Robotically Actuated Prevention/Intervention Device Full of Innovative and Responsible Engineering...

Robotically Actuated Prevention/Intervention Device Full of Innovative and Responsible Engineering

Critical Design ReviewFebruary 25, 2010

Riley PackEric Pahlke

Kelly ShusterGreg Stahl

RAPID FIRE

PROJECT OVERVIEW• The RAPID FIRE system will be able to recognize moving

targets in a room, choose the optimal target, and track it.

• Recognize one or more moving targets using digital cameras.

• Choose the optimal target, track its movement, and fire a projectile (foam dart or disk) at it.

• Be capable of fully autonomous operation.

• Have a user interface that allows for control of modes, manual turret control, and image viewing.

• Operate off of AC wall power.

BLOCK DIAGRAM

Power DSP(s)

Control Processor Motors

Camera Board(s) with FIFO

Digital ConnectionAnalog Connection

Power Connection

Mechanical

EXPANDABLE HARDWARE ARCHITECTURE

Power Supply

DSP PCB

Motor Controller PCB

Camera PCB

Data Connection Power Connection

Camera PCB

Camera PCB

Camera PCB

DSP PCB

Motors

Up to 4 Cameras per DSP

Up to 4 DSPs

Currently using 2 DSPs (8 total cameras)

CONTROL PROCESSOR

Power DSP(s)




Power Connection

Mechanical

CONTROL PROCESSOR

• Receives (x,y) location of optimal target from DSP

• Communicates with DSP(s) via SPI

• Triggers PWMs attached to 2 H-Bridges

• Receives feedback from 2 Optical Encoders

• Uses negative feedback PI Controller to adjust position

• Horizontal and Azimuth positions each have their own PI Controller

CONTROL PROCESSOR

• Processor Selection

• TI Stellaris LM3S2965

• Specifications

• 50 MHz Maximum Clock Speed

• 6 PWM Channels

• 2 Quadrature Encoder Interfaces (QEI)

• Single-cycle multiply instruction and hardware divide

• Variety of common interface modules

CONTROL PROCESSOR

PlantController

Target Motor Position from DSP SPI Interface

Actual Motor Position fromOptical Motor Encoder

CONTROL PROCESSOR

KPs + KI

Target Position

Actual Position

J = 0.5*M*R2

T = 0.4689 Nm = 66.4 oz-in = 80% of Max Efficiency

b = 0.045 M = 2.3kg R = 4.5 in

CONTROL PROCESSOR

KP = 100KI = 50tR = 1.5stS = 5 s20% overshoot

CONTROL PROCESSOR

CAMERA(S)

Power DSP(s)




Power Connection

Mechanical

CAMERA(S)• Camera Selection

• Toshiba TCM8230MD from Sparkfun

• Specifications

• 15 or 30 FPS

• VGA or QVGA supported

• Digital Output (YUV422 or RGB 565)

• Auto Gain Control, Auto White Balance

http://www.sparkfun.com/commerce/product_info.php?products_id=8667

CAMERA(S)

Camera

FIFOFIFO to

USB Converter

8-bit Parallel Data

Glue LogicDCLK

VDHD

EnableAndWriteStrobes

Debug to PC

SDA

SCL

uC/DSP

8-bit Parallel Data to DSP

CAMERA(S) – TEST BOARD

CameraUSB-FIFO

FIFO

SPLD


• Almost Able to Take Sub-QCIF (128 x 96) Resolution Pictures

• USB Write Speed Too Slow

• Solution: Upgrade to Faster USB Chip


FIFO WR

USB WR

CAMERA(S) – REVISION 2

• Current Camera Status

• Ready to Order Camera Board Revision 2

• Updated USB-FIFO Chip to Allow for 8 MBytes/sec

• Changed to Asynchronous FIFO to Simplify DSP Interface

CAMERA(S) – CAMERA / FIFO INTERFACE

CAMERA(S) – CAMERA / SPLD INTERFACE

CAMERA(S) – REVISION 2 LAYOUT

Camera

LevelShifter

FIFO

USB-FIFO

POWER

Power DSP(s)




Power Connection

Mechanical

POWER• Power Supply

• 12V (Motors)• 5V (Optical Encoder & FIFO)

• Isolated Integrated DC-DC Module from TI• 3.3V (DSP I/O Voltage)

• Linear Regulators from TI• 3.3V (Primary I/O Voltage)• 2.8V (Camera I/O)• 1.5V (Camera Sensor)• 1.26V (DSP Core)

POWER

• ATX12V V2.2 550W Power Supply

• 12 V Line Rated to 2 x 16 A

• 3.3 V Line Rated to 25 A

• 5 V Line Rated to 25 A

DIGITAL SIGNAL PROCESSOR

Power DSP(s)




Power Connection

Mechanical

DIGITAL SIGNAL PROCESSOR• Processes images from CMOS cameras to detect and

track moving targets• Subtraction for motion detection• Blob detection algorithm

• Replaced open source library with custom algorithm to make integration to DSP easier

• Communicates with the motor control processor• Sends debug data to PC using FIFO to USB

• USB is an easier debug port than an LCD

DIGITAL SIGNAL PROCESSOR• DSP Selection

• TI TMS320VC5501• Slightly lower performance than original selection, but QFP package greatly

reduces cost and risk. • Specifications

• 300 MHz, up to 600 MIPS• Hardware Memory Interface

• Used for SDRAM, FIFOs, FIFO to USB• Hardware I2C and SPI Controllers

• I2C used to control cameras and I/O expanders, and for boot loader• SPI used to transfer data to the motor controller

