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RAPID FIRE

RAPID FIRE. Robotically Actuated Prevention/Intervention Device Full of Innovative and Responsible Engineering Critical Design Review February 25, 2010 Riley Pack Eric Pahlke Kelly Shuster Greg Stahl. Project Overview .

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RAPID FIRE

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  1. RAPID FIRE Robotically Actuated Prevention/Intervention Device Full of Innovative and Responsible Engineering Critical Design Review February 25, 2010 Riley Pack Eric Pahlke Kelly Shuster Greg Stahl

  2. 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.

  3. Block Diagram Camera Board(s) with FIFO DSP(s) Mechanical Power Control Processor Motors Digital Connection Power Connection Analog Connection

  4. Expandable Hardware Architecture Camera PCB Camera PCB Up to 4 Cameras per DSP Camera PCB Camera PCB DSP PCB DSP PCB Up to 4 DSPs Currently using 2 DSPs (8 total cameras) Power Supply Motor Controller PCB Motors Data Connection Power Connection

  5. Control Processor Camera Board(s) with FIFO DSP(s) Mechanical Power Control Processor Motors Digital Connection Power Connection Analog Connection

  6. 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

  7. 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

  8. control Processor Target Motor Position from DSP SPI Interface Actual Motor Position from Optical Motor Encoder Plant Controller

  9. control Processor Target Position Actual Position KPs + KI b = 0.045 M = 2.3kg R = 4.5 in J = 0.5*M*R2 T = 0.4689 Nm = 66.4 oz-in = 80% of Max Efficiency

  10. control Processor KP = 100 KI = 50 tR = 1.5s tS = 5 s 20% overshoot

  11. control Processor

  12. CAMERA(s) Camera Board(s) with FIFO DSP(s) Mechanical Power Control Processor Motors Digital Connection Power Connection Analog Connection

  13. 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

  14. Camera(s) Camera SDA DCLK SCL Glue Logic VD HD uC/DSP Enable And Write Strobes 8-bit Parallel Data FIFO to USB Converter Debug to PC FIFO 8-bit Parallel Data to DSP

  15. Camera(s) – Test Board USB-FIFO Camera SPLD FIFO

  16. Camera(s) – Test Board • Almost Able to Take Sub-QCIF (128 x 96) Resolution Pictures • USB Write Speed Too Slow • Solution: Upgrade to Faster USB Chip

  17. Camera(s) – Test Board FIFO WR USB WR

  18. 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

  19. Camera(s) – Camera / FIFO Interface

  20. Camera(s) – CAMERA / SPLD Interface

  21. Camera(s) – Revision 2 Layout Level Shifter Camera FIFO USB- FIFO

  22. Power Camera Board(s) with FIFO DSP(s) Mechanical Power Control Processor Motors Digital Connection Power Connection Analog Connection

  23. 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)

  24. 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

  25. Digital Signal Processor Camera Board(s) with FIFO DSP(s) Mechanical Power Control Processor Motors Digital Connection Power Connection Analog Connection

  26. 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

  27. 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

  28. 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

  29. 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)

  30. Digital Signal Processor PCB Power 5V from MC PCB Isolated 3.3V DC-DC 1.26V VREG To Camera PCB I2C Switch USB Debug Isolators/ Level Shifters DSP AVR EEPROMs SDRAM Programming Port Data to MC PCB I/O Expanders LEDs/ Debug Memory Bus SPI RS232 Power Connection I2C GPIO

  31. Digital Signal Processor PCB Layout To Cameras I/O Expanders RS232 ISOLATORS DSP SDRAM Boot loader USB To MC

  32. Digital Signal Processor PCB Layout To Cameras I/O Expanders RS232 ISOLATORS DSP SDRAM Boot loader USB To MC

  33. Motion Detection Algorithm Subtract Current Image From Previous Break Difference Image Into an n-by-n Grid Start No Checked Each Region? Accumulate Location and Count of All Pixels in Region with Difference Above Threshold Yes Find Largest Connected Set of Regions Mark Region as Having Motion Find Centroid of Regions in Largest Set of Connected Regions RegionNorm > NORM_MIN? No Yes

  34. Motors/Mechanical Camera Board(s) with FIFO DSP(s) Mechanical Power Control Processor Motors Digital Connection Power Connection Analog Connection

  35. 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

  36. Motors/Mechanical • Turntable Selection • Shepherd 9548 • Purchased from Home Depot • Specifications • 500 lb Load Capacity • 6 in. x 6 in. Size

  37. 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

  38. Motors/Mechanical • Encoder Selection • AvagoAEDB-9140-F12 • Specifications • Optical Encoder • 256 Cycles/Revolution • 1024 Signal Changes/Revolution • Fits Motor Shaft http://www.avagotech.com/docs/AV02-1584EN

  39. 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

  40. Control Processor/Mechanical Interface uC SDA x2 SCL Encoder Relative Angular Position Changes DSP Mechanical Interface PWM Output Current H-Bridge Motor

  41. Division of Labor

  42. Expenses

  43. Schedule

  44. 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

  45. Milestone 2 • Control System Tuned Correctly • DSP Interfaced with One Camera • DSP Running Correct Algorithms • DSP Sending Targeting Positions to Control System

  46. Design Expo • Full System Operating Correctly with One or More Cameras • Technical Manual • User Manual

  47. Kelly Shuster • Riley Pack • Eric Pahlke • Greg Stahl Questions?

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