommunication of/not meeting important needs • Time schedule (milestones to accomplish) – not meeting deadlines • High learning curve – too much to learn to accomplish goals • Identify and acquire key design components early – dependent components come after • Good design on paper but not in reality – CAD and other design work should be realistic • Testing capabilities – have time and testing equipment • Not guaranteed that teams will collaborate– tension and design conflicts • Too much team collaboration will discourage uniqueness of design • Scheduling conflicts and difficult team meeting coordination • With some team structure options, the interface between segments will be difficult to manage

40. Outstanding Items • Finding interested students for the teams • Establish relative importance of specifications through follow-up surveys • Speak with Dr. Crassidis and Dr. Yang about their project needs

41. Question