1. Disturbance Correction Final Design Review Team 5 February 25, 2003 By:Tyler Ferman Matt DiLeo Jack Damerji

2. Laser Deflection System  Project Overview User supplies changing input. Goal is to compensate for measured input disturbance. Controller angles mirror to performs disturbance correction.  Objectives Develop accurate controller in order to keep a laser communication link. Develop controller to correct for all disturbance.

3. Approach  Input Measure the laser pen pan/tilt angles. Measure the mirror pan/tilt angles.  Controller Determination of desired mirror pan/tilt angles. Develop controller to achieve performance specifications.  Output Specified target (dot on wall)

4. Specifications: Positioning

5. Specifications Cont.  Input range of motion: 43 o  Mirror: 5’’ dia @ 55g (+ 45g mount)  Output Range of motion: 26 o  Controller Speed: >6rad/s  Overshoot Error: < 1%  Target: +-0.4”  Encoder Gearing: 1:4 (4X accuracy)

6. Math Model (Angle Calc.)Pan/Tilt & Mirror Design Mass & Inertia Calc. Motor & Gear Selection Simulation & Controller Design System Analysis Input Pan/Tilt Considerations Order parts Building Input Pan/Tilt Input Pan/Tilt &DSP Input Testing Build Control Pan/Tilt DSP Control of Pan/Tilt Testing and Fine Tuning Develop Full Interaction Testing, Tolerance Analysis & Fine Tuning 2/19 2/26 4/1 4/9

7. Math Model (Angle calc.)  Approach : Direct:  Solve by equating desired reflected unit vector with received reflected unit vector  Solve using parametric equations Indirect:  Solve using Coordinate Transformations  Solve using fminsearch & foreword equation Find foreword Equation (Maple) Solve For Mirror Angles (Maple) Create Math Model (MATLAB) Find foreword Equation (Maple) Educated Angles Guess (MATLAB) Iterate Until Guess Converges

8. Math Model (Angle Calc.)Pan/Tilt & Mirror Design Mass & Inertia Calc. Motor & Gear Selection Simulation & Controller Design System Analysis Input Pan/Tilt Considerations Order parts Building Input Pan/Tilt Input Pan/Tilt &DSP Input Testing Build Control Pan/Tilt DSP Control of Pan/Tilt Testing and Fine Tuning Develop Full Interaction Testing, Tolerance Analysis & Fine Tuning 2/19 2/26 4/1 4/9

9. Motor & Gears Selection Center Of Gravity and Inertia were obtained from Solid Work Models Simulate a number of motors Examples: Tested number of GM8000 series Needed more: Torque & Speed Motor Chosen: Pittman GM9234S016 Gear Ratio: 4:1

10. Math Model (Angle Calc.)Pan/Tilt & Mirror Design Mass & Inertia Calc. Motor & Gear Selection Simulation & Controller Design System Analysis Input Pan/Tilt Considerations Order parts Building Input Pan/Tilt Input Pan/Tilt &DSP Input Testing Build Control Pan/Tilt DSP Control of Pan/Tilt Testing and Fine Tuning Develop Full Interaction Testing, Tolerance Analysis & Fine Tuning 2/19 2/26 4/1 4/9

11. Input Considerations  Input trajectory accuracy is critical  S1 Optical Shaft Encoder 1024 CPR  360 0 /1024 =.35 0 per tick  S2 Optical Shaft Encoder 2048 CPR  360 0 /2048 =.176 0 per tick  Geared S1 Encoder 1024*4 CPR  360 0 /4096 =.09 0 per tick

12. Error Induced  Output error due to input measurement accuracy 0.1 0 input error  ~0.0745’’ output error >> [r,u,p]=find_reflected([0,-2.5,6], [0,.178543307087,-1], [0,0,1]); >> [x,y,z]=vec_plane_int(p,u,[0,0,-1],[0,0,36]) x = 0 y = 4.9988 z = 36 >> [r2,u2,p2]=find_reflected([0,-2.5,6], [0,.180344836659,- 1], [0,0,1]); >> [x2,y2,z2]=vec_plane_int(p2,u2,[0,0,-1],[0,0,36]) x2 = 0 y2 = 5.0745 z2 = 36

13. Ordering Parts  Project Budget List of Parts List of Materials Machine shop service

14. List of Parts QuantityPrice ($) Total ($) itemsource 14.25 5” diameter glass mirrorWalmart 14.50 Laser penRadio Shack 197.59 Pan motor, Pittman GM9234S016 Clickautomation 1 97.59 Tilt motor, Pittman GM9234S016Clickautomation 125.74 Pan gear setsdp-si.com/eStore/ 125.74 Tilt gear setsdp-si.com/eStore/ 12.92 Pan beltsdp-si.com/eStore/ 12.92 Tilt beltsdp-si.com/eStore/ 138.55 Input Pan/tilt encoder gear setsdp-si.com/eStore/ 144…mounting hardwaresdp-si.com/eStore/ 138.55 Output pan/tilt encode gear setsdp-si.com/eStore/ 144…mounting hardwaresdp-si.com/eStore/ 120.00 Misc electrical componentsTrojan electronics 12.00 Mirror mounting hardwareHome depo 40.893.566-32 x 2.5” hex head bolts, steelHome depo 371.91total

15. List of Materials QuantityPriceMaterialdimensionsitemSource 10.75Al1/8” x 1/2” x 3”Mirror mountHome Depo 10.75Al3/8” x 6” bar stockTilt shaftHome Depo 21.50Al3/8” x 1 1/4” x 2”Tilt spacersRPI machine shop 12.50Al3/8” x 1 1/4“ x 6”Tilt baseRPI machine shop 5.50total Machine Shop Service Quantityrate# hoursTotal ($) itemsource 1$35 / hr.258.75Mirror mountRPI machine shop 1$35 / hr.517.50Tilt shaftRPI machine shop 2$35 / hr.7526.25Tilt spacersRPI machine shop 1$35 / hr1.035Tilt baseRPI machine shop 87.50total

16. Total Cost itemCost ($) List of parts371.91 List of materials5.50 Machine shop service87.50 total$ 464.91 Project Budget Summary

17. DSP I/O Trajectory Calculator Mirror Position Calculator Angle Saturation Controller Torque  Motor Control State Estimator Θ in1 Desired States ( Θ 1, Θ 2, Θ 1dot, Θ 2dot) Estimated States ( Θ 1, Θ 2, Θ 1dot, Θ 2dot) Voltage for Motors Torque State Estimator Θ in2 Θ1Θ1 Θ2Θ2

18. Math Model (Angle Calc.)Pan/Tilt & Mirror Design Mass & Inertia Calc. Motor & Gear Selection Simulation & Controller Design System Analysis Input Pan/Tilt Considerations Order parts Building Input Pan/Tilt Input Pan/Tilt &DSP Input Testing Build Control Pan/Tilt DSP Control of Pan/Tilt Testing and Fine Tuning Develop Full Interaction Testing, Tolerance Analysis & Fine Tuning 2/19 2/26 4/1 4/9