Use or disclosure of document data is subject to the restrictions on the title pagePage 1 © 2014 Carnegie Robotics LLC. MARSUPIAL Detailed Design Review Carnegie Robotics LLC. #10 40th Street Pittsburgh, PA Jared Raby Nico Gallardo Chris Griffin Sean Greenslade Wesly Rice

Use or disclosure of document data is subject to the restrictions on the title pagePage 2 © 2014 Carnegie Robotics LLC. Agenda Introduction Systems Detailed Design  Tracks/Suspension  Wireless Node Payload  Wireless Node Deployment  Electrical Systems Test Plans Risks MSD II Schedule Questions

Use or disclosure of document data is subject to the restrictions on the title pagePage 3 © 2014 Carnegie Robotics LLC. Introduction MARSUPIAL Tracked Rover for CRL Scope  Suspended Track System  Wireless Node System  Electrical Systems Deliverables  Suspended Track System  Mesh Network Payload

Use or disclosure of document data is subject to the restrictions on the title pagePage 4 © 2014 Carnegie Robotics LLC. TRACKS AND SUSPENSION Wes

Use or disclosure of document data is subject to the restrictions on the title pagePage 5 © 2014 Carnegie Robotics LLC. Tracked Suspension System Suspension  Rugged Against Impact Shock  Various Environmental Areas  Climb Obstacles  Self Contained –IP Rated Seals Drive-Train  Off The Shelf Motors  Meet Speed And Torque Requirements –Simple Gearing  Integrated Electronics –Odometry

Use or disclosure of document data is subject to the restrictions on the title pagePage 6 © 2014 Carnegie Robotics LLC. Tracked Suspension System Suspension Design  Improved Christie  Volute Emphasis Maintainable  2 SHCS Sizes  Retaining Rings  Sealed Bearings  Sealed Gas Springs

Use or disclosure of document data is subject to the restrictions on the title pagePage 7 © 2014 Carnegie Robotics LLC. Tracked Suspension System

Use or disclosure of document data is subject to the restrictions on the title pagePage 8 © 2014 Carnegie Robotics LLC. Tracked Suspension System

Use or disclosure of document data is subject to the restrictions on the title pagePage 9 © 2014 Carnegie Robotics LLC. Tracked Suspension System Drive-Train  Required Speed –Min Of 5mph On Level Ground  Require Torque –To Move 150 lbs Of Robot And Payload  Off The Shelf Motor –Reduce Overall Price –Maxon ec60 Flat  Realistic Gear Train –14.0:1 –Planetary –Small Package

Use or disclosure of document data is subject to the restrictions on the title pagePage 10 © 2014 Carnegie Robotics LLC. Tracked Suspension System Risk Assessment

Use or disclosure of document data is subject to the restrictions on the title pagePage 11 © 2014 Carnegie Robotics LLC. Tracked Suspension System Upper Christie Arm  Bronze Bearings  Retaining Rings  Ball End Spring Joints Materials  6061-T6 Alum  914 Stainless 950  Igus Flange Bearings

Use or disclosure of document data is subject to the restrictions on the title pagePage 12 © 2014 Carnegie Robotics LLC. Tracked Suspension System Lower Christie Arm  Bronze Bearings  Press Fit Axel  Ball Bearings for Tensioning Wheels  Ball End Spring Joints Materials  6061-T6 Alum  914 Stainless 950

Use or disclosure of document data is subject to the restrictions on the title pagePage 13 © 2014 Carnegie Robotics LLC. Tracked Suspension System Dedicated Tensioner  Bronze Bearings  Press Fit Axel  Ball Bearings for Tensioning Wheels  Clock Spring For Preload

Use or disclosure of document data is subject to the restrictions on the title pagePage 14 © 2014 Carnegie Robotics LLC. Tracked Suspension System Non-driven Wheel Top Assembly  Ball Bearings –Preload  Grease Seal  O-Rings  Stock Pulley  Magnetic Encoder –Odometry

Use or disclosure of document data is subject to the restrictions on the title pagePage 15 © 2014 Carnegie Robotics LLC. Tracked Suspension System Motor Assembly  Sealed  Planetary Gearbox  Parking Brake

