AUV ROBOSUB 2016-2017 COLORADO STATE UNIVERSITY ELECTRICAL AND - - PowerPoint PPT Presentation

AUV ROBOSUB 2016-2017

COLORADO STATE UNIVERSITY ELECTRICAL AND COMPUTER ENGINEERING DEPARTMENT SENIOR DESIGN FALL 2016

PRESENTATION OVERVIEW

• 1. Introduction to the team and project
• 2. Sub-team constraints and design

i. Mechanical ii. Sensors iii. Power and Propulsion 3. Summary with Q&A

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Colorado State University, Electrical and Computer Engineering Department

TEAM MEMBERS

• Project Advisor
• Dr. Anthony Maciejewski
• VIP Team Advisor
• Olivera Notaros
• Senior Computer Engineer
• Tyler Loughrey
• Senior Electrical Engineers
• Brett Gonzales
• Chris McLean
• Phil Meister
• Senior Mechanical Engineers
• Nate Marquez
• Seth Purkey
• Mitchell Yohanan
• Graduate Student Advisors
• Megan Emmons
• Chris Robbiano
• Junior Team Members
• Marta Camacho
• Oren Pierce
• Billy Phillips
• Freshman Team Members
• Chris Alleman
• Ben Fox
• Katie Wood
• Prospective Senior Members
• Ty Henningsen (EE)
• Jordan Lankford (EE)

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Colorado State University, Electrical and Computer Engineering Department

TEAM ORGANIZATION

GSA GSA Sub-team Members Project Advisor Team Lead Sub-team Members Sub-team Members Mechanical Lead Sensor Lead Propulsion Lead

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Colorado State University, Electrical and Computer Engineering Department

PROJECT OVERVIEW

• Project Purpose
• Killick is a multi-disciplinary,

student-proposed senior design project involving the design, construction, and testing of an autonomous underwater vehicle (AUV) based on the US Navy RoboSub Competition

University of Florida SubjuGator 8

(SOURCE: http://subjugator.org/?page_id=2661)

Cornell University Argo (Double Hull)

(SOURCE: http://www.cuauv.org/vehicles.php)

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Colorado State University, Electrical and Computer Engineering Department

COURSE LAYOUT

Scoring Metrics

• Speed
• Accuracy
• Weight

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Known Features

• Depth control
• Path following

Colorado State University, Electrical and Computer Engineering Department

BUDGET AND FUNDRAISING

Item Cost

Motors $1800 Motor Control / MicroControl $1000 Power Supply $800 Sensors $2500 MISC $1000 Final Vehicle Chassis $1500 Prototype Vehicle Chassis $800 Mechanical Blunders $1000 Electrical Blunders $1300 Total $11,700

Sponsorships:

• Ball Aerospace
• Hewlett Packard
• IEEE

Funds raised:

• $16,600

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Colorado State University, Electrical and Computer Engineering Department

PROJECT TIMELINE

• First Year Goals
• Establish an operational platform for future

teams

• Restricted 1st year design
• Mechanical design and fabrication
• Inertial and image based sensing
• Propulsion
• Future teams to refine sensing, controls,

mechanical armature, and efficiency

• Gain practical engineering experience in

propulsion, control systems, vision, sensing mechanical design/test, and team dynamics

• Estimated Project Timeline
• September-December 2016
• Design and simulation, Test Rig
• Start build of Test Rig
• December-March 2017
• Rules release December 2016
• Design refinement, Final Rig
• Start build of Final Rig
• March-May 2017
• Design revision and additional testing

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Colorado State University, Electrical and Computer Engineering Department

MECHANICAL OVERVIEW

• Chassis Design
• Electrical Housing
• Ballast System

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Colorado State University, Electrical and Computer Engineering Department

CHASSIS

• Main purpose is to provide protection for the electrical housing and motors
• Modular design for mounting external motors
• Drag Force = 15.6 lb-f

Original Design Considerations: Box vs X-Wing Current Design

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Colorado State University, Electrical and Computer Engineering Department

ELECTRICAL HOUSING

• Maintain a safe and dry environment for the internal electrical components
• Potential Shapes
• Half Cylinder, Half Capsule, Full Cylinder
• Overall volume directly affects buoyancy
• Material
• Transparency required
• Options: Acrylic, Clear PVC, Polycarbonate

Full Cylinder Half Cylinder Half Capsule

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Colorado State University, Electrical and Computer Engineering Department

ELECTRICAL HOUSING CONT.

