1. 02.22.08 RP1 1kg Motor Module, First Generation P08208 – Mechanical Design P08205 – Wireless & PWM Motor Controller MSD I 20072

2. 02.22.08 WHAT IS A MOTOR MODULE ? DRIVE MODULAR MOUNTING STEER aka “ MM”

3. 02.22.08 1kg 10kg 100kg OFF THE SHELF MOTOR MODULES

4. 02.22.08 RP100 ( Wired ) RP10 ( Wired ) RP1 Sister projects! RP10 Redesign

5. 02.22.08 RP10 Redesign RP1 Wireless! Robust! Autonomous! Smaller! Lighter!

6. 02.22.08 ORGANIZATION BREAKDOWN P08208 Wendy Fung P08205 Reid Williamson Steer Matthew Benedict Artur Ponikiewski Drive Andrew Anderson Matthew Benedict Platform Eric Rodems Artur Ponikiewski Yoke James Edick Eric Rodems Electronics Bryan Jimenez Jonathan Maglaty Controls Brendan Hayes Philip Edwards

7. 02.22.08 System-Level Process Flow Computer Wireless Receiver Microprocessor Motor Controller RP1 Motor Module

8. 02.22.08 CRITICAL REQUIREMENTS Transport 1kg Payload Robust = Withstand Tabletop Drop Wireless Communication Power Motors with a PWM Signal Open Source & Open Architecture Reflect Design of the RP Family Modular Design for Multiple End Uses

9. 02.22.08 EXPECTATIONS oQuantity 2, Fully Functional oSize 12in x 6in x 6in oSpeed @ max efficiency 38 in/s oDroptest Repair Time < 5 min oWireless Range 300 ft max oBattery Life 1 hour + 1 2

10. 02.22.08 FORMAT Drive & Steering Q & A Yoke & Platform Q & A Electronics & Controls Q & A DFMA & MSD II Outlook Q & A

11. 02.22.08 Responsibilities: –Highly dynamic range of operating speeds –An array of different operating conditions –Robustness –Seamless system integration Risks –Difficulty obtaining different motor gearboxes –Drive Shaft Alignment (turntable wobble) –Robustness of design –Accurateness of systems modeling –Tolerances –Assembly DRIVETRAIN SYSTEM

12. 02.22.08 IG 32 Motor 27:1 Gear Reduction ¼” Stainless Steel Axles ½” Aluminum Spacers 2” Diameter Wheel Axle Couplings Thrust Bearings 2:1 Synchronous Belt and Pulley Axle Collars FINAL DESIGN

13. 02.22.08 SYSTEM LEVEL DESIGN

14. 02.22.08 SYSTEM LEVEL DESIGN

15. 02.22.08 STEERING Responsibilities: –Infinite Steering –Easy to assemble/disassemble –Robust –Seamless system integration Risks –Robustness of belt tension system –Turntable –Integration with electronics and controls –Tolerances –Assembly

16. 02.22.08 IG 32 Motor 71:1 Gear Reduction ¼” Stainless Steel Axles Turntable Custom Centerpost 1:3 Synchronous Belt and Pulleys STEERING SUBSYSTEM

17. 02.22.08 STEER BELT TENSION Axle Couplings Adjustable Steer Motor Mounting Plate Adjustable Bearing Plate

18. 02.22.08 DRIVE & STEERING Q & A

19. 02.22.08 YOKE

20. 02.22.08 YOKE Responsibilities: –Responsible for structural skeleton of Rp1 –Design a rigid and robust framework –House all other sub-systems within framing –Provide protection against a 36” drop to the floor Risks –Keeping within the weight requirements –Withstand drop without any significant damage or misalignment of components –Minimizing overall cost of yoke

21. 02.22.08 UPPER YOKE 1/8” AL Plate ½” x ½” Al Posts AL Angle Brackets 1/8” Al Upper Yoke to Turntable Mounting Plate Encoder standoff mounting plate 1/8” Al Motor Mounting Plates

22. 02.22.08 LOWER YOKE 1/8” Al Upper Yoke to Turntable Mounting Plate 80/20 90° Base Connector 1”x1” AL 80/20 Quick Frame Mounted Flanged sleeve bearings

23. 02.22.08 Design Justification Critical Decisions: –Frame built of aluminum instead of Lexan to improve strength –Used an open 80/20 fork design for lower yoke to provide maximum rigidity while minimizing weight –Used solid post box design in upper yoke to fully enclose drive, steering and electrical systems. Solid posts allows for easier hardware attachment –Turn table connected to mounting plates on both sides to support upper and lower yoke

24. 02.22.08 PLATFORM Responsibilities –Platform design –Mounting of modules to platform –Idler module development –Test fixture design Risks –Design was heavily reliant on upper yoke –Design of platform for drivability

25. 02.22.08 DRIVE PLATFORM 2 platforms (1 per team) –Holds 2 motor modules –Holds 2 idler modules –Square shape for adaptability

26. 02.22.08 IDLER MODULE Idler Design –Past RP project experience –Use of motor module parts –Simplified design –Caster offset (slot)

27. 02.22.08 TEST PLATFORM 1 test platform –Holds 1 motor module –Holds 2 idler modules –Will have quick connect adapters spec’d out from Molex

28. 02.22.08 YOKE & PLATFORM Q & A

29. 02.22.08 CONTROLS Graphical User Interface (GUI) –Allow the user to interact with and control the robotic platform Wireless –Responsible for the communication between the user and the platform Microprocessor –Generate control signals and monitor sensor feedback

30. 02.22.08 Controls Risks –GUI User is unaware of current state of RP1 User is unable to respond quickly –Wireless Wireless interference Insufficient data rate –Microprocessor “Swamped” with encoder feedback

31. 02.22.08 Final Design GUI Left Motor Module Drive Motor: Good Wheel Angle Battery Life Remaining Left Motor Module Steering Motor: Good Right Motor Module Drive Motor: Inefficiency Right Motor Module Steering Motor: Good

32. 02.22.08 Wireless MIB520 USB- Gateway MICAz 2.4 GHz Wireless Transceiver

33. 02.22.08 Freescale MC9S12DT256 –8 Channel PWM Module –Modular Communication IIC SPI SCI CAN Microprocessor

34. 02.22.08 ELECTRONICS System Responsibilities –Provide components for motor control –Placement of motor control components –Supply power to electrical components –Confirm electrical components are compatible with microprocessor Risks –Component ratings (i.e. heat, amps, etc.) –Lead time on final part selections –Compatibility between electrical components

35. 02.22.08 Final Design H-bridge –PWM Motor Controller 3A Encoders –US Digital EM5 EM1 HUBDISK

36. 02.22.08 Final Design Power Schematic for encoders (5V)

37. 02.22.08 Final Design Simulation for Encoder Power Schematic

38. 02.22.08 Final Design Battery Selection –NiMH –24V –3.5Ah –Rechargeable

39. 02.22.08 CONTROLS & ELECTRONICS Q & A

40. 02.22.08 Design For Manf. & Assembly Steering assembly implementation Degree of machining precision Bending of motor shaft Spacing and fasteners Control Communication Functional control

41. 02.22.08 Plans for MSD II Build RP1 prototype Test accuracy of system modeling Build test fixture Do the drop test Look into possible aesthetical improvements Optimize current design Build GUI Setup basic wireless communication Test all electrical components Full system integration and test