Use or disclosure of document data is subject to the restrictions on the title pagePage 16 © 2014 Carnegie Robotics LLC. Tracked Suspension System Tracks  Proper materials –Polyurethane  Outdoor resistant –Steel Banded  Ease to install and remove –Release Tensioning Wheels

Use or disclosure of document data is subject to the restrictions on the title pagePage 17 © 2014 Carnegie Robotics LLC. Tracked Suspension System Ordering Process  Major Design Review With CRL May 25th Through June 6 th  Request Quotes On June 6 th  Place Orders June 10th With 8-10 Week Lead Times  Receive Parts In Pittsburgh By August 20th At Latest Pre-Assembly Process  Inspect Parts Upon Arrival  Aluminum Parts Sent Out For Alodine  All Parts Are Powder Coated Assembly Process  Insert All Threaded Inserts, Press All Bearings  Build Sub Assemblies –Tensioner, Motor, Gearbox, Lower Christies, Upper Christies, Non-Driven Wheel  Attach Side Hull Plates to Chassis  Attach Sub Assemblies to Hull Plates

Use or disclosure of document data is subject to the restrictions on the title pagePage 18 © 2014 Carnegie Robotics LLC. Tracked Suspension System BOM

Use or disclosure of document data is subject to the restrictions on the title pagePage 19 © 2014 Carnegie Robotics LLC. Tracked Suspension System BOM 2

Use or disclosure of document data is subject to the restrictions on the title pagePage 20 © 2014 Carnegie Robotics LLC. Tracked Suspension System BOM 3

Use or disclosure of document data is subject to the restrictions on the title pagePage 21 © 2014 Carnegie Robotics LLC. WIRELESS NODE PAYLOAD Sean

Use or disclosure of document data is subject to the restrictions on the title pagePage 22 © 2014 Carnegie Robotics LLC. Wireless Node Payload Droppable Node  OLinuXino – 575 MHz ARM Core –Running Arch Linux with B.A.T.M.A.N. wireless mesh protocol –USB Wi/Fi adapter –Buck converter –Li-on battery providing upwards of 6 hours of runtime Current Prototype  3D printed shell  Off-the-shelf antenna

Use or disclosure of document data is subject to the restrictions on the title pagePage 23 © 2014 Carnegie Robotics LLC. Wireless Node Payload Block Diagram

Use or disclosure of document data is subject to the restrictions on the title pagePage 24 © 2014 Carnegie Robotics LLC. Wireless Mesh Node BOM IndexComponentCostDistributorManufacturer Manufacturer Part NumberQty. Syste m Price Est. 1 5 Volt Buck Converter$6.71Mouser RECOM PowerR Puck$ Single Board Computer $32.9 5MouserOlimex Ltd. IMX233-OLINUXINO- NANO8Puck$ WLAN USB Adapter $ Amazon LLCTP-LinkTP-LINK TL-WN722N8Puck$ Li-Ion Battery$3.39 Battery Space PL C24Puck$ Battery Protection Board$5.87 Battery Space PCB-LiS3A48Puck$46.96 Total$560.24

Use or disclosure of document data is subject to the restrictions on the title pagePage 25 © 2014 Carnegie Robotics LLC. WIRELESS NODE DEPLOYMENT Jared

Use or disclosure of document data is subject to the restrictions on the title pagePage 26 © 2014 Carnegie Robotics LLC. Wireless Node Deployment System Needs to readily deploy the node while keeping in place during high impact moments  High holding strength  Ability to drop the puck easily Deployment system should be isolated from the outside to comply with IP standards  Dust / water prevention  Short circuit protection Magnetic holding system developed  Magnetic arm

Use or disclosure of document data is subject to the restrictions on the title pagePage 27 © 2014 Carnegie Robotics LLC. Wireless Node Deployment System CAD

Use or disclosure of document data is subject to the restrictions on the title pagePage 28 © 2014 Carnegie Robotics LLC. Wireless Node Deployment Schematic

Use or disclosure of document data is subject to the restrictions on the title pagePage 29 © 2014 Carnegie Robotics LLC. Wireless Node Deployment System PCB

