DELIBERATE GECKO
Robotic Plot Table Camera
WSU EECS Senior Design II
Authors: Michael Mihalek, Michael Nguyen, and Miles Ramage
Fall Semester 2013
The team members of EECS Senior Design II team #1 (Deliberate Gecko) here by acknowledge by their
signatures that they have each contributed to and read this final report and agree upon its contents.
Michael Mihalek
Date
Michael Nguyen
Date
Miles Ramage
Date
ABSTRACT:
This report provides details of the prototype and recommended specifications, technical
description, bill of materials, and standards used for Deliberate Gecko’s robotic plot table camera. In
addition, this report includes a comprehensive description of the project’s historical perspective, business
viability, and future work needed to produce an industry-ready product to be used by the team’s client,
BTCO. The report attempts to provide justification for the implementation of a more professional build at
a later date.
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
This page intentionally left blank.
2
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
Table of Contents
ABSTRACT:..................................................................................................................................................... 1
SPECIFICATIONS: ........................................................................................................................................... 5
I.
Prototype Specifications ................................................................................................................... 5
II.
Recommended Specifications ........................................................................................................... 6
III.
Standards ...................................................................................................................................... 8
USER MANUAL: ............................................................................................................................................. 9
I.
Setup ................................................................................................................................................. 9
II.
Maintenance ................................................................................................................................... 10
III.
Service ......................................................................................................................................... 10
IV.
Troubleshooting .......................................................................................................................... 10
THEORY of OPERATION: .............................................................................................................................. 11
TECHNICAL DISCRIPTION: ........................................................................................................................... 13
I.
Prototype Drawing and Images ...................................................................................................... 13
II.
Bill Of Materials............................................................................................................................... 16
USABILITY STUDY: ....................................................................................................................................... 17
HISTORICAL PERSPECTIVE: .......................................................................................................................... 19
BUSINESS VIABILITY: ................................................................................................................................... 21
FUTURE WORK: ........................................................................................................................................... 23
CONTRACT and SCHEDULE:......................................................................................................................... 25
I.
Contract: ......................................................................................................................................... 25
II.
Schedule: ......................................................................................................................................... 26
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
This page intentionally left blank.
4
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
SPECIFICATIONS:
I.
Prototype Specifications
Note:
The following specifications are solely based on the prototype device. Specifications for
production grade system will vary with final components chosen.
Quality
Nominal Value
Motors
SureStep stepper motor (STP-MTRH-23079), NEMA 23
frame size, single shaft, 1.8 degree/ full step
Voltage
Current
Resistance
Inductance
Weight
PLC
Arduino MEGA 2560
Input Voltage (Recommended)
Input Voltage (Limits)
Current
Flash Memory
Default Matlab serial comms speed
USB 2.0
286
(2.02)
32 to 70
5.6
0.4
1.2
2.4
(1.1)
16
7 to 12
6 to 20
40
256
115
Stepper Drivers
Pololu A4988
Input Voltage
Output Current
Output Current (with forced cooling)
Step Range
Unit
oz-in
(N-m)
VDC
A/phase (max)
Ω/phase
mH/phase
lbs
(kg)
MHz
VDC
VDC
mA/IO pin
KB
kBaud
8 to 35 VDC
1 A/phase (max)
2 A/phase (max)
1/16 to 1
Workstation
Windows 7 (32 bit) PC
Matlab r2013a
RAM
USB 2.0
Output Device Voltage
Output Device Current
4
35
5V +/- 5%
100
220
5
GB
MB/s
VDC
mA
mA (max)
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
Camera
Resolution
Color Type YUY2
Optical Zoom
USB 2.0
640 x 480 pixels / sq-in
16 bits / pixel
0 to 300 multiplier
Gantry
Dimentions (Outer Frame)
width
depth
travel width (x axis motion)
Dimention (y axis)
width
depth
travel depth
Carriage
Cable Spindles
Cable, steel, twisted
Overall maximum camera travel area
60 in
60 in
54 in
9
60
54
9x9x4
~1
~3/32
45 x 45
in
in
in
in-cu
in diameter
in diameter
in-sq
Detailed linear bearing information (constructed for the prototype) is not included as this is outside the
scope and objective of this project. Being that size of the machine was not critical to show proof of
concept, gantry dimensions where shrunk from the first semester project as to make the device more
portable.
