Warwick Mobile Robotics 2014/15€¦ · Chassis Drivetrain Electronics & Software Final Design...

Warwick Mobile Robotics2014/15

Design & Development of a Miniature UrbanSearch and Rescue (M-USAR) Robot

Contents

IntroductionDesign

OverviewChassis Drivetrain

Electronics &Software

Final Design Conclusions

Introduction – Introducing the team, sponsors, aims and objectives

Design Overview – Design methodology and benchmarking

Chassis – Specification, design, development and manufacture

Drivetrain – Specification, design, development and manufacture

Electronics and Software – Specification, design, developmentand manufacture

Final Design – Final robot design, testing and critical review

Conclusions – Finances, project benefits, outreach and further work

2014/15

Team

Sponsors:

IntroductionDesign




Warwick Mobile Robotics – Background

IntroductionDesign




WMR Robots

IntroductionDesign




2013/14

Robot2013/14

Robot2013/14

Robot

2012/13

Robot2012/13

Robot2012/13

Robot

Strategy – 3-Year Plan

IntroductionDesign




Strategy – Project AimsAim 1:

Deliver a mechatronic framework for an innovative M-USARrobot by May 2015 as the first stage of a three-year plan

Aim 2:

Provision for design development by future WMR teams

Aim 3:

Exhibit the robot as an educational platform to inspire youngergenerations

IntroductionDesign




Strategy – Objectives

IntroductionDesign




Analyse currentUSAR designs

Benchmark existingWMR robots

Define anachievable

specification

Design a miniaturemulti-terrain robot

Include noveland innovativedesign in robot

Consider ease ofmanufacture and

maintenance in design

Test and validatecomponents and

features

Provision for furtherwork with handover

documents

Showcase the robotthrough exhibitionsand media sources

ProjectObjectives

Design Overview

IntroductionDesign




Presented by

RebeccaSaunders

Benchmarking

IntroductionDesign




USAR

Strengths Weaknesses

Strong manipulator MobileWide range ofsensors

Very bespoke Difficult to diagnoseand repair faults Unreliable drivetrain Heavy Large and unwieldy

M-USAR


Weight < 25kg Strong MakerBeam®

chassis Small size Uses off-the-shelfcomponents

Long battery change time Difficult to accessinternal components Poor chassis clearance Exposed brushed motorsWiring through movingcomponents Inadequate batterymanagement Poor battery life

Specification Overview

IntroductionDesign




Lightweight andadaptable chassis

Tracks

Suspension

Sensory array

Batterymonitoring

Strong shellMain

Features

Design Methodology

IntroductionDesign




ConceptDesign Stage

DesignDevelopment

Stage

DesignValidation

Stage

IntroductionDesign




Chassis

Presented by

Craig Fox

Chassis – Specification

IntroductionDesign




Max. length 522.0 mm

Max. height315.0 mmAccess panels

CoG low and central

Max. mass 5.0 kg

Crash at 1.0 ms-1

without chassis damage

Fall from 350.0mm without

chassis damage

Min. internal volume 3.9 x 10-3 m3

IntroductionDesign




Chassis – Concept Design

Chassis – MakerBeam®

Extruded 6000 seriesaluminium beam

Good ease of assembly

Good specific strength

Shell – 6082-T6 aluminium plate Good thermal conductivity

Good machinability

Lightweight properties

Chassis – Design Iterations

IntroductionDesign




V1 V2 V3 V4

Chassis – Design Iteration Summary

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Change in chassis design efficiency with version

Ratio of Internal Volume to LWH

IntroductionDesign




Chassis – Shell Design

IntroductionDesign




Chassis – Crash and Fall Resistance

SolidWorks buckling analyses of chassis response to a crash at 1.0 ms-1 and a fallheight of 350.0 mm

Maximum crash deflection of 32.7 mm and bending load factor of 41.4

Maximum fall deflection of 18.7 mm and bending load factor of -70.4

IntroductionDesign




Crash Fall

Chassis – Final Design

IntroductionDesign




IntroductionDesign




Drivetrain

Presented by

LeighDawson

Lightweight

Compact

Durable

Mobile

IntroductionDesign




Drivetrain – Specification

Steering: Dual drive

Motors: Maxon Motor, EC-4pole

Ø22 mm, brushless, 90 Watt motor

IntroductionDesign




Drivetrain – Power & Transmission

Power fromMotors

Power toTracks

Power toTracks

Drivetrain – Power & Transmission

Internal Layout:Sprocket & chainconfiguration turningdrive shafts

Motor &Gearhead

Sprockets &Chain

Drive Shaft

IntroductionDesign




Drivetrain – Suspension

Increased Mobility:Allows the M-USAR toeasier traverse rough terrain

Dual Shock Absorption:T-piece pivot handles smallinconsistencies; largervariations activate arm pivot