• Cap Design
• O-Ring for seal on detachable cap
• Main source of heat dissipation
• Thermodynamics
• Fans increase heat transfer rate
• Max internal temp of 70˚C
• Ease of access

Thermodynamics: Velocity Plot Thermodynamics: Temperature Plot

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Colorado State University, Electrical and Computer Engineering Department

BALLAST

• Achieve Neutral Buoyancy
• Volume of vessel determines dry land weight
• Current Upward Buoyant force: 95lbs
• Fail Safe
• Achieve positive buoyancy upon electrical failure
• Using a ‘balloon’ and mini CO2 Cartridge

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Colorado State University, Electrical and Computer Engineering Department

MECHANICAL - FUTURE WORK

Testing/Validation Re-Design Manufacturing

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Colorado State University, Electrical and Computer Engineering Department

PROCESS AND FLOW (ELECTRICAL)

Sensor Data (SD) Processing (SPU)

Detect Respond

Translate (MPU) Locomotion (MD+M)

Correct Decide

Decision (MCU))

Terminology

SD – Sensor Device SPU- Sensor Processing Unit MCU – Master Control Unit MPU – Motor Processing Unit MD – Motor Driver M - Motor

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Colorado State University, Electrical and Computer Engineering Department

Filtered Images Raw Images Raw Sensor Data

SENSOR AND PROCESSING OVERVIEW

Pressure Transducers Inertial Measurement Unit (IMU) Optical Devices (OD) Sensor Processing Unit (SPU)

To MCU Processed Sensor Data

Colorado State University, Electrical and Computer Engineering Department

Image Processing Unit

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SENSORS

• Inertial Measurement Unit (IMU)
• Provides movement data for 3 orthogonal axes
• Accelerometer
• Gyroscope
• Magnetometer
• Needs filtering to reduce noise
• Pressure Transducers
• Differential Pressure
• Outputs voltage relative to underwater pressure
• Calibrated at top of water

Sparton AHRS-8 IMU

Sparton (SOURCE: http://www.unmannedsystemstechnology.com/wp- content/uploads/2012/07/sparton.jpg)

Colorado State University, Electrical and Computer Engineering Department

• Sensors Processing Unit
• Low Power consumption
• GPIO pins for sensors communication

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PROGRESS

Colorado State University, Electrical and Computer Engineering Department

• Noise Reduction
• Signal-to-Noise Ratio (SNR)
• Filtering

Low SNR High SNR

• Research Issues
• Communication Protocols
• Python bit manipulation

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IMAGE PROCESSING

• Cameras
• Provide raw images of guiding line on bottom of pool
• Able to extract these images in real-time
• Needs to be filtered to find position of vehicle
• Image Processing Unit
• Converts raw images to navigational data for the SPU
• Filters to find only the line of tape and its position relative to the

camera

Allied Mako G-234 Allied Vision (SOURCE: https://www.alliedvision.com/en/products/cameras/detail/Mako%20 G/G-234.html) 19

Colorado State University, Electrical and Computer Engineering Department

IMAGE PROCESSING PROGRESS

• Have developed multiple schemes to filter for the line before finding one that works

Original Test Image First Filtering Attempt

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Colorado State University, Electrical and Computer Engineering Department

IMAGE PROCESSING PROGRESS CONTINUED

Image with Region of Interest Identified Final Filtered Image

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SENSORS - FUTURE WORK

• Image Processing
• Calculate position of line relative to whole

image

• Fine-tune filtering scheme for real-world

testing

• Master Control Unit (MCU)
• Convert navigation data to usable data for

Motor Controller

• Inertial Measurement Unit (IMU)
• Implement filtering schemes
• Calculate real position
• Sensors Processing Unit (SPU)
• Combine pressure transducer and IMU

data to increase positional accuracy

• Communication protocols to MCU

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Colorado State University, Electrical and Computer Engineering Department

OVERVIEW OF POWER AND PROPULSION

Control

Motor Driving

Power

IVP & Weight

Motors

Weight, Thrust, IVP & Size

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Colorado State University, Electrical and Computer Engineering Department

INITIAL DESIGN CONSTRAINTS

• Power Supply
• Weigh << 5lbs each
• Power systems must be

calculated to size batteries

• Must have built in Battery

Management

• Must report to Master

Control unit for safety reasons

• Motor Processing Unit
• Most likely digital signal

processor

• Cost should be ≈ $300-

800

• Must be able to control 6

motors independently and in real-time

• Reinforces DSP

notion

• Motors
• “Small” motors
• Compact
• Easily mountable
• Weighs under 1lb per

motor

• Cost of motors ≤ $300/motor
• Must exceed torque

requirements for vehicle

• Can always use less but
• nly if available

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Colorado State University, Electrical and Computer Engineering Department

MOTORS

WEIGHT

• 3 phase BLDC sensorless
• ~430 W
• ~770 Kv
• ~30 A
• ~16 V nominal

VOLTAGE, CURRENT, POWER

• Less weight = higher score
• Naked motor ( 0.16 lbs )
• Housing ( < .16 lbs)