II.
Recommended Specifications
Note:
Overall physical dimensions will be subject to the linear motion system chosen for the production
system. The important factor will be maximum travel area. The plot tables in use by BTCO are
128 inches wide by 42 inches deep. Therefore the minimum camera travel area is 128 x 42 in-sq.
Quality
Nominal Value
Unit
Motors
SAME AS PROTOTYPE
PLC
NOT YET CHOSEN
Stepper Drivers
SureStep Microstepping Drive (STP-DRV-80100)
Input Voltage
Output Current
Recommended Input Protection (time delay fuse)
Operation Temperature
6
24 to 80
0.1 to 10.0
6.25
0 to 55
VDC
A/phase
A
deg C
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
Workstation
SIMILAR TO PROTOTYPE
Camera
Resolution (minimum)
Lens Focal Length (mimimum)
RGB or YUY2 format
Lens Type
Lens Filters (recommended based on table light color)
8 MPixels
1.5 in
Parallax Correct
Gantry
Minimum camera travel area
128 x 42 in-sq
Power Supply
SureStep Power Supply (STP-PWR-7005)
Input Voltage
Input Current
Output Voltage (@ Full Load)
Output Current
120 / 240
7
70
5
7
VAC
A
VDC
A
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
Note:
Further information can be obtained from the following sources.
Motor Data Sheet:
http://www.automationdirect.com/static/specs/surestepmotors.pdf
Motor Drive Data Sheet:
http://www.automationdirect.com/static/specs/surestepdrive.pdf
Power Supply Data Sheet:
http://www.automationdirect.com/static/specs/suresteppower.pdf
III.
Standards
The following standards should be adhered to during the construction, assembly, and operation of this
device wherever applicable and possible.
1. NFPA 70 (National Electrical Code)
2. NFPA 70E (National Standard for Electrical Safety in the Workplace)
3. USB 2.0 (Serial Communications Port Standard)
4. UL Listed (Underwriters Laboratories Approved Components)
5. ADA (Americans with Disabilities Act)
8
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
USER MANUAL:
Thank you for purchasing Deliberate Gecko’s Robotic Plot Table Camera (RPTC) system.
Note: These instructions are for the current revision of the Robotic Plot Table Camera system, P4.
Improper installation and usage will void product warranty.
I.
Setup
Included with this RPTC system are 4 custom-built stands. Place these stands on the outer perimeter of
the RPTC frame, spreading them out to the corners to provide the most stability. Proprietary table mounts
are sold separately, and will require hand fitting.
After the stands are placed, gently lower the RPTC system onto the stands, making sure to place the outer
frame in the provided grooves.
Now that the RPTC is in position, connect the power and data cables into the side of the proprietary
control box. Connect the USB cable on the side of the control box to the workstation.
On the workstation, launch the RPTC Start program.
A user-friendly GUI should appear.
The GUI will display a live camera feed of what the RPTC is currently monitoring.
Press the Capture button to capture an image from the live feed and process it.
Green dots will display where measurements are being taken.
Distance measurements will be displayed on the Captured Image screen. These measurements are in
1/1000″, provided that the calibrated plotting table uses 1″ squares as the reference.
The slider bars are for motor control. You can select the speed and direction of the camera box.
There is another slider bar to control image filtering. This is to clean up imperfections in the plot print or
visible dust.
To exit the program, click the Close button.
Congratulations! Your RPTC system is now ready to use.
9
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
II.
Maintenance

Ensure no long hair; loose clothing or overhanging articles are around RPTC, as it may be caught
in the moving parts, causing a jam.

