Advanced Remote Monitoring and Operated Recon Device Andrew Lichenstein Kevin Jadunandan Thomas Kehr
Mar 13, 2016
Advanced Remote Monitoring and Operated Recon Device
Andrew LichensteinKevin Jadunandan
Thomas Kehr
Motivation
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Dragon Runner surveillance robot Extremely Durable Fast and lightweight platform ≈$32,000 per unit
Objectives: Fraction of the Price(< $2000) Withstand drop of two stories Maneuverability on all terrains Wireless Control/Video
iPhone Control
Hardware Block Diagram
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Specifications
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Low High Units
Length 1 2 Feet
Width 1 2 Feet
Height ¼ ¾ Feet
Weight 5 15 Lbs
Low High Units
Motor Battery 12 24 Volts
Control Battery 9 12 Volts
Low High Units
Peak Speed 3 5 MPH
Wheel Size 5 10 Inches
Motor RPM 200 340 RPM
Turn Radius 0 5 Degrees
Locomotion
Battery Life
Low High Units
Video Frame Rate 20 30 FPS
Operating Distance 15 100 Feet
Communication
Body
Operating VoltageLow High Units
High Usage ½ 1 Hours
Low Usage 1 4 Hours
Chassis
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Raw Material Selection
Suspension
Body Design
Polyurea
Component Mounting
Camera
Chassis: Raw Material Selection
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Aluminum Low-cost Light weight High cost of manipulation
Fiberglass Composite Extremely low cost Easily manipulated High Strength Experienced with fabrication Permeable to Radio frequencies
Fiberglass Carbon Fiber AluminumUltimate Strength (MPa) 3,450 5,650 40-50
Yield Strength (MPa) N/A N/A 15-20
Density (g/cm3) 2.57 1.75 2.7
Average Price ($/ft) 0.91 13.80 7.50
Carbon Fiber High cost High Strength Complex manipulation
Chassis: Suspension
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Aluminum Frame – 1/8” Aluminum Sheet Provide mounting for components No metal on metal; rubber washers
Spring Suspension System 32 Springs 8 Motor Clamps
Chassis: Body Design
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Fiberglass-Composite Construction
Clam-Shell Design
Plug and Mold Fabrication
Accommodate Peripherals
20”
7”
17”
Chassis: Body Design
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Ventilation and Cooling 4 12V Micro CPU Fans 2 Intake; 2 Outtake
Component Mounting Spring Suspension No Metal Contact
Chassis: Polyurea
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Truck Bed Liner Rhino Liner, etc.
Extreme Durability 41 MPa Tensile Strength
Quick Reaction Time Build up Multiple Layers
Explosive and Ballistic resistance
Drive Train
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Geared Motor
Wheels and Locomotion
Drive Train: Motor Selection
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IG42 Geared Motor 24:1 Gear Ratio 24V DC 252 rpm 2300mA 10 kgf-cm Torque
4.8”
1.75”
Drive Train: Wheels and Locomotion
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Wheels Wheel + Tire 10” Diameter Custom Mounting Hardware
Wheel Speed Speed (fpm) = (Diameter of wheel (in) x π x rpm of
motor) /12 = (10” x π x 252) /12 = 659.7 ft/m = 7.59 mph
Power System
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Batteries
Control Battery
Drive Battery
Power System: Batteries
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NiMH Rechargeable Packs 24V 4500 mAHr
Drive Battery 12V 4000 mAHr
Control Battery
5" x 2" x 2"
10" x 2" x 2"
Power System: Control Battery
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Capacity = 4000mAHr
Current Drain of system = 795mA
Estimated battery life ≈ 5 hrs
Regulators of 3.3V, 5V, and 9V are used to power the main logic and peripheral devices of ARMORD
Component Current Draw
Operating Voltage
Power Consumption
XBee Pro 55ma 3.3V 0.18 Watts
Falcom FSA03 40ma 3.3V 0.132 Watts
PIC18F4520 200ma 5V 1 Watt
Wireless Camera
500ma 9V 4.5 Watts
Total 795ma 5.812 Watts
Power System: Drive Battery
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Battery Capacity= 4.5 A Hr
Current Draw= 2300mA x 4 = 9.2 A
Battery Life = 29.3 minutes
Component Current Draw Operating Voltage
Power Consumption
IG42 Geared Motor 2300mA 24V 55.2Watts
Video System: Camera
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380-lines resolution
150-foot range (no obstacles)
2.4 GHz output frequency
Built-in microphone
Internal Hardware
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MCU
GPS
Communication
Motor Controller
Internal Hardware: MCU
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Features our group looked for in MCU: CPU Speed >= 4MIPS (10 MIPS)
Program Memory >= 16KB (32KB)
Internal Oscillator >= 4MHz (16MHz)
IO Pins >= 15 (30)
ADC >= 2 (15)
Program in C/C++ using MPLAB IDE
Temperature Range (-40 to 125 C)
PDIP
*PIC18F4520 Max Spec’s in ()
PIC18F4520
Internal Hardware: MCU
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Communication is the most essential part of our robot, we will need to be sending and receiving data from our Gateway to be able to control our robot. We will be using the USART pins on the MCU, which allows us to send serial data.