• Driver Library Available from TI

DIGITAL SIGNAL PROCESSOR PCB• Four layer board

• DSP• SDRAM• Hardware support for 4 cameras

• IO and I2C expanders allow multiple cameras to send data through the DSP’s External Memory Interface

• FIFO to USB converter (same as on camera boards) allows the DSP to send images and computation results to a PC

• Status: Schematic and Layout 100%, almost ready to order

DIGITAL SIGNAL PROCESSOR PCB

• Boot loader

• DSP has an I2C EEPROM boot mode

• Use an ATMEGA32 AVR to transfer code from RS-232 to I2C EEPROMs

• Isolation

• All signals from the DSP connecting off the board are isolated to protect the DSP (ISO7240 from TI)

• The 3.3V DC-DC converter for the DSP is isolated (DCR010503 from TI)

DIGITAL SIGNAL PROCESSOR PCB

Power5V from MC PCB

DSPUSB

Debug

I/O Expanders

To Camera

PCB

Memory BusI2C Power Connection

Isolators/ Level Shifters

Isolated 3.3V

DC-DC

1.26V VREG

I2C Switch

LEDs/ Debug

SDRAMAVR

Programming Port

EEPROMs

GPIOSPI

Data to MC PCB

RS232

DIGITAL SIGNAL PROCESSOR PCB LAYOUT

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U_DSP General

U_DSP Host Port

U_DSP Memory Control

U_DSP USB

U_Interface to Camera

U_Interface to Motor Control

U_IO Expanders

U_Programming and Debug

U_DSP Power

Cam0

Cam1

Cam2

Cam3

DSP

Boot loader

SDRAM

ISOLATORS

I/O ExpandersTo Cameras

To MCUSB

RS232

DIGITAL SIGNAL PROCESSOR PCB LAYOUT

DSP

Boot loader

SDRAM

ISOLATORS

I/O ExpandersTo Cameras

To MCUSB

RS232

MOTION DETECTION ALGORITHMSubtract Current Image From

Previous

Break Difference Image Into an n-by-n

Grid

Accumulate Location and Count of All

Pixels in Region with Difference Above

Threshold

RegionNorm > NORM_MIN?

Mark Region as Having

Motion

Checked Each Region?

No

Yes

No

Yes

Find Largest Connected Set

of Regions

Find Centroid of Regions in

Largest Set of Connected

Regions

Start

MOTORS/MECHANICAL

Power DSP(s)




Power Connection

Mechanical

MOTORS/MECHANICAL

• Two rotating platforms have been created

• One platform for azimuth, one for elevation

• Rotation achieved using turntables (Lazy Susan)

• DC motors used to rotate platforms

• Controlled with H-Bridge with PWM control

• Protection for deactivation feedback voltage from motor inductance

• Digital optical encoder used for position detection

MOTORS/MECHANICAL

• Turntable Selection

• Shepherd 9548

• Purchased from Home Depot

• Specifications

• 500 lb Load Capacity

• 6 in. x 6 in. Size

MOTORS/MECHANICAL

• Motor Selection

• Robot MarketPlace ML-50

• Specifications

• 120 RPM

• 730 mA Nominal Current

• 3.3 A Stall Current

• 320 oz-in Stall Torque

http://www.robotmarketplace.com/products/ML-50.html

MOTORS/MECHANICAL

• Encoder Selection

• Avago AEDB-9140-F12

• Specifications

• Optical Encoder

• 256 Cycles/Revolution

• 1024 Signal Changes/Revolution

• Fits Motor Shaft

http://www.avagotech.com/docs/AV02-1584EN

MOTORS/MECHANICAL

• H-Bridge Selection

• Texas Instruments DRV8412

• 2 X 3A Full Bridge Continuous Output (2 X 6A peak)

or

• 1 X 6A Full Bridge Continuous Output (1 X 12A peak)

• Controlled With PWM up to 500kHz

• Self-Protection Circuits

CONTROL PROCESSOR/MECHANICAL INTERFACE

DSP

H-Bridge Motor

MechanicalInterface

EncoderRelative Angular Position Changes

Current

SDA

SCLuC

PWM Output

x2

DIVISION OF LABORTask Riley Pack Eric Pahlke Kelly Shuster Greg Stahl

Camera Board P S S S

DSP Board Hardware

S P S

DSP Software P S S

Motor Control Board

S P S

Motor Control Software

P S

Mechanical S P

Power S P

User Interface S S S P

P = Primary S = Secondary

EXPENSES

SCHEDULE

MILESTONE 1

• Mechanical System Complete

• Control System Can Move Platform to Desired Position

• DSP Board Populated and Verified Functional

• Camera Board Populated

• Camera Board Sending Pictures to Computer

• Power Distribution Works with All Boards

MILESTONE 2

• Control System Tuned Correctly

• DSP Interfaced with One Camera

• DSP Running Correct Algorithms

• DSP Sending Targeting Positions to Control System

DESIGN EXPO

• Full System Operating Correctly with One or More Cameras

• Technical Manual

• User Manual

Questions?• Kelly Shuster

• Riley Pack

• Eric Pahlke

• Greg Stahl

Robotically Actuated Prevention/Intervention Device Full of Innovative and Responsible Engineering...

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Transcript of Robotically Actuated Prevention/Intervention Device Full of Innovative and Responsible Engineering...