Do not place objects beside or on top of control box, as that will block air flow for cooling of
components inside control box.

All wires should be kept free from tangling or entanglement.

Camera lens should only be cleaned if necessary, ensure that it is properly aligned with the table
after maintenance.

No additional lubrication should be necessary. Cleaning of the metal components should be done
with a damp cloth and vinegar. Components should then be dried and buffed with a lint free cloth.

Check all cables and wires to confirm that they are well connected.

Check all bolts and fittings for proper fitting. Fittings require a minimum of 15 in-lb of torque.
III.
Service
Internal components are not user serviceable and should not be dismantled. This will void the warranty of
your product. If any components or repairs are needed, the local Deliberate Gecko should be contacted to
arrange a service call.
IV.
Troubleshooting
RPTC GUI does not start
-Check USB cable from control box to workstation.
-Check power cable to control box.
RPTC does not move
-Check USB cable from control box to workstation.
-Check power cable to control box.
-Check motor cables from motors to control box.
Green points on measurement screen are measuring points incorrectly
-Check camera alignment and plot lighting.
-Check image filtering amount.
10
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
THEORY of OPERATION:
The RPTC system is easy to use and operate. It carries a camera around a plot table in the X and Y axes.
The primary goal of the product is to enable users in wheelchairs to be able to take measurements on a
plot table. Without being confined to a wheelchair, normal users can operate more ergonomically.
Movement
The RPTC system uses pulleys and stepper motors to move the camera to any location within the frame.
Slider bars within an included GUI on a workstation control these motors. An optional
joystick/thumbstick accessory is sold separately. There is one motor for travel on the X-axis and another
for travel on the Y-axis.
Image Processing
The RPTC system does not only have the capability to capture and store images, but automatically take
measurements of the desired distances between lines on the plots and the calibrated table. These images
are processed into black and white images to find exact measurements. This is done entirely in the
background, while the raw image is displayed with measurements superimposed on the raw image. The
center of each point of intersection of the lines should be marked with a green star. The distances are
displayed between the green stars. These measurements are in 1/1000″.
Product Use
The intended use of the RPTC system is to enable measurements to be taken at a workstation, rather than
manually. This will reduce back strain and increase efficiency. The measurements are taken to verify
printed plots to ensure that the printer is operating correctly. To use the RPTC system, simply open the
provided software. It may ask for the USB port to be provided. Enter the USB port that the system is
plugged in to. The GUI should appear and be fully functional. To capture an image and process it, press
Capture Image. It will also take and display all of the measurements on screen.
This also opens employment opportunity to users that are unable to lean over the current plot table to take
measurements. The entire task is now possible to finish at the workstation. The RPTC system can be used
to quickly take measurements without the need to be zeroed on the specific point of measurement.
Measurements can be calculated from an image that contains the entire red square on the calibrated plot
table that contains the point to be measured.
Unique Features
The RPTC system offers many unique features that other competing products do not. The RPTC system is
built-to-order for each and every customer at an affordable cost. It is robust and has few moving parts to
malfunction. It will work with left-handed or right-handed users. It will be usable by anyone not able to
stand over the plot table. It is also usable by any users that are colorblind, deaf, or near-sighted. This also
allows normal employees to not suffer from back tension or eye strain. If used correctly, the RPTC
system can also increase productivity by lowering the time required to verify printed plots.
Why Choose RPTC?
Other than the RPTC system, high-end scanners are available to take measurements for print verification.
Compared to the alternative products that are suitable for fulfilling the print verification, this product is
only a fraction of the cost, and continues to utilize the calibrated back-lit plot tables that are already in
use. The high-end scanner costs approximately 17 times as much as a single RPTC system.
Protocols and Standards
11
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
Americans with Disabilities Act – The project was developed for residents at CPRF that are confined to a
wheelchair.
