Mars RoverMars Rover

By: By: Colin SheaColin SheaDan DunnDan Dunn Eric SpillerEric Spiller

Advisors: Dr. Huggins, Dr. Malinowski

OutlineOutline• Project SummaryProject Summary• Review of Previous WorkReview of Previous Work• Division of LaborDivision of Labor• Project DescriptionProject Description• Data SheetData Sheet• Equipment and PartsEquipment and Parts• Design ChangesDesign Changes• ScheduleSchedule• Progress UpdateProgress Update

Project SummaryProject SummaryThe main objective is to design the Rover for long battery life The main objective is to design the Rover for long battery life that must last 7 days without recharging. that must last 7 days without recharging.

The Rover will use PC104 to control the interface among the The Rover will use PC104 to control the interface among the user and the Rover and high level software.user and the Rover and high level software.

It will also use the MicroPac 535 microprocessor to control It will also use the MicroPac 535 microprocessor to control low level software such as the motors for motion, the sonar low level software such as the motors for motion, the sonar system, and the battery level. system, and the battery level.

The user will be able to enter a specific distance, move the The user will be able to enter a specific distance, move the Rover using the keypad, or rotate the Rover to get a preferred Rover using the keypad, or rotate the Rover to get a preferred direction. direction.

Previous WorkPrevious Work• 20022002

• Rob Shockency and Randall SatterthwaiteRob Shockency and Randall Satterthwaite• Robotic Platform Design Robotic Platform Design • EMAC 8051 and a CPLDEMAC 8051 and a CPLD• Design GoalsDesign Goals 1. Create Cheaper version of Telerobotics 20011. Create Cheaper version of Telerobotics 2001 2. Upgradeable and expandable in the future 2. Upgradeable and expandable in the future

Division of LaborDivision of LaborDan DunnDan Dunn Colin SheaColin Shea Eric SpillerEric SpillerAssembly CodeAssembly Code Java/ServerJava/Server HardwareHardware- Motor Speed - Motor Speed - Image Capture- Image Capture - DC Motors- DC Motors- Wheel Sensors- Wheel Sensors - Rover Controls- Rover Controls - Platform Construction- Platform Construction- Battery Charge Level- Battery Charge Level - Serial Communication- Serial Communication - H-bridge/Motor Driver - H-bridge/Motor Driver - Serial Communication- Serial Communication - Battery Charger- Battery Charger- Acoustics Sensors- Acoustics Sensors

Functional DescriptionFunctional Description

• Wait modeWait mode – – • All systems are powered, except the motors. All systems are powered, except the motors. • The CPU monitors the wireless card for network activityThe CPU monitors the wireless card for network activity• The last image captured from the camera is displayed to the The last image captured from the camera is displayed to the

user.user.• Web page accessible to userWeb page accessible to user• Battery Status is monitored Battery Status is monitored

• Sleep mode –Sleep mode – • The sub-systems are powered down except for the CPU and The sub-systems are powered down except for the CPU and

the wireless network card. the wireless network card. • CPU runs in a reduced power mode. CPU runs in a reduced power mode. • Web page accessibleWeb page accessible• Battery Status is monitored. Battery Status is monitored. • Rover remains in sleep mode until signaled by the user. Rover remains in sleep mode until signaled by the user.

Functional DescriptionFunctional Description• Low battery mode – Low battery mode –

• Battery drops below 10% of charge Battery drops below 10% of charge • Email sent to Dr. Malinowski requesting a charge Email sent to Dr. Malinowski requesting a charge • Rover shuts down all components. Rover shuts down all components.

