Measure Phase SENIOR DESIGN TEAM 25: PALM HARVESTER

Presenters Ricardo Aleman, ME Brian Newman, ME Yuze Liu, ME David Boswell, ECE Louis-Olivier Verret, IE Bolivar Lobo, IE Gianni Alessandria, IE 2 Ricardo

Project Review 1.Original team didn’t finish robot ( Class of 2012) 2.ME Team 25 assigned to project (Class of 2014) 3.Decided against 2012 design “King Climber” 4.Brainstormed Cart with Telescoping Pole 5.Built a small mechatronic prototype 6.Developed the Mechatronic Concept 7.Replaced Mechatronic with Manual Concept (CURRENT) Palm Harvester Goal Develop an effective, efficient, and economical oil palm harvester 3 Ricardo

King Climber – 2012 Concept CAD DESIGNASSEMBLED PROTOTYPE 4 Assembled prototype was never tested Ricardo

Cart with Telescoping Pole – 2014 Concept COMPONENTS Cutting Tool (A) Telescoping Pole (B) Tree Grips (C) Cart (D) Power/ Auxiliary System (E) 5 A B D & E Oil Palm Palm Harvester R = 5ft H ≤ 40ft h = 4ft Drawing not to scale C Ricardo

Small Mechatronic Prototype $150 from Home Depot & HobbyTown Gained better understanding of functionality Gained better appreciation of project’s complexity Starting point for in-depth design 6 Ricardo

Mechatronic Concept Based on small prototype Three DOF 1 – Pitch 2 – Translation 3 – Yaw Powered by DC motors with motor drivers Risks 3 DOF = complex & expensive Mechatronics = complex & expensive Too complicated Simplified Design Manual design = 2 DOF No mechatronics Cheaper & simpler Can be built & tested by April Ricardo

Prototype 1.0 FALL SEMESTER Simple system  Design simple working system  Will cost half the budget  Manual components,  Poor ergonomics  It will be completely built and tested by January  Low risk SPRING SEMESTER Optimized system  If Prototype 1.0 is effective, optimize design  Potentially use electric winches  More ergonomic  Higher risk 8 This presentation will discuss the mechanical design of Prototype 1.0, but the ergonomics of the Prototype 2.0 Ricardo

Prototype 1.0 Overview A – Cutting Tool B – Telescoping Pole C – Tree Grips D – Cart with Legs 9 A B D C Ricardo

Cutting Tool Design 10 Brian

Cutting Tool Design In order to simplify the cutting tool, only two degrees of freedom were chosen: pitch and horizontal swivel 11 Brian

Cutting Tool Design Self-Locking Shoulder Screw Pivot Block 12 Brian

Cutting Tool Design Lazy Susan Welded Square Tubes Camera Angle Brackets 13 Brian

Cutting Tool Design Top platform swivels by pulling the attached ropes Pole saw rotates by pulling two other ropes 14 Brian

Cutting Tool Design Brian 15

Telescopin g Pole Design Brian

Telescoping Pole Design Original design called for 6”, 5”, 4”, and 3” diameter sections The 5” size is not readily available Instead, a 2” diameter section will become the smallest- sized tube Galvanized steel conduit will be used for the top section to add rigidity Thin-walled, weighs only 14 lbs The rest of the pipes will be Schedule 40 PVC 17 Brian

Telescoping Pole Design 18 6 in Diameter PVC 4 in Diameter PVC 3 in Diameter PVC 2 in Diameter Steel Brian

Telescoping Pole Design The total weight of the poles will be about 100 lbs 1/8” galvanized steel rope will be used Holds up to 1540 lbs in tension Corrosion resistant 2” diameter pulleys will be used, supported by L brackets These L brackets also act as stoppers, so the poles only retract to their designed heights Rope is attached to inner pole with small L bracket 19 Brian

Telescoping Pole Design High density poly-ethylene bars will be used to fill the gaps between poles This makes the structure much more rigid Outer Pole Inner Pole HDPE Bar 20 Brian

