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MARSUPIALDetailed Design Review

Carnegie Robotics LLC.#10 40th Street

Pittsburgh, PA 15201

Jared RabyNico Gallardo

Chris GriffinSean Greenslade

Wesly Rice

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Agenda

• Introduction• Systems Design

® Tracks/Suspension® Wireless Node Payload® Wireless Node Deployment® Electrical Systems

• Risks• MSD II Schedule• Questions

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Introduction

• MARSUPIAL Tracked Rover for CRL• Scope

® Suspended Track System® Wireless Node System ® Electrical Systems

• Deliverables® Suspended Track System® Mesh Network Payload

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TRACKS AND SUSPENSIONWes

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Tracked Suspension System• Suspension

® Rugged against impact shock® Various environmental areas® Climb obstacles® Self Contained

– IP Rated seals

• Drive-Train® Off the shelf motors® Meet speed and torque requirements

– Simple gearing® Integrated electronics

– Odometry

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Tracked Suspension System• Tracks

® Proper materials– Coefficient of friction– Material stretch

® Outdoor resistant– Chemical and physical ruggedness

® Ease to install and remove

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Tracked Suspension System• Drive-Train

® Required Speed– Min of 5mph on level

ground® Require Torque

– To move 150 lbs of robot and payload

® Off the Shelf Motor– Reduce overall price

® Realistic Gear Train– 8.0:1 – 12.0:1– Planetary

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Tracked Suspension System BOM

Index Component Indv Price EstQty System Price Est1 TENSIONER BASE 150.00$ 4 UPPER TENSIONING ASSY 600.00$ 2 TENSIONER ARM 50.00$ 4 UPPER TENSIONING ASSY 200.00$ 3 UPPER TENSION SHAFT 30.00$ 4 UPPER TENSIONING ASSY 120.00$ 4 UPPER TENSIONING WHEEL 75.00$ 4 UPPER TENSIONING ASSY 300.00$ 5 BEARING, ZFM_1214 10.00$ 8 UPPER TENSIONING ASSY 80.00$ 6 WASHER, FLAT, M12 0.50$ 8 UPPER TENSIONING ASSY 4.00$ 7 WASHER,FLAT,M10 0.50$ 4 UPPER TENSIONING ASSY 2.00$ 8 WASHER,BELVILE 10MM 2.00$ 4 UPPER TENSIONING ASSY 8.00$ 9 WASHER,BELVILE 18.5MM 2.00$ 4 UPPER TENSIONING ASSY 8.00$

10 RETAINING RING,SMALLEY,VSM-14 2.00$ 4 UPPER TENSIONING ASSY 8.00$ 11 RETAINING RING,SMALLEY,VSM-12 2.00$ 8 UPPER TENSIONING ASSY 16.00$ 12 RETAINING RING,SMALLEY,VSM-6 2.00$ 4 UPPER TENSIONING ASSY 8.00$ 13 RETAINING RING,SMALLEY,VSM-10 2.00$ 4 UPPER TENSIONING ASSY 8.00$ 14 CLOCK TORSION SPRING 30.00$ 4 UPPER TENSIONING ASSY 120.00$ 15 M5-0.8X16MM 0.50$ 4 UPPER TENSIONING ASSY 2.00$ 16 BALLBEARING,SEALED,10MMID 8.00$ 8 UPPER TENSIONING ASSY 64.00$ 17 CHRISTIE ARM LOWER 75.00$ 4 LOWER ARM ASSY 300.00$ 18 BALLBEARING SEALED, 8MMID 10.00$ 8 LOWER ARM ASSY 80.00$ 19 BALLJOING ROD END 5.00$ 4 LOWER ARM ASSY 20.00$ 20 NUT NYLOC M5-0.8 0.50$ 4 LOWER ARM ASSY 2.00$ 21 LOWER CHRISTIE AXEL 20.00$ 4 LOWER ARM ASSY 80.00$ 22 M5-0.8X25MM 0.50$ 4 LOWER ARM ASSY 2.00$ 23 TENION WHEEL SHAFT 20.00$ 8 TENSIONWHEEL ASSY 160.00$ 24 TENSIONING WHEEL 65.00$ 16 TENSIONWHEEL ASSY 1,040.00$

