SYNTHESIZING MANAGERIAL AND TECHNICAL KNOWLEDGE AND SKILLS:Guiding a Student Team Through the Process of Developing a Robot for the ATMAE Student Competition

OVERVIEW

Objectives for the project Review of the develop process Concepts and tools

OBJECTIVES

Develop a robot that can compete Limited timeline Limited experience Stringent requirements Small budget

Teach advanced concepts through application

Emergent objectives Continuity for future years Groundwork for continuous improvement

DEVELOPMENT PROCESS

Planning ConceptDevelopment

ConceptApproval

System LevelDesign

Detail Design DesignReview Build Test

Refine Test Ready forCompetition

PROJECT PLANNING

REQUIREMENTS AND CONSTRAINTS

Basic requirements: December 2009 Complete requirements: February 2010

Remotely-operated navigation from base to target area Autonomous operation within target area: Find and

retrieve a partially-submerged cylinder Return cylinder to base

Constraints Deadline = competition date Budget = $1,500 from CWU + out of pocket Limits of team expertise

ACTION PLAN1 1. Planning ------ --- ---

2 a. Gather requirements, determine constraints Team 4 ---

3 b. Create baseline plan Arthur 1 2

4 2. Concept Development ------ --- ---

5 a. Determine possible system configurations Team 2 3

6 b. Apply selection criteria Team 1 5

7 c. Define system configuration Team 1 6

8 d. Create design sketches Jose 1 7

9 e. Build and test alpha-level prototypes Team 2 8

10 3. System Level Design & Specification ------ --- ---

--- a. Electro-Mechanical Systems ------ --- ---

11 i. Chassis Jose 1 9

12 ii. Drive system Arthur 1 9

13 iii. Manipulator system Jonathan S. 2 9

--- b. Electronics systems ------ --- ---

14 i. Programmable controller Arthur, Jose 4 9

15 ii. Motor controls Arthur 2 14

16 iii. Sensor system Team 4 9

17 4. Detail Design ------ --- ---

18 a. Make-buy decisions Arthur, Jose 2 16

19 b. Specify purchased components Arthur 2 18

20 c. Design fabricated components Jose 4 18

21 5. Build ------ --- ---

22 a. Procure purchased systems & components Arthur 2 15, 16, 19

23 b. Build fabricated components Team 1.5 20

24 c. Assemble and test subsystems Team 0.5 22, 23

25 d. Refine Team 1 24

26 e. Assemble robot Team 1 25

27 f. Integrate electronics Byron, Austin 1 26

28 6. Final Adjustments ------ --- ---

29 a. Test Team 0.2 27

30 b. Refine Team 0.4 29

NETWORK DIAGRAM

GANTT CHART DATA

GANTT CHART

LINEAR RESPONSIBILITY CHART

Arth

ur M

orke

n (G

A)

Proj

ect M

anag

er

Jose

Mor

a (U

G)

De

sign

& b

uild

, mac

hini

st

Jona

than

Spi

ry (U

G)

De

sign

and

build

Jona

than

Hor

ner (

UG)

De

sign

and

build

Byro

n Ch

an (U

G)

Elel

ctro

nics

Austi

n Bo

yd (U

G)

Elec

tron

ics

Ted

Bram

ble

(GA)