• Charge mode – Charge mode – • Rover continues to charge until power button is pressedRover continues to charge until power button is pressed• Stays in this mode until battery level reaches 100%Stays in this mode until battery level reaches 100%

• User mode –User mode – • All Systems poweredAll Systems powered• Distance and Direction ControlDistance and Direction Control• Web Page accessible to userWeb Page accessible to user• Image capture and displayImage capture and display• Battery Status is MonitoredBattery Status is Monitored

Functional DescriptionFunctional Description

Wait

Charge

Low BatterySleep

User

Low Battery

Tim

eout

Connect

Disconnect

Activity

Man

ual

Full Charge

Low Battery

Low Battery

System Block DiagramSystem Block DiagramUser

Computer Internet

Embedded System

Motor Control

Wheel Sensors

Battery ChargeLevel

Camera

Control TCP/IP

Photons

AcousticSensors

Upper level softwaremicroprocessor

WirelessNetwork

card

802.11bRF signal digital bit stream

Monitor

Transmit pulse

Object

USB Protocol

Java Applet

Image

Com

mands

Sta

tus

Ech

o pu

lse

Mouse andKeyboard

Software Flow ChartSoftware Flow Chart• High Level SoftwareHigh Level Software

• Rover ControlRover Control

Software Flow ChartSoftware Flow Chart• High Level SoftwareHigh Level Software

• Image Retrieval/DisplayImage Retrieval/Display

Software Flow ChartSoftware Flow Chart• Low Level SoftwareLow Level Software

• Motor Control Motor Control

Software Flow ChartSoftware Flow Chart• Low Level SoftwareLow Level Software

• Object DetectionObject Detection

Software Flow ChartSoftware Flow Chart• Low Level SoftwareLow Level Software

• Battery Voltage LevelBattery Voltage Level

Micropac 535 A/D converter

Battery terminalvoltage

Compare to DataTable

User present

Display to userapproximate battery

charge levelCharge too low

Stop rover and switchto low charge mode

User not present, charge

low

Charge G

ood

Continue operatingrover

User not present, charge good

Data SheetData SheetSpecificationsSpecifications

Turning accuracy - ± 5° for an individual turn commandTurning accuracy - ± 5° for an individual turn commandTurning resolution - 15° Turning resolution - 15° Driving accuracy - ± 5cm and ± 2° for a 100cm commandDriving accuracy - ± 5cm and ± 2° for a 100cm commandCamera capture speed – 5 frames/sec @ 324x288 resolution for a 10BaseT Camera capture speed – 5 frames/sec @ 324x288 resolution for a 10BaseT connectionconnectionWeight – ~28lbsWeight – ~28lbsBattery life – 7 days without a rechargeBattery life – 7 days without a rechargeTop speed – 10cm/sTop speed – 10cm/sAcoustic sensors – Acoustic sensors –

Time between transmit signals – 1 secondTime between transmit signals – 1 secondFarthest object detection – 200cmFarthest object detection – 200cmClosest object detection – 50cmClosest object detection – 50cm

Data SheetData SheetMotors – Motors –

Model number – GM9X12Model number – GM9X12Gearing – 1:65.5Gearing – 1:65.5Max current – 4.56AMax current – 4.56AVoltage – 12VVoltage – 12V

Wheel Sensors – Wheel Sensors – Output – TTLOutput – TTLPulses per revolution of shaft – 512Pulses per revolution of shaft – 512Voltage required – 5VVoltage required – 5V

Battery charge level accuracy - ± 5%Battery charge level accuracy - ± 5%Wireless protocol – 802.11bWireless protocol – 802.11bDimensions – 31.4cm x 46.4cm x 21cm (L x W x H)Dimensions – 31.4cm x 46.4cm x 21cm (L x W x H)Battery – 2 X 12V @ 7.2Ah Battery – 2 X 12V @ 7.2Ah Wheels – 5cm x 16cm (Width x Diameter) Wheels – 5cm x 16cm (Width x Diameter)

Data SheetData SheetPC104 –PC104 –

Max Current, during bootup – 1.5AMax Current, during bootup – 1.5ANormal operating current – .8ANormal operating current – .8ASleep mode current – .026A Sleep mode current – .026A Processor – National Semiconductor Geode Processor @ 300MHzProcessor – National Semiconductor Geode Processor @ 300MHzRAM – 128MBRAM – 128MBVideo – Onboard Video cardVideo – Onboard Video card

PCMCIA module –PCMCIA module –Current - .07ACurrent - .07A

Wireless Card – Wireless Card – Linksys WPC11Linksys WPC11Max Current - .3AMax Current - .3ACurrent in Sleep mode - .02ACurrent in Sleep mode - .02A

