1. Human Extraction Rescue Robot Material Handling Methodology & Proof-of-Concept Prototype Matthew P. King Erin B. Rapacki In partnership with… ADVISORS Prof. Tom Cullinane Prof. Greg Kowalski

2. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Problem Statement Perform a Robotic Extraction of a 200lb Manikin ATHENA Proof-of-Concept Payload

3. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University iRobot WARRIOR Robotic Mobility Platform Length Length –40 Inches Width Width –29 Inches Height Height –18 Inches (stowed) Distance: Front wheels Distance: Front wheels –24 Inches Weight Weight –Vehicle weight: 250lbs 250lbs Onboard power & communication for tele- operation Onboard power & communication for tele- operation Payload Surface Tilts Payload Surface Tilts –Rotates upward around wheel hubs Center of Rotation Tilts Upward 24” Span

4. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Rescue Randy 200lb Manikin Height Height –73 Inches Width Width –Shoulders 23 Inches 23 Inches Head dimensions Head dimensions –Diameter 7 Inches 7 Inches –Top of head to shoulders 10 Inches 10 Inches Weight Weight 200lbs 200lbs

5. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Extraction Scenario Flat Back & Face Up; Indoor Setting Established base-line scenario Established base-line scenario –Rescue Randy Flat back Flat back Face up Face up –Environment Indoor setting Indoor setting Smooth floor Smooth floor –Hard flooring –Office carpet Proof-of-concept payload Proof-of-concept payload –Mechanically functional system 200lb manikin 200lb manikin

6. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Design Considerations iRobot WARRIOR & Rescue Randy Extract manikin in a head first orientation Extract manikin in a head first orientation –Utilize WARRIOR’s tilt capabilities Torque and loading specifications Torque and loading specifications –Manikin’s physical dimensions Center of Rotation Tilts Upward 24” Span

7. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Material Handling Methodology Outline Head-First; Use Tilt Head-first extraction Head-first extraction –Use shoulders to initiate lift 23” span to manipulate 23” span to manipulate Create access point under the torso Create access point under the torso –Extend platform underneath the back Transfer manikin’s mass to platform surface Transfer manikin’s mass to platform surface –Rescue Randy conveyed up WARRIOR platform

8. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Prototype Design Head & Shoulder Lift Linear drive delivers head support and effecting forks Linear drive delivers head support and effecting forks –Head support cushions bias forward –Cushions articulate around head –Effecting forks initiate lift by propping the shoulders off the ground 3 54 1 2

9. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Prototype Design Convey Rescue Randy up Payload Extend platform under torso Extend platform under torso –Utilizing access point created by shoulder lift –Driven by rack & pinion system Unfurl conveyor belt under torso Unfurl conveyor belt under torso –Manikin’s mass on belting –Pull belting up platform Via linear drive Via linear drive –Belting stored under payload Spring-loaded roller Spring-loaded roller 8 7 6

10. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Prototype Design Conveyor Function Conveyor belting (yellow line) loaded onto a spring roller at the beginning of extraction Conveyor belting (yellow line) unfurled 80” at the completion of an extraction

11. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Extraction Description 123 5 4 876

12. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Component Definition Four Sub-Assemblies Head Support / Forks Motors & Linear Drives Spatula Litter

13. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Litter Design Components & Structural Analysis: 200lbs Components Components –0.5” Aluminum Side Rails Cut-outs for weight reduction Cut-outs for weight reduction –0.5” Aluminum Base Rails Interface with WARRIOR Interface with WARRIOR –Top Panel 3/16” Aluminum Sheet 3/16” Aluminum Sheet Analysis Analysis –Lowest safety factor: 4.3 Non-uniform loading on cantilevered portion Non-uniform loading on cantilevered portion Front Litter Support Analysis: Stress and Deformation Rear Litter Support Stress Analysis

14. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Spatula Design Components & Structural Analysis: 200lbs Components Components –0.5” Aluminum Rails –3/16” Aluminum Platform –Spatula-Conveyor Interface Fixed at end of spatula Fixed at end of spatula Drawer Slide Capacity: Drawer Slide Capacity: –280lbs at 24” span Analysis Analysis –Lowest safety factor: 3.6 Non-uniform loading on tip of front rail Non-uniform loading on tip of front rail Front-Rail DeformationFront-Spatula Stress Analysis

15. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Head Support & Forks Bio-metrics & Structural Analysis: 200lbs Head Cushions Head Cushions –Head cushion rails rest on forks Spring Biasing Arm Spring Biasing Arm –Provide passive head support and biasing along forks Fork Design Fork Design –Frelon Slides & Blocks –3” Wide, 1.5” Thick Analysis Analysis –Safety factor: 3.2 Single fork supporting 200 lb. load at end Single fork supporting 200 lb. load at end Forks Head Cushions Spring Biasing Arm Fork Deformation Fork Stress Analysis

16. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Linear Drive Assemblies Central Lead Screw and Spatula Rack 0.5” precision lead screw 0.5” precision lead screw –50 in-lb torque Spider coupling Spider coupling –Lead screw–to–motor shaft –misalignment compensation Versa-mount rail and block Versa-mount rail and block –Buckling resistance Spatula extension and retraction Spatula extension and retraction –Rack and pinion, ½” face width –Under mount on spatula surface

17. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Motor and Control Design Pulse width modulating RC controller and DC gear motors Vantec speed controller Vantec speed controller –RC to maintain tele-operation when mounted to WARRIOR –Dual 20 amp continuous channels –Pulse width modulation 24 vdc gear motor 24 vdc gear motor –Torque to 100 in-lbs at 19.12 amps Independent Power Supply Independent Power Supply –Dual 12 vdc motorcycle batteries –Provide necessary instantaneous current source

18. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Final Deliverable Payload Prototype Demonstrates component functionality Demonstrates component functionality –Loading and actuation Drive systems and structure Drive systems and structure Functional mechanical system Functional mechanical system –Load capacity for 200 lb manikin –Motor specifications for control integration

19. ATHENA: Final Report 17 April 2007 Matt King & Erin Rapacki Northeastern University Projection Design Improvements At iRobot At iRobot –Integrate motors and control system –Demonstrate extraction methodology with WARRIOR Long Term Long Term –Weight reduction: Custom slide system for spatula Custom slide system for spatula Light materials Light materials –Titanium –Delrin –Aluminum Super Alloys –Modify extraction process according to testing Additional features, details, & appendages Additional features, details, & appendages –Extraction in tighter areas

20. Human Extraction Rescue Robot Material Handling Methodology & Proof-of-Concept Prototype Final Report QUESTIONS?