Use or disclosure of document data is subject to the restrictions on the title pagePage 30 © 2014 Carnegie Robotics LLC. Wireless Node Deployment System BOM IndexComponentCostDistributorManufacturer Manufacturer Part NumberQty. Price Est. 1ALEL 1uF 50V$0.23MouserNichiconUVR1H010MDD1TD MLCC 0.1uF 50V X7R$0.10MouserKemetC0603C104K5RACTU1$ ISP Connection Headers$0.54MouserMolex $0.54 4Servo Connections$0.19MouserMolex $1.88 5Payload Microcontroller$1.30MouserAtmelATTINY2313A-SUR1$ TTL to RS232 Converter$3.84Mouser Maxim IntegratedMAX232ACSE+1$ MHz Crystal$0.49MouserVishayXT9SNLANA12M1$ pF capacitor$0.20DigikeyYageoCC0402JRNPO9BN2202$0.40 9Magnets$2.43KJ Magnetics D782$ Servos$3.56Hobby King HK $3.56 Total $17.12

Use or disclosure of document data is subject to the restrictions on the title pagePage 31 © 2014 Carnegie Robotics LLC. POWER MANAGEMENT AND DISTRIBUTION Nico and Chris

Use or disclosure of document data is subject to the restrictions on the title pagePage 32 © 2014 Carnegie Robotics LLC. Electrical Diagram

Use or disclosure of document data is subject to the restrictions on the title pagePage 33 © 2014 Carnegie Robotics LLC. Electrical Diagram – Batteries

Use or disclosure of document data is subject to the restrictions on the title pagePage 34 © 2014 Carnegie Robotics LLC. Electrical Diagram – Power Train

Use or disclosure of document data is subject to the restrictions on the title pagePage 35 © 2014 Carnegie Robotics LLC. Electrical Diagram – Peripherals

Use or disclosure of document data is subject to the restrictions on the title pagePage 36 © 2014 Carnegie Robotics LLC. Power Budget DeviceRail Voltage (V)Power (W) Efficiency (converters, drivers, etc) Motor # Motor # Motor Controller # Motor Controller # Main Computer510 Power Management uC55.00E-02 Payload (Pucks) Payload (Dispenser)510 Lighting2440 Camera51.2 Ethernet Switch55 Level Shifter51.44 E-Stop Comm Receiver2410 IMU51 WLAN Radio55 5V DC-DC V DC-DC RailPower (W)Current (A) 24V V V

Use or disclosure of document data is subject to the restrictions on the title pagePage 37 © 2014 Carnegie Robotics LLC. Power Management Schematic

Use or disclosure of document data is subject to the restrictions on the title pagePage 38 © 2014 Carnegie Robotics LLC. Power Management Schematic (cont.) Two 24V Lithium Ion batteries provide 2kW of power (max) All current is sourced through pin 5 of the current sensor

Use or disclosure of document data is subject to the restrictions on the title pagePage 39 © 2014 Carnegie Robotics LLC. Power Management Schematic (cont.)

Use or disclosure of document data is subject to the restrictions on the title pagePage 40 © 2014 Carnegie Robotics LLC. Power Management Schematic (cont.) Low current will be passed through the circuit → Low power dissipation Potentiometer is used to tune the divider

Use or disclosure of document data is subject to the restrictions on the title pagePage 41 © 2014 Carnegie Robotics LLC. Power Management Schematic (cont.)

Use or disclosure of document data is subject to the restrictions on the title pagePage 42 © 2014 Carnegie Robotics LLC. Power Management Schematic (cont.) Rail# of outputs 24Vu 5 5V 8 3.3V3 GNF20 TX1 RX1

Use or disclosure of document data is subject to the restrictions on the title pagePage 43 © 2014 Carnegie Robotics LLC. Power Management Pin Allocations ATMEGA328Serial CommunicationISPSamplingCrystalTotalAnalogDigital Input Output1 110

Use or disclosure of document data is subject to the restrictions on the title pagePage 44 © 2014 Carnegie Robotics LLC. Power Management Flowchart

Use or disclosure of document data is subject to the restrictions on the title pagePage 45 © 2014 Carnegie Robotics LLC. Wire Routing Diagram

Use or disclosure of document data is subject to the restrictions on the title pagePage 46 © 2014 Carnegie Robotics LLC. ROS Communication Diagram