IntroductionDesign




IntroductionDesign




Drivetrain – Suspension Design Iterations

V2 V3

Drivetrain – Suspension Validation

IntroductionDesign




Theoretical Modelling FEA Abaqus Simulations

IntroductionDesign




Drivetrain – Tracks

Tread Design: 20mm spacing of 10mmrubber treads; 10mm backing tread

Material: AbbrX 55 - silica-reinforcednatural and synthetic rubber mix tread

Track Guidance & Tensioning: 10mmraised guide on backing track to preventlateral disengagement. Adjustabletensioning

IntroductionDesign




Drivetrain – Final Designs

Power & Transmission Suspension Tracks

IntroductionDesign




Electronics& Software

Presented by

Avnish Popat &John Strutton

Electronics and Software – Architecture Overview

IntroductionDesign




IntroductionDesign




Electronics and Software – Computational Architecture

Archi diagram

Electronics and Software – Architecture Diagram

IntroductionDesign




Software E-StopPico-ITX comms.

Battery Voltage Monitor

Electronics and Software – Safety System: BatteryMaster Switching

IntroductionDesign




Electronics and Software – Power Distribution Board

IntroductionDesign




Additional outputs

Thick Traces forflexibility

High power DC-DCconverters

Interchangeable fuses

Miniaturisation

Network and SLAM

Provision for reliable code, architecture and internal wiring

Test with singular motors prove capability and controllability

Modularity, power, and space for further expansion

IntroductionDesign




Electronics and Software – Summary

IntroductionDesign




Final Design

Presented by

RebeccaSaunders

Final CAD Design

IntroductionDesign




Wireframe Model Fully Rendered Model

Manufacturing

IntroductionDesign




Orion M-USAR

IntroductionDesign




Critical Review

IntroductionDesign




Orion


Optimised drivetrain with tracks and suspensionto enable multi-terrain travel Strong & accessible chassis and shell Battery safety system through quick access andemergency stop Easily adaptable mechanical and electricalsystems

Internal use of space could be more efficientWeight distribution Limited Battery Life Suspension is vulnerable to side impacts

IntroductionDesign




Conclusions

Presented by

Paul Martin

Total Project Cost:£58,964.94

Material Cost:£4,082.94

Estimated Cost of Human Life:£6.1 million

IntroductionDesign




Costs

Outreach

IntroductionDesign




Imagineering Fair 2014

3D Printing in Schools Showcase at theHerbert Art Gallery

WMG’s “Thinking About University?” andother recruitment events

School of Engineering Open Days

Cheltenham Science Festival

Publicity

IntroductionDesign




Project featured in: Eureka Magazine (website), January 2015 Control, Drives and Automation (website), January 2015 (Editor’s Pick) Maxon e-Newsletter, January and February 2015 Design Engineering News, February 2015 (Page 1) The Engineer (website), February 2015 Motion Control Newsletter, March 2015 P&T Review (website), March 2015

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IntroductionDesign




Strategy – Objectives1. Analyse Current USAR Designs

2. Benchmark Existing WMR Robots

3. Define an Achievable Specification

4. Design a Miniature Multi-Terrain Robot

5. Include Novel and Innovative Features

6. Consider Ease of Manufacture and Assembly

7. Test and Validate Components and Features

8. Provision for Further Work with Handover Documents

9. Showcase the Robot through Exhibitions and Media

IntroductionDesign




Aim 1:

Deliver a mechatronic framework for an innovative M-USAR robot byMay 2015 as the first stage of a three year plan

Aim 2:

Provision for design development by future WMR teams

Aim 3:

Exhibit the robot as an educational platform to inspire youngergenerations

Strategy – Project Aims

Recommendations

IntroductionDesign




IntroductionDesign




Innovative Design & Analysis

Manufacture & Testing

Programming & Architecture

Under Budget

Outreach, Media & Publicity

Achievement of Aims &Objectives

Long Term Three-Year Plan

Summary

IntroductionDesign




Thank You for Listening,Any Questions?

Warwick Mobile Robotics 2014/15€¦ · Chassis Drivetrain Electronics & Software Final Design...

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Transcript of Warwick Mobile Robotics 2014/15€¦ · Chassis Drivetrain Electronics & Software Final Design...