Hard Drive – Hard Drive – IBM Travelstar 2.5 inch IDE hard drive, 10GBIBM Travelstar 2.5 inch IDE hard drive, 10GBMax Current - .94A (Spin-up Current)Max Current - .94A (Spin-up Current)Current in Sleep Mode - .02ACurrent in Sleep Mode - .02A

Camera –Camera –Logitech USB WebcamLogitech USB WebcamMax Current - .1AMax Current - .1A

Power CalculationsPower CalculationsPower Consumption for Sleep Mode:Power Consumption for Sleep Mode:

PC104 computer PC104 computer .026A.026APC104 PCMCIA module PC104 PCMCIA module .07A.07AIDE Laptop Hard drive IDE Laptop Hard drive .015A.015APCMCIA Wireless CardPCMCIA Wireless Card .009A.009AEMACEMAC .045A.045A

+ _____+ _____TotalTotal .165A.165A24hrs * 7days = 168hrs24hrs * 7days = 168hrs168hrs * .165A = 27.72 Ah @ 5V168hrs * .165A = 27.72 Ah @ 5V27.72Ah * 5V = 27.72Ah * 5V = 138.6Wh138.6WhUsing 2 - 12 Volt, 7.2Ah batteries:Using 2 - 12 Volt, 7.2Ah batteries:12V * 7.2Ah * 3 = 12V * 7.2Ah * 3 = 259.2 Wh259.2 Wh available available

Power CalculationsPower CalculationsPower Consumption for User Mode:Power Consumption for User Mode:

PC104 computerPC104 computer .8A.8APC104 PCMCIA modulePC104 PCMCIA module .07A.07AIDE Laptop Hard driveIDE Laptop Hard drive .4A.4APCMCIA Wireless CardPCMCIA Wireless Card .285A.285AEMAC EMAC .045A.045ACameraCamera .1A.1A2 Polaroid Ultrasonic 65002 Polaroid Ultrasonic 6500 .2066A .2066A

+ ______+ ______TotalTotal 1.9066A1.9066A

Power CalculationsPower CalculationsThe motors chosen by the Robotic Platform Design The motors chosen by the Robotic Platform Design project were Pittman GM9236, which pull 2A per motor. project were Pittman GM9236, which pull 2A per motor.

Total with motorsTotal with motors 1.9066A + 2A * 2 = 5.911.9066A + 2A * 2 = 5.91AA

If we assume that user is connected 1.3% (or 2.1 hrs out If we assume that user is connected 1.3% (or 2.1 hrs out of a week) of the time, then power consumption is as of a week) of the time, then power consumption is as follows: 36.5Ah * 5V = 182.48Wh requiredfollows: 36.5Ah * 5V = 182.48Wh required

[(4A * 12V + 1.9066A * 5V) * 1.3% + (.165A *5V)* [(4A * 12V + 1.9066A * 5V) * 1.3% + (.165A *5V)* 98.7%]*168hrs=259.2Wh required98.7%]*168hrs=259.2Wh required

Parts and Price ListParts and Price ListEquipment List for Mars Rover

Part Qty Website Manufacturer Location of Vendor Part # Price

10 Gb 1www.pricewatch.com IBM

www.basoncomputer.com $80.00

128 Mb RAM 1www.pricewatch.com Infineon

www.18004memory.com

LG1064U/064/G3VAC $14.20

PC/MCIA Wireless Card 1

www.pricewatch.com Logictech

www.legendmicro.com DL1150 $69.00

USB Webcam 1www.pricewatch.com Logictech www.enpc.com 961137-0403 $16.00

PC104 300MHz w/ USB 1

www.square1industries.com National Semi

www.square1industries.com CM-588 $399.00

Dual PC/MCIA Adaptor 1

www.square1industries.com

National Semi 

www.square1industries.com

NC-893   $94.00

Pittman DC Motor #9236 2 Bradley OwnedBradley Owned Pittman www.pittmannet.c

om   

  $672.20

Design ChangesDesign Changes

Replaced Linux based operating system Replaced Linux based operating system with Windows based operating systemwith Windows based operating system