THRUST

• Fluid Modeling  15.6 lb-f
• Thrust proportional to speed

x effective area

• Effective area

proportional to torque

• 𝑈𝑁𝐵𝑌 = 𝐿𝐹 ∗ 𝐽𝑁𝐵𝑌
• 10 lb-f for 3 inch

propeller

TMotor UAV Brushless Motor MS2814 770Kv (BLDC) Machinable Wax Blocks 2" Thick

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POWER SUPPLY

WEIGHT

• Less weight = higher score
• LiPo ( < 2 lbs)
• IP68 housing

VOLTAGE, CURRENT, POWER CHARGER

• Middle of the road estimate
• 8 Ah @ 150 C (1200 Amp

Burst)

• 4 S / 2 P (14.8 Volts nominal)
• Voltage taps at cell level for

BMS

• 5C charge rate

iCharger 206B, Junsi P350 Power Supply LiPo 8000 4S 14.8v Dual Core Battery Pack

• Built in BMS (for charging)
• 20 Amp/h charge rate
• 300 W supply
• Provides cell balancing

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Colorado State University, Electrical and Computer Engineering Department

MOTOR CONTROLLER

DSP+ MCU

• Field-Oriented Control
• Best type of feedback

mechanism for BLDC

• Not implemented in 2016-

2017

VERTICAL INTEGRATION

• C2000 Piccolo F28069M

MCU

• 24 PWM channels, 12-bit

ADC, I2C, CAN2B, USB, UART, SPI

DEVELOPMENT BOARD

• Uses Code Composer Studio

and MotorWare

• No on board voltage

regulator

• Electronic speed control

multiplexes each PWM Signal for 3 phase BLDC

Texas Instruments LAUNCHXL-F28069M 40A BlueSeries Brushless Speed Controller

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Colorado State University, Electrical and Computer Engineering Department

POWER AND PROPULSION - FUTURE WORK

• Testing of Prototype
• Motor load testing
• IVP under various “modes”
• Design &Testing of a variety
• f propellers and shrouds
• Thermodynamic Data

Collection

• Vetting of BMS
• In Final Phase
• PCB for BMS
• PCB for IMU
• PCB for Systems Integration
• Additional motors and PID

control development

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Colorado State University, Electrical and Computer Engineering Department

SUMMARY

POWER AND PROPULSION

• Motors
• 14.8 V, 30 amp (max), 1 A no-

load

• Cheap and light but not

waterproof

• Power Supply
• LiPo 4S/2P 150 C 14.8 V
• Light but not cheap
• Motor Processing
• Vertical integration capability

SENSORS

• Chassis
• Protection
• Corrosion Resistance
• Modular Motor Placement
• Electrical Housing
• Clear PVC material
• Heat Dissipation
• Ease of Access
• Ballast
• Neutral Buoyancy
• Fail Safe

MECHANICAL

• IMU
• Movement Data
• Noise Reduction
• Pressure Transducers
• Depth Sensing
• SPU
• Processes Sensor Data
• Image Processing
• Filters Images
• Finds Position of Sub

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Colorado State University, Electrical and Computer Engineering Department

PROJECT ASPECTS

• Propulsion
• Motor size
• Motor power
• MCU
• Sensor power
• Temperature management
• Wire management
• Component choice
• RF design
• Wireless communication for

testing

• Motor control signaling
• Systems interfacing
• Risk/Failure management
• Functional indicators
• Mechanical
• Chassis design
• SolidWorks model
• Electronics location
• Buoyancy
• Propulsion
• ANSYS model simulation
• Stress analysis
• Fluid dynamics
• Heat transfer
• Temperature management
• Material consideration
• Weight
• Rigidity
• Water tightness
• Corrosion resistance
• Risk/Failure management
• Manufacturing/ assembly logistics
• Material acquisition
• Sensor
• MCU/CPU programming
• Language choice
• Programming environment
• Mode control
• Surface control for testing
• Algorithm implementation
• Signal implementation
• Sensor location/ selection
• Image processing
• Sensor processing
• Data logging
• Vehicle-Surface communication for

testing

• Systems interfacing
• Image analysis
• Data logging

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Colorado State University, Electrical and Computer Engineering Department

BUDGET BREAKDOWN

• Motors

$ 1800

• Primary RMCU

$ 400

• Motor Microcontrollers

$ 600

• Battery Power Supply

$ 700

• Controller Power Supply

$ 100

• Inertial Measurement Unit

$1200

• Hydrophone System (HS)

$ 800

• Test Rig

$ 5500

• Electrical Tether

$ 200

• Signal Amplifiers

$ 100

• Underwater Cameras

$ 400

• Connectors

$ 500

• Gaskets

$ 70

• Wires

$ 200

• Mechanical Tether

$ 30

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Colorado State University, Electrical and Computer Engineering Department