Preliminary Mechanical BOM

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Tracked Suspension System BOM 225 RETAINING RING SMALLEY VSM-8 3.00$ 16 TENSIONWHEEL ASSY 48.00$ 26 WASHER, FLAT, M8 0.50$ 16 TENSIONWHEEL ASSY 8.00$ 27 WASHER, BELVILLE M8 2.00$ 8 TENSIONWHEEL ASSY 16.00$ 28 CHRISTIE ARM, UPPER 150.00$ 2 CHRISTIE ARM,UPPER ASSY 300.00$ 29 BALLBEARING SEALED, 8MMID 10.00$ 4 CHRISTIE ARM,UPPER ASSY 40.00$ 30 BALLJOING ROD END 5.00$ 4 CHRISTIE ARM,UPPER ASSY 20.00$ 31 BEARING,ZFM_1214 10.00$ 2 CHRISTIE ARM,UPPER ASSY 20.00$ 32 BEARING,ZFM_2023 10.00$ 4 CHRISTIE ARM,UPPER ASSY 40.00$ 33 AIR SPRING, TGF-8-20-150 40.00$ 2 CHRISTIE ARM,UPPER ASSY 80.00$ 34 M5-0.8X35MM 0.50$ 4 CHRISTIE ARM,UPPER ASSY 2.00$ 35 NUT NYLOC M5-0.8 0.50$ 4 CHRISTIE ARM,UPPER ASSY 2.00$ 36 UPPER ARM TO CHASSIS MOUNT 150.00$ 4 SUSPENSION MOUNT TO CHASSIS 600.00$ 37 RETAINING RING SMALLEY FS020 10.00$ 4 SUSPENSION MOUNT TO CHASSIS 40.00$ 38 FLAT WASHER, M20 0.50$ 8 SUSPENSION MOUNT TO CHASSIS 4.00$ 39 WASHER,BELVILLE M20 2.00$ 4 SUSPENSION MOUNT TO CHASSIS 8.00$ 40 CHRISTIE ARM UPPER REVERSE 150.00$ 2 CHRISTIE ARM,UPPER REVERSE ASSY 300.00$ 41 BALLBEARING SEALED, 8MMID 10.00$ 4 CHRISTIE ARM,UPPER REVERSE ASSY 40.00$ 42 BALLJOING ROD END 5.00$ 4 CHRISTIE ARM,UPPER REVERSE ASSY 20.00$ 43 BEARING,ZFM_1214 10.00$ 2 CHRISTIE ARM,UPPER REVERSE ASSY 20.00$ 44 BEARING,ZFM_2023 10.00$ 4 CHRISTIE ARM,UPPER REVERSE ASSY 40.00$ 45 AIR SPRING, TGF-8-20-150 40.00$ 2 CHRISTIE ARM,UPPER REVERSE ASSY 80.00$ 46 AIR SPRING, TGF-8-20-500 40.00$ 2 CHRISTIE ARM,UPPER REVERSE ASSY 80.00$ 47 M5-0.8X35MM 0.50$ 4 CHRISTIE ARM,UPPER REVERSE ASSY 2.00$

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Tracked Suspension System BOM 348 NUT NYLOC M5-0.8 0.50$ 4 CHRISTIE ARM,UPPER REVERSE ASSY 2.00$ 49 FRONT UNDRIVEN BASE 95.00$ 2 UNDRIVEN WHEEL TOP ASSY 190.00$ 50 BALLBEARING,SEALED,35MMID 10.00$ 4 UNDRIVEN WHEEL TOP ASSY 40.00$ 51 ENCODER SHAFT HOLDER 75.00$ 2 UNDRIVEN WHEEL TOP ASSY 150.00$ 52 USGIDITAL MAE3-X-197-220-7-X 35.00$ 2 UNDRIVEN WHEEL TOP ASSY 70.00$ 53 UNDRIVEN WHEEL BEARING CAP 95.00$ 2 UNDRIVEN WHEEL TOP ASSY 190.00$ 54 GREASE SEAL, 40MMID 20.00$ 2 UNDRIVEN WHEEL TOP ASSY 40.00$ 55 FRONT UNDRIVEN, AL 70 TK20K13-20250.00$ 2 UNDRIVEN WHEEL TOP ASSY 500.00$ 56 WASHER BELVILLE 35.5MMID 5.00$ 2 UNDRIVEN WHEEL TOP ASSY 10.00$ 57 M4-0.7X12MM 0.50$ 8 UNDRIVEN WHEEL TOP ASSY 4.00$ 58 M5-0.8X12MM 0.50$ 10 UNDRIVEN WHEEL TOP ASSY 5.00$ 59 BEARING CAP, LOWER, LEFT 50.00$ 2 CHRISTIE UPPER BEARING ASSY 100.00$ 60 BEARING,ZFM_1214 10.00$ 2 CHRISTIE UPPER BEARING ASSY 20.00$ 61 BEARING CAP, LOWER, RIGHT 50.00$ 2 CHRISTIE UPPER BEARING REVERSE ASSY 100.00$ 62 BEARING,ZFM_1214 10.00$ 2 CHRISTIE UPPER BEARING REVERSE ASSY 20.00$ 63 CHASIS LEFT SIDE 750.00$ 1 LEFTSIDE SUSPENSION_TOP ASSY 750.00$ 64 M5 THREADED INSERTS 1.00$ 36 LEFTSIDE SUSPENSION_TOP ASSY 36.00$ 65 M5-0.7X12MM 0.50$ 12 LEFTSIDE SUSPENSION_TOP ASSY 6.00$ 66 M5-0.7X14MM 0.50$ 42 LEFTSIDE SUSPENSION_TOP ASSY 21.00$ 67 CHASIS RIGHT SIDE 750.00$ 1 RIGHTSIDE SUSPENSION_TOP ASSY 750.00$ 68 M5 THREADED INSERTS 1.00$ 36 RIGHTSIDE SUSPENSION_TOP ASSY 36.00$ 69 M5-0.7X12MM 0.50$ 12 RIGHTSIDE SUSPENSION_TOP ASSY 6.00$ 70 M5-0.7X14MM 0.50$ 42 RIGHTSIDE SUSPENSION_TOP ASSY 21.00$ 71 MAXON EC60 FLAT 280.00$ 2 MOTOR TOP ASSY 560.00$ 72 SEPAC BRAKE SEB-175 150.00$ 2 MOTOR TOP ASSY 300.00$ 73 MOTOR,BRAKE,MOUNTING FLANGE 150.00$ 2 MOTOR TOP ASSY 300.00$ 74 MOTOR CHASSIS CASE 100.00$ 2 MOTOR TOP ASSY 200.00$ 75 REAR DRIVE WHEEL 250.00$ 2 MOTOR TOP ASSY 500.00$ 76 M4-0.7X10MM 0.50$ 22 MOTOR TOP ASSY 11.00$