NFPA 70/NFPA 70E – The project adheres to the standards provided to ensure that the electrical
components within the project are not a safety hazard.
USB 2.0 – The project needed a method of communication to relay data for not only the control system,
but the camera system. USB 2.0 streamlined the process because it was already well established in the
components used in the project build.
UL Listed – When applicable, parts used in the project build are preferred to be made to these safety
specifications to ensure safety of the users.
12
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
TECHNICAL DISCRIPTION:
I.
Prototype Drawing and Images
Fig. 1 Preliminary Sketch of RPTC
The Robotic Plot Table Camera (RPTC) consists of a 2 axis linear motion system and sensor
carriage. The system is propelled by 2 stepper motors. The carriage supports the digital camera and yaxis drive motor. At BTCO, the calibrated plot QA surfaces are supported by standard formica topped
tables that are of the same dimensions. The outer frame of the gantry would be clamped to this table
by some bracket as yet designed.
The motors each drive a spindle that winds and unwinds steel cable that (through pulleys) is
attached to the opposite side of the axis from the motor. This system insures an even amount of cable
is taken in or paid out on each side of the moving surface thus reducing any torque induced from a
single side / single direction force.
13
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
Fig. 2 RPTC Gantry and Carriage Assembly
Fig. 3 x-axis Linear Bearing and Motor Assembly
14
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
Fig. 4 Carriage Detail ( y-axis motor and digital camera)
15
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
II.
Bill Of Materials
Note: The following Bill of Materials is for the recommended / deliverable device that would be setup
at BTCO. All items listed are only for the purpose of estimation. Alternatives are available.
Part Number
Description
y-axis System Materials
ZLW-0630-B-R-1220
y-axis Linear Motion System 1220 mm stroke
IK-0001
Normally Closed Limit Kit
IK-0002
Normally-Open Limit Kit (Alternative)
MAT9043716-D
3m Sensor Cable
NEMA230630
Motor Flange
Supplier
Qty
Unit Price
Total Price
IGUS
IGUS
IGUS
IGUS
IGUS
1
2
2
2
1
509.80
106.68
106.68
20.84
100.00
509.80
213.36
(213.36)
41.68
100.00
x-axis System Materials
WS-10
x-axis Linear Motion Rail
WJRM-02-10
90 Deg Hybrid Linear Bearing
IGUS
IGUS
2
4
164.74
15.56
329.47
62.24
x-axis System Materials (Alternative)
WS-10
x-axis Linear Motion Rail (non-powered side)
WJRM-02-10
90 Deg Hybrid Linear Bearing
ZLW-0630-B-R-2440
y-axis Linear Motion System 2440 mm stroke
IK-0001
Normally Closed Limit Kit
IK-0002
Normally-Open Limit Kit (Alternative)
MAT9043716-D
3m Sensor Cable
NEMA230630
Motor Flange
IGUS
IGUS
IGUS
IGUS
IGUS
IGUS
IGUS
1
2
1
2
2
2
1
164.74
15.56
~1000.00
106.68
106.68
20.84
100.00
164.74
31.12
~1000.00
213.36
(213.36)
41.68
100.00
Stepper Motor Systems
STP-MTRH-23079
289 oz-in Bipolar Stepper Motor
STP-DRV-80100
Stepper Motor Driver
STP-PWR-7005
Stepper Motor Power Supply
STP-EXT-020
STP-MTRH Stepper Motor Ext. Cable 20ft
Automation Direct
Automation Direct
Automation Direct
Automation Direct
2
2
2
2
51.50
265.00
178.00
15.00
103.00
530.00
356.00
30.00
~500.00
~250.00
~60.00
~500.00
~250.00
~60.00
Microcontroller
Needs Extensive Research
Workstation
PC / Laptop
ANY
Monitor
Trackball
Windows 7 64 bit OS Workstation
8 Gb RAM (Video Processing)
128 Gb Solid State Drive (for OS)
500 Gb Hard Drive (file storage)
USB 2.0 / 3.0
21in 16x9 ratio
In place of a standard mouse
Logitech
1
2
1
Matlab
Matlab r2013b
Toolbox
IDE for measuring algorithm and GUI
Image Acquisition Toolbox
Mathworks
Mathworks
1
1
~500.00
~200.00
~500.00
~200.00
8 Mega Pixel Minimum
Parallax Correction Macro Lens
ANY
ANY
1
1
~2000.00
~600.00
~2000.00
~600.00
ANY
?