Use or disclosure of document data is subject to the restrictions on the title pagePage 47 © 2014 Carnegie Robotics LLC. Electrical BOM Inde xComponent Ind. Price Estimat eManufacturer Manufacturer Part NumberQty.Function Price Est. 1ATMega328$3.74ATMELATMEGA328-PW1Power management Control$ MHz Crystal$0.81ECS Inc.ECS X1Crystal for ATMega328$ pF capacitor$0.20Yageo CC0402JRNPO9BN2 202Caps for Crystal$ k resistor$0.20Vishay PR JR5 001Resistor for ATMega328$ pin header$0.503M AR1Programming header for ATMega$0.50 6Current Sensor$7.26 Allegro Microsystems LLC ACS770LCB-50B- PFF-T1 Sense the battery current and supply that as a voltage input to ATMega$ uF Capacitor$0.10Paiyo YudenEMK105B7104KV-F1Caps for current sensing$ V DC-DC$36.68Murata UWS-12/4.5-Q48NM- C1Regulates 24V to 12V$ V DC-DC$36.68MurataUWS-5/10-Q48NM-C1Regulates 24V to 5V$ V Linear Reg.$1.61TILM2937ET-3.3/NOPB1Regulates 5V TO 3.3V$ uF Capacitor$0.10Paiyo YudenTMK105B7104KV-F1Cap for 3.3V regulator$ uF Capacitor$0.16Yageo CC0805ZKY5V6BD10 61Cap for 3.3V regulator$ Trimmer Potentiometer (0- 2.2k)$2.31Bournes Inc3296W-1-222LF1 Resistor for resistive divider for battery level$ k resistor$0.20Vishay PR JR5 001 Resistor for resistive divider for battery level$ uF Capacitor$0.10Paiyo YudenTMK105B7104KV-F1Cap output of resistive divider$ Circuit breaker$5.23TE ConnectivityW58-XB1A4A-301Circuit breaker$ Power Switch$25.64NKK SwitchesS822D1Power switch$ nF cap$0.10KemetC0402C103K4RACTU1output cap for current sensing$ k resistor$0.10YageoRC0603JR-074K7L1resistor for curren sensing$0.10 Total Cost$121.92

Use or disclosure of document data is subject to the restrictions on the title pagePage 48 © 2014 Carnegie Robotics LLC. Misc. Electrical BOM

Use or disclosure of document data is subject to the restrictions on the title pagePage 49 © 2014 Carnegie Robotics LLC. Systems Total Costs

Use or disclosure of document data is subject to the restrictions on the title pagePage 50 © 2014 Carnegie Robotics LLC. Test Plans IndexSystem/SubsystemSubsystemFunction to be tested Engineering Req.Customer Req. 1CommunicationsPucksData transfer rateE6C5 2Mechanical/Electrical Motor Control Drive Train SuspensionPlatform speedE7C1 3Mechanical/Electrical Motor Control Drive Train SuspensionMax incline capabilitiesE12C4 4Mechanical/Electrical Motor Control Drive Train SuspensionStair climbingE13C4 5Mechanical/Electrical Motor Control Drive Train SuspensionOvercoming obstaclesE15C4 6Mechanical Drive Train Suspension ChassisDurability (shock test)E16C6 7ElectricalPower ManagementBattery Life (runtime)E17C1 8CommunicationsPucksCommunication rangeE18C5 9ElectricalCPUComputational PowerE19C7 10ElectricalPower ManagementVoltage Level lines (proper voltage/current) 11CommunicationsPucksObstructed LOS communication/Mesh reliabilityE20C10 12 Electrical/Communication sPucks/User InterfaceRemote viewing capabilityE10, E11C9 13Entire System Follows industry and environmental safety standardsE3, E4C3 14PayloadCommunications Payload can be removed to allow the use of a different payloadE2C2 15Entire System Max payload weightE8C2 16Mechanical Suspension Driver TrainGround pressure exerted by vehicleE15C4 17Entire System/Mechanical Overall size/form factorE9C8 18Entire System Mean time between failuresE1C11 19Entire System Weight (no Payload)E5C1

Use or disclosure of document data is subject to the restrictions on the title pagePage 51 © 2014 Carnegie Robotics LLC. Tests Descriptions

