Senior Design Team 5: Final Presentation May 9, 2009

Outline Team & Project Introduction Design Process Obstacles Prototype Design Conclusion

Team Introduction Ryan Mejeur (EE) David VanKampen (EE)David VandeBunte (EE) Matt Lubbers (EE)

Inspiration Service-oriented Design automated system Robotics/ motor control

Project Overview Traditional Warehouses + Robots Automated Storage & Retrieval Systems (AS/RS) - Built w/ warehouse STORBOT

Project Scope Evolution Beginning Implement RTOS on open core Exhibit small amount of controls Vastly coding oriented End More mechanical Limited real-time capabilities Full Business Plan Bottom-up robot system design

System Architecture

Host PC sends command PC Sends Command FPGA decodes and receives command FPGA signals wheel motors to advance FPGA Decodes Robot Moves At proper shelf, truck stops, rotator starts Arm Rotation After rotation, the elevator raises the arm Elevator Up Once correct height is reached, the forearm advances Forearm Extension Upon contact with the product, a vacuum is created, and the product is pulled back Vacuum Enabled Once the product is over the tray, vacuum is released, and arm is lowered Elevator Down Robot Workflow

From Concept… Redesigned over Spring Break Addressed specific issues Visual conception drawn in Sketch-up … To Reality New Design Taller tower Longer arm Shelf Motor Linear bearings

Design Process Task breakdown o Dave VandeBunte – FPGA o Dave VanKampen – Sensors o Matt – Elevator o Ryan – Robot Base Working in parallel Late nights and early mornings

Testing and Performance Tests “Agile” development style – Incremental tests – Feature by feature Bench tests for mechanics – Vacuum – Elevator – Arm – Wheel motors Performance Calibration – Setting Elevator Heights – Sizing of Suction Cups Know when to call it quits – Wheel steppers – Turn-disc – PCBs vs. breadboards

Obstacles Elevator limitations – Small range of motion – Structure too weak Turn-disc inaccuracy – Error magnification – Poor drive system Stepper Controller inconsistency – Voltage stepper failure – Development board damage

Solutions and Tradeoffs Redesign elevator – Linear bearings – Improved structural design Fix Turn-disc – Bolt in place – Loss in range of motion Controller opto-isolation – Far too much time & too many gray hairs – No level translation necessary

Prototype Design Base Design Elevator/Arm Design

Base Design Base Design Elevator/Arm Design Power Supplies Stepper Motor Controllers Wheel Stepper Motors Turn-disc Stepper Motor H-Bridge and Relay Development Board Powertrain

Arm Design Bearings Rack and Pinion Adjustability

Elevator Design Elevator Assembly Arm Assembly Plate Assembly Tower Assembly Turn-disc Assembly Vacuum Pump Distance Sensor

Prototype -- Analog Sensors Reflectance Encoders Ultrasonic Distance IR Proximity Vacuum Peripheral Circuits High current H-bridges Voltage steppers Opto-isolation Transistor switches

Prototype -- Digital Functional GUI Front end for Serial Port Inventory Management System Successful coordination with CS student

Prototype -- Digital

Final Prototype

Conclusions Success Heavier Box 15 to 30 lbs Larger Dimensions12 “ to 18” Lessons learned Robotics Field Debugging Potential Development Expandability Patent follow-up Debug turn-disc

Acknowledgements Phil Jasperse – Shop Attendant Josh Vroom – CS Student Chuck Holwerda – Electronics Professor Bossemeyer & Calvin Faculty DornerWorks Xilinx University Program Ben Lubbers and Jonathan Mejeur

Questions?