Automated Refueling for Hovering Robots Nigel Cochran, Janine Pizzimenti , Raymond Short
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Transcript of Automated Refueling for Hovering Robots Nigel Cochran, Janine Pizzimenti , Raymond Short
18/22/2011
Automated Refueling for Hovering Robots
Nigel Cochran, Janine Pizzimenti, Raymond Short
WPI Major Qualifying Project with MIT Lincoln Laboratory Group 76
Project Presentation Day
19 April 2012
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Problem Statement
• Currently, there is an insufficient mission duration for small hovering robots compared to the down-time required to charge their batteries
• An autonomous apparatus for exchanging and charging batteries quickly is needed
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Project Goals
UAV to Base Communication
Reliable UAV Positioning
Exchange and Store Batteries
Charge and Balance Lithium-
Polymer Batteries
Maximize In-Flight Duty
CycleEasily Adapted for other UAVs
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Requirements and Assumptions
• Navigating: UAV navigates itself to landing zone in negligible time• Landing: X-Y disp. of ± 6”, Yaw of ± 30°, Pitch/Roll of ± 15°• Base Size: < 3’x3’x2’ and < 30 lbs (excluding batteries)• UAV Modifications: < 100 g added to UAV (excluding battery)• Battery: 5000 mAh, Discharge time 18 mins• Battery Exchange: < 3 mins, Hot swap capable • Electrical Constraints: Balance charging batteries, < 200 W,
Conversion will be provided• Software Requirements: ROS communication via Ethernet/WiFi,
Initiate request for landing give battery voltage• Environment: Indoors (no weather)
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• Off-the-shelf charge/balancing with custom interface• Enough batteries and short service to allow missions of any
length with high duty cycle• ~ 2’x2’ open landing area with active alignment• Custom battery mount and UAV skids
– Can be made universal for many UAVs
• Rotating battery track• ROS communication
– UAV reports battery level– Base signals when UAV can land
Solution Features
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• Venom Easy Balance AC LiPO Charger– Small: 4.01”x2.44”x1.39”– Charge Rate: 0.1-4.5 A (Mechanical Dial)– Balances: 1 Battery, 2-4 Cells– Design Advantage: COTS
• Reverse Engineering– Dial glued at 4.5A (Maximum)– Pololu output port to activate start button– Monitor LED Voltage to know charger’s state
Lithium Polymer Battery Charging
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Model of Batteries Required
1 2 3 4 5 6 7 8 9 100
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Number of Batteries
% o
f Cyc
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in F
light
In Flight Duty Cycle
Swap and Recharge SystemCharge Only System
Flight Time = 18 minsCharge Time = 80 minsService Time = 4 mins
1 2 3 4 5 6 7 8 9 100
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Number of Batteries
% o
f Cyc
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ime
in F
light
In Flight Duty Cycle
Swap and Recharge SystemCharge Only System
Flight Time = 18 minsCharge Time = 80 minsService Time = 2 mins
Ideal System Prototype
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• Aligns UAV in center of base orientated in increments of 90°• Two Servo-actuated four-bar linkages
– One servo per four-bar– Required torque of 200 oz-in, using 582 oz-in servos– L-shaped arms interlock for consistent positioning
UAV Alignment Device
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• Based on Pelican’s skid design• Includes extended feet to widen base for easy battery
exchange
• Weight added to UAV: 109g
Universal UAV Skids
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• Raise/Lower Batteries– Scissor lift– Same 582 oz-in servo
• Move between dock and UAV– Rack/pinion & linear bearing– 582 oz-in continuous servo
Enough for 2 cars Limit switches
• Rotate between charging docks– Turntable– 219.5 oz-in Stepper motor
Battery Transfer System
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• Connects correctly to base and UAV independent of rotation
• 0.2” of compliance in mechanical alignment– Pyramid guided touch latch
2.6lb of holding force• 3D printed ABS Plastic Casing
Battery Mating and Alignment
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• Battery (8x)– Start Charge Relay: Digital-Out– Monitor LED State: Analog-In– Presence Limit Switch: Digital-In