~250.00
250.00
Digital Camera
Misc. (Cabling, Fasteners, Brackets, etc.)
Misc. hardware
Estimated Total (Without alternates) per unit
6635.55
16
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
USABILITY STUDY:
No usability study was performed for this project as per a verbal agreement between Dr. Skinner
and Michael Mihalek in September of 2013. BTCO’s plot tables are valued at $100k each and the
logistics of “strapping” the device to one of those tables was determined to be beyond the scope of the
project for this semester. If (at a future date) BTCO determines the financial risk involved in
implementing this design into their plot QA program is worth funding, a study will be conducted on the
first unit installed. This study will enable improvement to the design for the second unit and upgrades to
implement on the first unit.
17
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
This page intentionally left blank.
18
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
HISTORICAL PERSPECTIVE:
In the beginning of our first semester of senior design, our class visited a local Cerebral Palsy
Research Foundation (CPRF) campus to meet cerebral palsy patients in order to possibly meet some of
their needs through our design projects. While most of the requests came from general CPRF residents,
one particular need that was brought forward came from a business located on the campus known as
BTCO.
BTCO was effectively an income producing arm for the CPRF campus that prints physical
schematics based on digital drawings from local aerospace companies. As part of BTCO’s quality
assurance task, BTCO employees previously had to perform measurements of every print produced by
stretching over a highly calibrated light table with a handheld microscope to measure the offset of the
print from the table at one end and then comparing the offset of the print from the table at the other end.
As long as the print does not deviate by more than 20 mils down the length of the table, a print passes
inspection and can be shipped to the customer requesting the prints.
While BTCO’s role within the CPRF campus seemed solid, there was one obvious issue that
needed to be addressed for the company: their quality assurance process required able-bodied people to
do the task rather than cerebral palsy patients. BTCO requested that one of WSU’s senior design teams
propose and build a possible alternative to their current process that would allow CPRF residents to work
at BTCO to do quality assurance work. BTCO claimed that a stable job would allow a resident to become
self-sufficient and an income producing member of society. As our team looked around the room at the
ideas of our other classmates that seemed somewhat farfetched, we became immediately excited about
possibility of working on a design project that had a very real need in society. We wouldn’t have to find
an application for our project; the application was right in front of us!
When compared to the final product, our initial concept for the project looks very similar. Our
project was conceived as a dual-axis robotic gantry whose frame would be mounted onto one of BTCO’s
calibrated light tables. The gantry would house a high resolution digital microscope, allowing a user to
conduct measurements. Our final product ended up conceptually being exactly that. The only design
change that was made through the course of the project was the method that the project used to take
measurements.
Our initial prototype was conceived as a to-scale frame build from rigid electrical conduit. The
housing for the camera itself would allow for two parallel aluminum bars to pass through the center of it,
allowing the housing to be moved by a stepper motor that was fastened to one end of the housing with a
3” spool protruding out of a hole in the side of the housing. Using a dangling set of cables to send current
to the stepper motor and communication to the digital microscope, the housing would then be capable of
allowing for y-axis movement along the light table. While the camera housing is capable of moving down
the length of the parallel aluminum bars, those bars were fastened to another set of short bars
perpendicular to the longer bars and held two sets of wheels on each end that the bar/camera housing
would use to ride along the frame. Between the two sets of wheels at one end of the bar set would be
fastened a stepper motor and a junction box which would allow for the connection of the controller box to
19
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
the pair of stepper motors. Literally only the dimensions and the quality of materials has changed
throughout the history of our project.