Telescoping Pole Design 21 Pivot Block Self-locking shoulder screw The pole can fold down Rotate with the pivot block The pole can translate through the hole of the pivot block Alignment Block

Telescoping Pole Design 22 Brian

Tree Grips 23 Ricardo

Need for Tree Grips System is 40 ft tall Total weight is ~200lbs About 100lbs is vertical System can tip over 3 out of 4 tubes are PVC PVC bending stress isn’t safe if the system is not absolutely rigid The PVC can break Need to design something that stabilizes the system to prevent tipping over and/or PVC fracture 24 Ricardo

Tree Grip Secures Cart to Tree 25 Ricardo

Tree Grip Design 26 Grips Close Pull the rope Close Procedure 1.Pull the rope 2.The grips close Ricardo

Tree Grip Materials 27 ¼” x 1” Aluminum bars (6 – 12in) 1” x 1” 80/20 Aluminum (4ft) Folding Bracket 2” OD Pulley Fixed pin 5” Spring Sliding Rope Attachment pin Ricardo

Tree Grip Budget 28 2 Tree Grips come out to $116 total Ricardo

Cart Design 29 Yuze

Need for Cart Modify a premade cart Large, soft wheels are mounted on the extension Two winches are fixed on the side of the cart Monitors will be put on the cart 30 Yuze

Cart Materials 31 Swivel Caster Rigid Caster Winch Monitor Modified cart Perforated Tube Yuze

Cart 32 Modified a pre made cart Edsal 24 in. W x 36 in. D x 32 in. H Steel Service Cart $80.95 Yuze

Cart Design-Extended legs 33 Extended legs with the maximum of length 3 ft and the minimum is 1.5ft Use perforated tube and lock pins to adjust the length Easy to transport and stable to use Detail: Perforated Tube (size:1 1/2" 6ft) $29.23 Perforated Tube (size:1 3/4" 6ft) $30.56 Locking pins $6.02 Yuze

Cart Design - Wheels 34 The two front wheels are swivel caster, easy to turn The two rear wheels are rigid, increase stability. Details: 10 In. Pneumatic Caster 10 In. Pneumatic Swivel Caster Yuze

Cart Budget 35 Yuze

Power Configuratio n David 36

Power Draw On-board Battery Monitor (~8W) Camera (~1W) Batter Pack Pole Saw (100 cuts) David 37

Power Supply 12VDC battery and charger $ Amp Hour (84W-hr) 9.5 hours of use PROS Easy to replace No startup time 12VDC is compatible with auto electronics (car, camera) Quiet CONS Has to be recharged Runs out quicker than generator Rechargeable-Battery- Charger/dp/B002NYN7EM David 38

Camera & Monitor Durable $30.40 Requires waterproofing case 12VDC 8W Waterproof and durable Easy setup $13.64 Outputs video via RCA cable Waterproof 12VDC 60mA (.72W) David 39

Wiring Supply power from battery to camera 100 ft copper wires $20.00 Supply image from camera to monitor 50 ft RCA cables $11.49 David 40

Waterproofing Hose prevents tangling and waterproofs wires $ ft long, about 0.3” diameter Fits all power cables inside Liam Acrylic case with sealant Stores monitor Waterproof David 41

Example Pole Saw Black and Decker 20V Max Lithium Ion Pole Pruning Saw $159 at Home Depot Up to 100 cuts Cuts up to 6” thick branches 8” long cutting bar Pole can extend 6.5 – 10ft Includes battery & charger 42 David

Pole Saw Configuration Pole Saw will be cut in half Pushbutton used to activate cutting tool Wires will be used for connections David 43