Our MCU will need to be data parsing when it receives GPS updates which come in the form of a string of data. We will be emulating the hardware by using software USART, which is also know as bit-banging.
Motor Control will be done by having two variables set , one for the left motors and one for the right motors. We will be sending a value of 0 to 255, which will tell which motor to move and how which direction it should spin the motor. This also will be using software USART.
Battery life testing will be done using AD Converters, so we will know when the battery is running low.
Communication: Options
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XBee vs. XBee Pro vs. Bluetooth Class 1
XBee XBee Pro Bluetooth Class 1
Indoor Range Up to 100ft
Up to 300ft
Up to 330 ft
Outdoor/LOS Up to 300ft
Up to 1 Mile
Up to 330 ft
Data Rate 250Kbps 250Kbps Up to 3 Mb/s
Unit Price $22.95 $37.95 $59.95
The Bluetooth was a bit to expensive and the regular XBee distance was a bit to small. This is why we chose the XBee Pro which was a good combination of both data rate and distance. We really only need 300 to 400 ft max for our application.
Internal Hardware: GPS
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We originally were looking at the Copernicus GPS Module that was sold on Sparkfun, but after talking with other sources they pointed out to me the Falcom FSA03 unit. Here are the details of the unit:
Copernicus FalcomCold Start 39 sec 29 sec
Hot Start 9 sec <1 sec
Antenna Not Included Attached
Update Rate 1Hz 4Hz
Channel 12 32
One of the best features of this chips is that it has a Sarantel helical antenna which lets you orient this GPS any way you would like , so you don’t have to make it point towards the sky.
Communication: GPS Purpose
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The GPS’s main purpose was to be sending latitude and longitude to our microcontroller so that we could use this data with our iPhone application. The GPS sends NMEA(National Marine Electronics Association) data to our MCU; here is an example of what it looks like:
$GPGLL,4916.45,N,12311.12,W,225444,A,*1D
As you can see the data that is sent is not an easy to read format so our MCU will parse the data needed and send to a variable that will be sent out via XBee.
Geographic Lat & Lon
49o16.45
123o11.12
Time(UTC)
Data Active
Checksum
Motor Controller: Selection
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Originally we were thinking of creating our own motor controller using PNP BJTs but due to the fact we wanted stability and more features we decided to buy the Sabertooth 10A Dual Motor Controllers. One of the key features that we really liked as a group was that it is a regenerative motor driver, so when the robot stops or reverses it recharges the batteries with the wasted energy. It also has over current and thermal protection which means we won’t have to worry about damaging the motor controllers.
Motor Controller: Setup
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In our setup we will be using two motor controllers in parallel. So we will be using one pin on our MCU a Tx line that uses software USART that connects to the S1 ports on the motor controllers.
The Tx line on the MCU will transmit to both of the motor controllers S1 lines at the same time. We will be sending values of 0 to 255 to the motor controllers .