• Battery Cart– Endpoint Limit Switch (2x): Digital-In– Middle Limit Switch: Digital-In– Positioning Motor: PWM– Scissor Lift Servo : PWM– Scissor Lift Current Sense: Analog-In
• Turntable– Stepper Motor Direction: Digital-Out– Stepper Motor Number of Steps: Digital-Out– Photo Interrupter (8x): Digital-In
• UAV Centering– Arm Actuation Servo (2x): PWM– Arm Actuation Current Sense (2x): Analog-In
• Total I/O Required: 44
I/O Devices
2x 24-pin Pololu Maestro USB Controllers
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High-Level Program Flow
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• BaseStation– Manages system state progression using ROS– Contents:
Callback - handle messages from UAVs Init - initialize starting variables and ROS parameters State - state functions for actions and state transitions Thread - run state and listener threads
• MaestroController– Manages control of peripherals (sensors, servos, etc.)– Contents:
Actions - abstracted functions called by the BaseStation Batteries - all battery-related functions Cart - all cart and scissor-lift related functions Inputs - handling for gathering information from the controllers Low_Level - abstraction for basic USB communications Servos - general servo functions Stepper - all stepper motor-related functions
Program Structure
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• Total Time: Between 4 and 5 minutes– Scissor Lift took approximately 3 of the 4 minutes
• Video:– mqp complete.wmv will be shown at this time
• Future Recommendations:– New battery mating systems– Lighter aluminum or plastic frame– Hot-swapability– Faster motor on scissor lift– Second cart– GUI with system states and battery life– Sensor feedback on alignment system, like limit switches– Shorter stepper motor
Results
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• Lincoln Lab Staff:– Brian Julian (Group 77)– Mike Boulet (Group 76)– Byron Stanley (Group 76)– Mike Stern (Group 77)– Mike Crocker (Group 72)– Group 76 Technicians– Emily Anesta and Seth Hunter
• WPI Faculty:– Prof. Ken Stafford (ME/RBE), Advisor– Prof. Bill Michalson (ECE/RBE/CS), Advisor– Prof. Ted Clancy (ECE), MITLL Site Director– Joe St. Germain (RBE), Robotics Lab Manager
Acknowledgements
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• Problem Statement & Goals• Requirements & Assumptions• Solution Features• LiPoly Battery Charging• UAV Alignment Device• Universal UAV Skids• Battery Transfer System• Battery Mating & Alignment• Controls & Communications• Program Structure
Summary
Questions?
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• Pole LED voltage 3 times over 1 second to determine states
• Possible States:
Charger LED Color Code
LED Colors StateAll orange (2.4V) Charging
All green (4.7V) Charged
Orange and no light (0V) Waiting: Battery connected
Green and red (0.6V) Waiting: No battery connected
Red and no lightErrorAll red
No light
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• Approximate Number of Batteries Required (Worst Case)
(Tf + Ts)n = Tc + Tf + Ts
– Tf = Flight time = 15 minutes (min from specification)
– Ts = Service time = ~1.5 minutes
– Tc = Charge time = 5 Ah battery / 4.5 A charge = ~ 75 minutes
– N = Number of Batteries = (Tc+Tf+Ts)/(Tf+Ts) = (91.5)/(16.5) = ~ 5 batteries
• With a safety factor of about 1.5, we choose 8 batteries
System Battery Requirements
Tf Ts Tf Ts Tf Ts Tf Ts
TfTs
2Tc
Ts
2
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Estimated Analysis of Base Power – 8 Batteries
0 20 40 60 80 100 120 140 160 180 2000
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100
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Pow
er U
sed
(Wat
ts)
Time (minutes)
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UAV Communications Simulation in ROS
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Prior Art
UMichigan (2010):Swap/Recharge
KAIST (2011):Swap/Recharge
MIT/Boeing (2011):Swap/Manual
Recharge
MIT (2007):Recharge Only
• 2 min Service• No Hot-swap• Sloped Landing Area• Servo-actuated Magnet Mating• Offset Battery Ring
• 21.8 sec Service• Hot-swap• 2 Arm Catching• Rail Battery Contacts • 2 Vertical Battery Drums
• 47.5 sec Service• No Hot-swap• Mechanical Arm Catching• Electromagnets• Battery Ring with Pusher
• 30-70 min Service• Charge Via Contacts on Feet• Sloped Landing Area w/ Recess