Team

Con

sulta

nt

Establish Project Plan 1 1 = Actual responsibility

Platform Design 3 1 3 3 2 = General supervision

Manipulator Design 3 3 1 3 3 = Must be consulted

Manipulator integration 3 3 1 3 4 4 = May be consulted

Drive mechanism design 3 3 3 1 5 = Final approval

Drive mechanism integration 3 3 3 1 4

Selection of microprocessor system 1 4

Design of sensor system 1 3 3 3 3 3 4

Specification of sensors 3 1 1 4

Design of control system 1 3 3 3

Integration of control system 1 1 4

Integration of sensors 1 1 4

Programming of search and retrieval routines 1 1

CONCEPT DEVELOPMENT

CONCEPT DEVELOPMENT PHASE

Release ofCompetition

RulesIdentify Needs Establish

Specifications

GenerateConceptsSelect ConceptBegin Build

Phase

FUNCTION DIAGRAM: POSITION ROBOT

1. Execute Search Pattern2. Scan for Cylinders

3. Position Robot

Positioned RobotSensor Data

Program Directive

CONCEPT TREE: SEARCH PATTERN

SearchPattern

DirectPath

Sweep

Point andShoot

Guided Path

Latitudinal

Longitudinal

CONCEPT TREE: SCAN

Scan

Optical

Electro-Magnetic

Color

Size

MetalDetector

DirectContact

Bumper

Curb Feeler

Ultrasonic

CONCEPT TREE: POSITION ROBOT

PositionRobot

RelativeCoordinates

AbsoluteCoordinates

Corner ofSearch Area

Point onRobot

GPS

Triangulate

CONCEPT TABLE: POSITION ROBOT

Execute Search Pattern Scan for Cylinders Position Robot

Point and Shoot

Guided Path

Latitudinal Sweep

Longitudinal Sweep

Bumper

Curb Feeler

Color

Size

Metal Detector

Ultrasonic

RelativeCoordinates: Corner

of Search Area

RelativeCoordinates: Point

on Robot

GPS

Triangulate

FUNCTION DIAGRAM: RETRIEVE CYLINDER

1. Activate Mechanism2. Clear Away Excess Sand

3. Grasp Cylinder4. Load Cylinder

Loaded CylinderProgram Directive

CONCEPT TABLE: RETRIEVE CYLINDER

Activate Mechanism Clear Away Sand Grasp Cylinder Load Cylinder

Limit Switch

Signal fromProcessor

Dig

Sieve

Sweep

Blow

Vacuum

Bull Doze and Scoop

Grasp WithManipulator Arm

Crane Bucket

Expansion Anchoron a Spear

Pinch Rollers

Dig and Scoop

Manipulator

Linear Lift

Articulated Lift

SYSTEM-LEVEL DESIGN

DESIGN PLATFORM: SOLIDWORKS

SYSTEM DESIGN PRINCIPLES

Passive defensesHeavy & Low CGRigid structure

Use a drive-over strategy and a large capture bay (reduces required level of precision)

Ease of service & transport

DETAIL DESIGN:QFD

HOUSE OF QUALITY

Wei

ght

Ext

erio

r D

imen

sion

s

Tot

al H

orse

pow

er

Pre

cisi

on o

f T

orqu

e D

eliv

ery

Cha

ssis

Thi

ckne

ss

Pla

ting

Thi

ckne

ss

Typ

e of

Sen

sors

Num

ber

of S

enso

rs

Pla

cem

ent

of S

enso

rs

Typ

e of

Mic

roco

ntro

ller

Typ

e of

Circ

uit

Shi

eldi

ng

Typ

e of

Bat

tery

Cha

ssis

Mat

eria

l

Pla

ting

Mat

eria

l

Typ

e of

Driv

e S

yste

m

Met

hod

of L

ocom

otio

n

Typ

e of

Ret

rieva

l Mec

hani

sm

Customer Requirements 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1 Finds cylinder autonomously 11.49 9 9 9 3

2 Retrieves cylinder autonomously 11.49 3 9 9 3 9

3 Deposits cylinder autonomously 11.49 3 9

4 Completes task once within time limit 8.05 1 1 3 9 3 3 3 3 1 3 3 9

5 Can be driven remotely 5.75 3

6 Operator can drive without line of sight 5.75 9 1 9

7 Operator can initiate autonomous function 5.75 3

8 Avoids interference 3.45 3 9 9 3 3 3 3 3

9 Resists attack 3.45 9 1 9 3 3 9 3 3 3 3 9 9 3 3 3

10 Maintains traction 5.75 9 9 1 9 9

11 Can operate in the rain 5.75 9 9 3 1

12 Does not malfunction 11.49 3 3 3 3 9 9 3 3 9

13 Can maneuver well 3.45 3 3 9 3 3 3 9 9

14 Can be transported easily 3.45 9 9 1 9

15 Can be serviced easily 3.45 3 3 1 1 3 3 3 3 3 3 9 9

Importance Factor 143 74 55 248 24 34 293 302 348 217 176 145 55 41 172 210 430Percent of Total

I

mp

ort

ance

wt.

(b

y %

)

PARETO ANALYSIS: HOUSE OF QUALITY DATA

Type

of R

etrie

val M

echa

nism

Place

men

t of

Sen

sors

Numbe

r of

Sen

sors

Type

of S

enso

rs

Precision

of T

orqu

e Del

iver

y

Type

of M

icro

cont

rolle

r

Met

hod

of L

ocom

otio

n

Type

of C

ircui

t Shi

eldi

ng

Type

of D

rive

Syste

m

Type

of B

atte

ry

Wei

ght

Exte

rior Dim

ension

s

Chass

is M

ater

ial

Tota

l Hor

sepo

wer

Platin

g M

ater

ial

Platin

g Th

ickn

ess

Chass

is T

hick

ness

0

2

4

6

8

10

12

14

16

18

20

0

10

20

30

40

50

60

70

80

90

100

DESIGN REFINEMENT

DETAIL DESIGN PRINCIPLES

One successful iteration of task Increase reliability via simplicity

Minimize partsMinimize motionsLess sophisticated electronicsLess sophisticated programming

RISK ANALYSIS: PDPC/NAVIGATE ROBOT

Function Actions Risks Countermeasures

Sense cylinderlocation and

stop

Execute searchpattern

Sensors missthe cylinder

Insufficientprecision

Redundantsensors

(different type)

Use an array ofsensors totriangulate

Navigate robotDifficult to

create6 stick tocoord . system

Don't usecoordinate

system

Interferingrobot disruptssearch pattern

Systematicpattern too time

consuming

Aim robot fromoutside roped

area

Use a straightline search

path

Exit roped areaand re-aim

Use a large bay& a convergingpair of rollers

RISK ANALYSIS: PDPC/RETRIEVE CYLINDER

Function Actions Risks Countermeasures

Grasp cylinder

Load Cylinder

Not enoughsurface

exposed

Insufficientgrasping force

Add flaps orbristles to

rollers

Use tackymaterial on

rollers

Usescissor-jackmechanism

Retrievecylinder

Cylindercross-feeds

Foreignmaterial jams

mechanism

Roller's startingz-position =

ground level -d

Inspect andclean between

matches

Roller's startingz-position =

ground level -d

THANK YOU

Questions?

PowerPoint file available at: http://www.cwu.edu/~olsondar/robot