20
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
BUSINESS VIABILITY:
As previously mentioned, the business viability of a fully-functional product is at least guaranteed
on a smaller scale. As BTCO has explicitly requested this project for industrial application and have
continued to be involved through communication along the way, our team is very confident that BTCO
would be interested in such a product if it were to be built to the quality that is desired.
Of course, the gap between our current progress and the progress necessary is somewhat large. As
every physical aspect of our design is too small, too slow, and made of insufficiently low quality
materials, a complete rebuild of the physical frame would be necessary to deliver a functional product to
BTCO. The majority of the necessary parts could be fabricated in a machine shop by professionals, and
many of the other necessary parts could be purchased and easily assembled to the frame. In short, the only
real limitation for producing a product viable for business is funding for additional work and materials.
21
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
This page intentionally left blank.
22
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
FUTURE WORK:
It should be obvious from our previous notes that most of the time out team has yet to spend
producing a viable product can be attributed to rebuilds. To produce a working product, we will need to
add the following capabilities and enhancements to the physical structure of our project:









A machined frame that can be easily attached to BTCO’s light table and allows for the removal of
the camera gantry in the case of temporary setbacks
Quality linear motion equipment (for dual-axis movement)
Two stepper motors with motor drivers capable of delivering the necessary supply current
One digital microscope with a short focal length, high resolution optics, and a considerable pixel
count
A physical joystick that would be capable of overriding the currently implemented terminal input
Better junction boxes
An embedded microcontroller
A cabling system that allows cable to move down the length of the table without bunching up as it
approaches the near side of the table
A permanent power supply
In addition, the code used to operate the machine will need to be modified to accommodate the
overriding feature of the physical joystick to be added. The code will also need to be compiled into an
executable file that can be run without requiring a Matlab license for the end user. If the microcontroller
is to be changed from an Arduino Mega to an embedded controller, the Matlab code used to control the
project will obviously need to be changed as well. Finally, since the robotic gantry is likely to be subject
to z-axis movement, it is important that the camera have digitally controlled zoom and code will have to
be written to add that functionality as well.
23
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
This page intentionally left blank.
24
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
CONTRACT and SCHEDULE:
I.
Contract:
Contract for EECS Senior Design II Fall 2013
Team Deliberate Gecko
Project RPTC
Team Deliberate Gecko intends on delivering a prototype demonstration of our Robotic
Plot Table Camera utilizing a downsized variant of last semester’s hardware and a new control,
capture, and calculation software being developed this semester.
The current project consists of five major goals:
– Build software to capture an image, identify a calibrated red square as 1” sq, and measure
the offset of black lines from the sides of the red square.
– Build software to control motion equipment from the workstation via USB.
– Complete the demonstration build utilizing current machine and present at Exploration
Place.
– Provide a BOM (Bill Of Materials) of COTS (Commercial Off The Shelf) equipment for
all hardware needed and detailed assembly instructions for the completion of the actual
machine at BTCO.
– Wrap up software developed in a user friendly GUI that will be accessible to the
employees of BTCO and deployable in a MS Windows operating environment.
These current goals may require more than one semester to realize. Therefore, Deliberate
Gecko will wrap up the project with the emphasis on the software this semester. Another team or
BTCO may need to complete final assembly. The deliverable product will not be built by this
time due to budgetary constraints.
Deliberate Gecko shall demonstrate the following at Exploration Place using the current
machine:
- Local, analog control (from last semester)
- Workstation Control
- Capture and Calculation of images
Instructors shall attempt to supply assistance and access to university resources as needed
for project completion upon request. Instructors shall take the prior semester's performance into
account during the calculation of final grades due to the uncertainty level of this project’s
ultimate outcome.
25
Deliberate Gecko
EECS Senior Design II
WSU Fall 2013
II.
Schedule:
26