Use or disclosure of document data is subject to the restrictions on the title pagePage 52 © 2014 Carnegie Robotics LLC. RISKS

Use or disclosure of document data is subject to the restrictions on the title pagePage 53 © 2014 Carnegie Robotics LLC. System Risks RiskSeverity Occurrence ProbabilityMitigationOwner 1 Staffing/engineering ability41 Consultation with advisor/customer Scale back of scopeNico 2Budget51 Consultation with advisor/customer Scale back of scopeWes 3Machine setbacks31Plenty of lead timeWes 4Shipping setbacks31Plenty of lead timeNico 5Part setbacks31Plenty of lead timeJared 6 Incorrect Engineering Analysis 23 Thorough verification of analysis Per subsystem 7Ordering errors33Thorough verification of BOMNico 8 Catastrophic prototype failure51 Proof of concepts Small scale tests before large scale testsChris 9Time constraints24 Consultation with advisor/customer Scale back of scopeJared 10Hardware failure34 Thorough design verification Spare componentsChris 11Mechanical failure34 Thorough design verification Spare componentsWes 12Software failure34 Thorough design verification Spare componentsSean 13Environmental factors15Review weather conditionsJared 14Technological limits31Review current technologiesSean

Use or disclosure of document data is subject to the restrictions on the title pagePage 54 © 2014 Carnegie Robotics LLC. Mechanical Risks RiskSeverity Occurrence ProbabilityMitigationOwner 1 Unstable control of the robot while it's hanging from straps connected to mini-crane5 0 Consultation with advisor/customer Scale back of scope Wes 2Module being dropped 5 2 Reinforced chassis and shock absorption Wes 4 Lose control of vehicle while it's descending from the ramp5 1 Manual brakes/emergency brakes Limited/no power to the motors -> -> "coasting function" or clutch Wes 4Limited slip to turn5 3 Make sure motors are powerful enough to cause slipping Wes

Use or disclosure of document data is subject to the restrictions on the title pagePage 55 © 2014 Carnegie Robotics LLC. Electrical Risks RiskSeverity Occurrence ProbabilityMitigationOwner 1 Visual inspection of robot is not adequate in identifying all malfunctions 5 2 Perform electrical self tests to identify other malfunctions Nico 2Battery short circuits 5 1 Fuse to break circuit Chris 3Emergency stop malfunction 51 Rigorous testing Chris 4Electrical noise in the system41 Proper signal conditioning and isolation Nico 5Packet loss5 5Apply failsafe Sean 6Lighting malfunction2 1 Infrared / additional backup Jared 7Faulty IMU readings41 redundant IMU Jared

Use or disclosure of document data is subject to the restrictions on the title pagePage 56 © 2014 Carnegie Robotics LLC. Software Risks RiskSeverity Occurrence ProbabilityMitigationOwner 1Packet loss5 5Apply software failsafe Sean / Jared 2 Wheel slippage causes bad odometry readings3 4 Use GPS / Inertial sensors to correct odometry readings Jared 3 Poor / Unavailable GPS connectivity3 3 Fall back on inertial sensors / odometry alone Jared / Sean 4Faulty IMU readings41 redundant IMU Jared 5Unstable control loop5 1 Vigorous control loop testingNico

Use or disclosure of document data is subject to the restrictions on the title pagePage 57 © 2014 Carnegie Robotics LLC. Safety Risks RiskSeverity Occurrence ProbabilityMitigationOwner 1 Weight consideration when lifting the robot5 1 >1 person is used to lift the robot Chris 2 Unstable control of the robot while it's it's hanging from straps connected to mini- crane5 1 There needs to be 3 hook points in order to safely move the robot using a crane Wes 3Safety to personnel53 Needs to meet military safety standard MIL 883E Chris 4 Lose control of vehicle while it's descending from the ramp4 1 Manual brakes/emergency brakes Limited/no power to the motors -> -> "coasting function" or clutch Wes

Use or disclosure of document data is subject to the restrictions on the title pagePage 58 © 2014 Carnegie Robotics LLC. Schedule

Use or disclosure of document data is subject to the restrictions on the title pagePage 59 © 2014 Carnegie Robotics LLC. Questions