Senior Design 2010
Group 01
Members:
Team Leader: Seth Beinhart
Peter Martinson
Joshua Clausman
Advisors:
Dr. Nicola Elia
Matt Griffith
Client:
Department of Electrical and Computer Engineering
Iowa State University
Purpose
 To build a third omnidirectional robot for Dr. Nicola
Elia’s research on cooperative tasks in distributed
robotics
 Robot design should be simple enough so that
additional robots can be easily produced
 To create collaborative tasks for three robots which
support the direction of Dr. Elia’s research
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Legacy Robots – Kryten & Dalec
 Strengths to keep
 Small profile
 Software system
 Limitations to overcome
 Computational limitations
 Motor power limited
 Wheel production
 Computer hardware not in
production
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Legacy Vision System
Overhead
Camera
Robot
 (x,y) localization system
 Vision algorithm run LabView
 Localization packets sent
WiFi with robot ID
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Legacy I/O Server
 Ubuntu desktop
 SHH to robots and load AIs
 AI is program to control robot
 WiFi
 Scripts: drive mounting,
libraries
 GUI to upload programs and
manually control robots
 Data logging system
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Legacy Concept Diagram
Concept Diagram adopted from May-09-05 Senior Design Group
Requirements
 Computer and Software
 x86, Linux, integrate previous system, overcome comp
limits, I/O board, IMU, PC/104+
 Wheels
 Easily reproducible, omnidirectional
 Electrical
 Variable motor power, old battery swap
 Physical
 Size, Weight, Speed, Acceleration
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Requirements Changes
 Dropped
 I/O board – due to compatibility and integration time
 IMU – Still in project and tested on bench, not mounted
 Variable motor power supply
 Requirements changed mostly due to equipment
failure and lack of integration time
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Design Overview
Legacy Software System
Linux, Drivers, APIs
Computer Hardware
Power System
Physical System
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Design: Computer Hardware
 Main System
 CPU Board – Diamond Systems Pluto
 Motor Controller – MESA SoftDMC Motor Controller
 Peripheral
 IMU - Pololu CHR-6d
 Wireless – NetGear WG111
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Design: Computer Boards
 Diamond Systems Pluto
 Intel Atom N270 1.6GHz
 ETX Form Factor
 USB2.0/CFII/PC104+
 2 GB
 5v @ ~2A
 4I68 FPGA
 400K gate Xilinx Spartan3
 72 programmable I/O bits
 50 Mhz crystal oscillator
 PC104+ bus
 SoftDMC 4 axis VHDL motor controller
 Requires ~200k logic units
 Mesa Electronics
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Design: Peripherals
 IMU – Pololu CHR-6d
 3 accelerometer, 3 gyro axis
 ARM Cortex Processor
 TTL 3.3 converted to RS-232
 Wireless – NetGear WG111
 USB2.0 Wireless G adapter
 Linux community driver support
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Design: Power System
 Power Board
 Input: 6~16V
 Output:



3.3V @ 2A
5V @ 4A
6~12V @ 60A
 Motor Drivers
 20kHz PWM
 2 channel 5.5-16V 014A
 Current Sensing
 Batteries
 Motors
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Design: Physical System
 Wheels
 Modified schematic from
Kryten
 Injection molded
 ABS polymer
 Cheaply mass produced
 Frame
 Lower COM
 Larger Battery
 Kryten & Dalec
 Dual layer
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Implementation: Software
 Linux – Ubuntu 10.10
Sensor
Manager
Sensor
config
 Legacy Integration
 libconfig
 Scripts
Network
Libconfig
Robot ID,
IP addr
Localization
IP addr
 Cross compilation
parameters
Motor
controller
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Implementation: Software
 Motor Controller
 Legacy Code: MotorController.cpp
 Driver: DMCCom.cpp
 IMU
 Legacy Code: SensorManger.cpp
 Driver: imu.cpp, serial.cpp
 Encoders
 Legacy Code: SensorManger.cpp
 Driver: DMCCom.cpp
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Implementation: Computer
 PC/104+
SoftDMC
 Serial - TTL
IMU
TTL-Serial
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Pluto
Implementation: Motor Controller
 SoftDMC
 Source provided by Mesa Electronics
 Modified VHDL


Dual PWM
Pin assignments
 Upload program


Linux program for 4i65 (PLX 9030)
Changed for 4i68 (PLX 9054)
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Implementation: Power
 5 VDC Supply
 Pluto
 Murata Power Solutions OKR-T/6 CD/CD Converter

4.-14VDC input, 0.591-6.0 VC @ 6A output
 3.3 VDC
 IMU, motor drivers, intermediate motor logic
 Murata Power Solutions NGA 10S15033SC DC/DC
Converter

4.75-28 VDC input, 3.3 VDC @ 2A output
 Motors run directly off battery power
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Implementation:
Frame
 Plate
 18 cm diameter x 15 cm
 Diagonal slots to bypass
wires
 Motor Mount
 1016 Aluminum
 CNC Mill
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Implementation:
Drive Train
 Wheels
 ABS plastic
 Wire ring
 Rollers from mold
 Transmission
 Series 20/1 Planetary
Gearhead
 Motors
 Faulhaber Series
2232006 SR DC Motors
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Implementation: Wiring
 Connector board
 Motor, encoders, driver
out, 3.3V power
 FPGA 8 pin connectors
 FPGA PWM to drivers
 Motor encoder to FPGA
 Batteries
 To power board
 To motor drivers
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Testing: Computer
 Localization packets
 Previously developed AIs
 Arithmetic operation
comparison
 Startup time
10000
1000
Eris Integer
 ~ 2 min 47 sec
 Serial
 115200 BAUD
 1000 packets, size 30 bytes
 10% packet error
 Retransmission policy
Single operation time (ns)
Kryten Integer
100
Eris Float
Kryten Float
Eris Double
Kryten Double
10
1
Add
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Mul
Div
Testing: Power
 Computer Power
 5V +/-5%


4.95V
-1%
 3.3V +/-5%
 3.15V
 -4.5%
 Motor Power
 20A/motor peak @ 7.4V
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Team Evaluation
 Large undertaking, splitting up not always best approach
 Still have final touches: IMU mount, generate SoftDMC
configs, more testing
 “Tales from the Crypt”
 Motor controller
 IO board
 Linux flash drive…the night before
 Motor drivers
 Wheels
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Future improvements
 Software – none, integrated smoothly
 Hardware – I/O board, current sensing
 Motor Controller – Velocity based PID
 Electrical – Variable motor voltage
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Leland Harker for everything electronical 
James Rasmussen for helping with CNC machining
Peter Wallace and all the techs at Mesa Electronics for answer our onslaught of
emails and sending us lots of cards
Larry Couture for helping with mold design and injection molding
Matt Griffith for being the resident ‘wizard’
Dr. Elia letting us spend all his money and still buying us Chinese! (and all his help
of course)
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson
Omnidirectional Robots – Senior Design ‘10
Beinhart ,Clausman, Martinson