A value of 1 to 127 controls the left motors and a value of 128 to 255 controls the right motors
MCU Software Diagram
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RECEIVE THREAD SEND THREAD
DATA STRUCTURES
-Left Motor-Right Motor
-GPSLat-GPSLon
-BatteryLife
Board Design Prototype
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Created in EagleCAD
Jumpers make it easy to connect peripherals
Custom PCB
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Using a flatbed plotter we make our own single sided PCBs for testing purposes. We can create 15 PCBs for less than $25.
Gateway / iPhone Interface
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Software applications
iPhone Application
Gateway Application
Software Communication
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Software
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iPhone Application Primary controlling device
Touch based interface
Displays map with location of user and ARMORD
Software
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iPhone Application Written in Objective C
Apple’s object oriented version of C Runs all C code natively
Xcode IDE and Interface Builder Provides drag and drop UI design
Software: iPhone GUI
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Software: iPhone GUI
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Software: iPhone GUI
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Software: iPhone
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Software: iPhone
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Distance Calculation Uses latitude and longitude
Distance in miles = 3963.0 * arccos[sin(lat1) * sin(lat2) +
cos(lat1) * cos(lat2) * cos(lon2 - lon1)]
Software: Gateway Application
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Purpose Wireless bridge between the iPhone and the ARMORD
Necessary because iPhone cannot easily connect to the XBee module
Communication Wi-Fi – iPhone XBee – Robot
Software: Gateway Application
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Requirements Wi-Fi connection COM port access
Options C# Java
Decision – Java More robust XBee API and support Cross platform development
Software: Gateway Application
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Software
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Packet Structure From iPhone To ARMORD
From ARMORD To iPhone
$ LEFT_MOTOR , RIGHT_MOTOR ;
$ LATITUDE , LONGITUDE , MOTOR_BAT , MCU_BAT ;
Video Transmission – Original Design
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Video is received by video capture card Computer broadcasts live stream over Wi-Fi iPhone plays live stream
Video Transmission – Original Design
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Problems For live video, iPhone only plays H264 video, with AAC
audio, encapsulated in an MPEG2-TS
Capture card software could not output proper video format
10 second video lag from camera to a computer watching the stream
Video Transmission – New Design
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Solution – External LCD Display Allows direct video feed from camera to display No processing on a computer to reduce video delay iPhone can now display more information on the
screenMapsGPS locationsDistanceBattery Life
Controller
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•Components 7” Standalone Monitor Ruggedized Grip and Frame AV Receiver 9.6V NiMH Battery
Video and Control up to 100 feet
Components attached to controller via aluminum bracket
Power supplied to AV Receiver and Monitor through 9.6V NiMH battery
Swivel mount to account for inversing camera orientation
AV Receiver
Administrative Information
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Project Status
Budget
Timeline
Additional Time
Project Status
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Budget
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Part Name Quantity Price Total Cost12V 2200mAHr NIMH 1 $23.90 $23.90 24V 4500mAHr NIMH 2 $124.80 $249.60 Falcom FSA03 GPS 1 $59.95 $59.95 24V 252 RPM Geared Motor 4 $44.90 $179.60 IPhone Grip 1 $25.50 $25.50 Sabertooth 10A Motor Controller 2 $79.99 $159.98 7 in. LCD 1 $79.99 $79.99 2.4GHz Mini Wireless Camera 2 $42.50 $85.00 Truck Bed Liner 2 $9.95 $19.90 XBee Pro 3 $37.95 $113.85 XBee USB Explorer 2 $24.95 $49.90 XBee Breakout Board 1 $9.95 $9.95 PIC18F4520 3 $4.50 $13.50 Misc(Body, Copper Clad, Etc.) NA $150.00 $150.00
Developmental Tools NA $150.00 $150.00
Shipping/Handling NA $150.00 $150.00
Total 25 $1,018.83 $1520.62
Timeline
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Additional Time..
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Hardware Add-ons: Accelerometer to determine speed and orientation IR Sensors for Motion Detecting Night Vision Camera
Software Add-ons: Zero Configuration using Bonjour Protocol UDP Broadcast instead of TCP Connection Eliminate Gateway
Questions
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