Video Card was incompatible with Linux although manufacturer Video Card was incompatible with Linux although manufacturer stated the card was compatiblestated the card was compatible

Linux operating system was not stable on PC-104 boardLinux operating system was not stable on PC-104 board

Design ChangesDesign Changes

Flash Memory Card and PCMCIA Hard Flash Memory Card and PCMCIA Hard drive replaced by Laptop Hard drivedrive replaced by Laptop Hard drive

Flash Memory Card was not capable of booting the PC-104 at Flash Memory Card was not capable of booting the PC-104 at start-upstart-up

PCMCIA Hard drive was not visible by computer until system PCMCIA Hard drive was not visible by computer until system completed start-up sequencecompleted start-up sequence

Laptop Hard drive booted easier and still remained low powerLaptop Hard drive booted easier and still remained low power

Laboratory Week Project Milestones19-Jan-03 Assemble PC104 and interface with previous Robotic Platform Design project.

26-Jan-03 Create boot software for Linux.

  Install drivers for all components in Linux.

2-Feb-03 Develop and test motor control software on Micropac 535.

  Develop software to interpret wheel sensor bit streams.

9-Feb-03 Continue working on software development for motor control and feedback loop.

16-Feb-03 Develop software to capture image from camera and send to user.

  Continue working on software development for motor control and feedback loop.

  Work on web server development.

23-Feb-03 Create Java applet for user interface.

2-Mar-03 Continue with Java applet

  Work on software to estimate battery charge level.

9-Mar-03 Finish working on software to estimate battery charge level

16-Mar-03 Spring Break

23-Mar-03 Develop software to operate acoustic sensors

30-Mar-03 Finish Java applet.

6-Apr-03 Testing of individual components and overall system.

13-Apr-03 Testing of individual components and overall system.

20-Apr-03 Preparation for presentation and final report

27-Apr-03 Presentation

Progress Flow ChartProgress Flow ChartUser

Computer Internet

MicroPac 535Embedded System

Motor

Wheel Sensors

Battery ChargeLevel

Camera

Voltage

Control TCP/IP

Bit

Stre

a m

AcousticSensors

PC104Upper level software

WirelessNetwork

card

802.11bRF signal digital bit stream

Transmit pulse

TTL Signal

Object

USB Protocol

PWM Signal

Java Applet

Image

Com

mands

Sta

tus

Ech

o pu

lse

H-Bridge

Green = DevelopedRed = Partially Developed

Progress UpdateProgress UpdateSecond Semester  

Date Progress Description

1/19/03 to 1/25/03

Installed Linux Red Hat 8.0 onto an older Pentium 166 computer.

Waited to get the PC104 board and modules.

1/26/03 to 2/1/03

Attempted to install Linux on the PC104 board using the PCMCIA hard drive as the main hard drive.

Linux never recognized the drive, so we decided to use a 2.5 inch IDE hard drive.

2/2/03 to 2/8/03

Attempted to install Linux on the 2.5 inch hard drive.

Linux would install and boot, but not run.

After many hours of installing and adjusting configurations for Linux, we discovered that Linux was incompatible with Geode processors.

We decided to use Windows 2000 instead, because of stability and compatibility.

2/9/03 to 2/15/03

After establishing a stable platform to work with, we began to add the peripherals and necessary software.

Setup servers at http://webrover.bradley.edu and at http://webrover.bradley.edu:8080

2/16/03 to 2/22/03

Tested serial communication between a windows based computer and the Micropac 535.

Tested H-bridge design with Pittman DC motor.

2/23/03 to 3/01/03

Continued testing serial communication between a windows based computer and the Micropac 535.

Tested PWM signal from MicroPac 535 to generate signal for H-bride operation.

Tested H-bridge design mounted on circuit boards with 30V Pittman DC motor and later with PWM signal from MicroPac 535.

3/02/03 to 3/08/03 Reconstruct Rover and Presentation

3/09/03 to 3/15/03 Continued constructing Rover, established moving routines, and developed user interface.

3/23/03 to 3/29/03 Continued testing Rover

3/30/03 to 4/5/03 Tested mobility of the Rover

Questions and AnswersQuestions and Answers