Power Configuration 44

Parts List: Power and Electrical System PartQty Price Per Unit TotalSerial NumberDistributorComment 50-ft Blue Coil Hose1$ AmazonWaterproof cables Waterproof Camera1$13.33 B005CTKYB4Amazon Monitor1$29.96 B007SLDF7OAmazon 12V Battery and Charger 1$32.99 B002NYN7EMAmazonFor camera 50 ft Video Cable1$11.49 B006IVGL80Amazon 100 ft Red Copper Wire1$ K932McMaster Supply power to cutting tool and camera 100 ft Black Copper Wire 1$ K931McMaster Supply power to cutting tool and camera Inline Hand Held Switch 1$ MCM Electronics Activate pole saw Total $ David 45

Top Risks – Prototype Thin Sheet Metal on Cart 2. Pole Stresses 3. System Weight 4. Concentrated stress on Pivot Bolts 5. Level Ground Ricardo 46

Risk 1: Thin Sheet Metal Cart Simplified analysis Thin stainless steel 150lb Load area is 10x16” patch Min. FOS is 6.55 Max deformation is 0.06" Cart handles 500lbs uniformly distributed, so keep an eye on concentrated stresses Ricardo 47

Risk 2: 40ft of Telescoping Pole Fixture stabilizes but concentrates stress on top tube With Fixture VS. No Fixture Ricardo 48

Risk 3: System Weight Total weight is 227lb  Can lower by optimizing weight of heaviest parts. Ricardo 49

Risk 4: Concentrated Pivot Stresses Do not raise pole if ground isn’t level Pivot Screw Ricardo 50

Risk 5: Non-Level Ground Need to ensure horizontal plane is truly horizontal Use Bullseye level If not level, be careful $12.10 Do not raise pole if ground isn’t level Ricardo 51

Industrial Aspects 52

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Mini Prototype VS Final Prototype 58 Louis

Project Budget 59 Louis

Updated Human-Machine Interface Focus on simplicity by selecting hand operated motions. Increased human labor. Overall analysis of the ergonomic risks involved with each task Bolivar 60

Setup of the Pole Heavy Solutions Automate task More than one operator Bolivar 61

Rolling the Cart Inputs: Floor to hand height: Shoulder level Frequency: 1/2 min. Push distance Inclination or terrain issues Output Initial force allowed: 31 lbs. < x < 48 lbs. Sustained force allowed: 9 lbs. < x < 31 lbs. Bolivar 62

Cranks as Control Activation Mechanism Gripping the tree Extending the pole Bolivar 63

Extending the Pole Handle dimensions Length 3.0 – 5, 3.75 preferred Diameter 1.0 – 1.5, 1.0 preferred Turning radius If below 100 rpm Above 100 rpm 5.0 – 9.0, 2.5 preferred Bolivar 64

Gripping the Tree Handle dimensions: Length 1 – 3, 1.5 preferred Diameter.4 –.625,.5 preferred Turning radius: If below 100 rpm (for this crank it most likely will be under 100 rpm) , 3.0 preferred Bolivar 65

Ropes as Control Activation Mechanism Rotate the device Cut the fruit Inputs: Distance of pull: 7 feet Frequency: 1/6s Floor to hand height: elbow level Output: Maximum force recommended Initial Force: 35 lbs. Sustained force: 15 lbs. Bolivar 66

Prototype 1.0: Feasible Prototype 2.0: Ergonomic Bolivar 67

Strengths Simple Safer than conventional climbing Portable Waterproof Easy to use/low training costs Environmentally harmless Low power consumption Economical Opportunities Rising demand for palm oil Increasing concern for the safety of human personnel Lack of competition Threats Cutting tools and complex motions at large heights Human error Weaknesses Total process takes longer than conventional climbing operations Stability concerns Still lacking fail safe system Intense human labor required Gianni 68

Fall Schedule 69 Ricardo

Spring Schedule 70 Ricardo

Summary Cart with Pole instead of tree-climbing robot Designed manual prototype (1.0) Completing procurement next week If Prototype 1.0 works, make 2.0 later 71 Ricardo Prototype 1.0

Questions? 72