Est Total 9,980.00$

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WIRELESS NODE PAYLOADSean

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Wireless Node Payload

• Droppable Node® OLinuXino – 575 MHz ARM Core

– Running Arch Linux with B.A.T.M.A.N. wireless mesh protocol– USB Wi/Fi adapter– Buck converter– Li-on battery providing upwards of 6 hours of runtime

• Current Prototype® 3D printed shell® Off-the-shelf antenna

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Wireless Node Payload Block Diagram

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Wireless Mesh Node BOM

Component Cost Distributor Manufacturer Manufacturer Part Number Qty. SystemPrice Est.

5 Volt Buck Converter $6.71Mouser RECOM Power R-785.0-0.5 8Puck $53.68Single Board Computer $32.95Mouser Olimex Ltd. IMX233-OLINUXINO-NANO 8Puck $263.60

WLAN USB Adapter $14.33Amazon LLC TP-Link TP-LINK TL-WN722N 8Puck $114.64

Li-Ion Battery $3.39Battery Space Battery Space PL-402248-2C 24Puck $81.36

Battery Protection Board $5.87Battery Space Battery Space PCB-LiS3A4 8Puck $46.96

Total $560.24

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WIRELESS NODE DEPLOYMENT

Jared

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Wireless Node Deployment System

• Needs to readily deploy the node while keeping in place during high impact moments

® High holding strength® Ability to drop the puck easily

• Deployment system should be isolated from the outside to comply with IP standards

® Dust / water prevention® Short circuit protection

• Magnetic holding system developed ® Magnetic slide in the track

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Wireless Node Deployment System CAD

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Wireless Node Deployment Schematic

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Wireless Node Deployment System PCB

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Wireless Node Deployment System BOM

Index Component Cost Distributor ManufacturerManufacturer Part Number Qty.

Price Est.

1 ALEL 1uF 50V $0.23Mouser Nichicon UVR1H010MDD1TD 3 $0.69

2 MLCC 0.1uF 50V X7R $0.10Mouser Kemet C0603C104K5RACTU 1 $0.10

3ISP Connection Headers $0.54Mouser Molex 10-89-7061 1 $0.54

4 Servo Connections $0.19Mouser Molex 87891-0306 10 $1.88

5Payload Microcontroller $1.30Mouser Atmel ATTINY2313A-SUR 1 $1.30

6TTL to RS232 Converter $3.84Mouser

Maxim Integrated MAX232ACSE+ 1 $3.84

7 12 MHz Crystal $0.49Mouser Vishay XT9SNLANA12M 1 $0.49

8 22 pF capacitor $0.20Digikey Yageo CC0402JRNPO9BN220 2 $0.40

Total $9.24

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POWER MANAGEMENT AND DISTRIBUTION

Nico and Chris

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Electrical Diagram

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Electrical Diagram – Batteries

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Electrical Diagram – Power Train

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Electrical Diagram – Peripherals

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Power Budget

Device Rail Voltage (V) Power (W)Efficiency (converters, drivers, etc)

Motor #1 24 100Motor #2 24 100Motor Controller #1 24 15 0.85Motor Controller #2 24 15 0.85Main Computer 5 10Power Management uC 5 5.00E-02Payload (Pucks) 24 1.68Payload (Dispenser) 5 10Lighting 24 40Camera 5 1.2Ethernet Switch 5 5Level Shifter 5 1.44E-Stop Comm Receiver 24 10IMU 5 1WLAN Radio 5 55V DC-DC 24 5.11725 0.853.3V DC-DC 5 0.425 0.66

Rail Power (W) Current (A)24V 286.8 11.945V 34.115 6.8233.3V 0.825 0.25

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Power Management Schematic

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Power Management Schematic (cont.)

• Two 24V Lithium Ion batteries provide 2kW of power (max)• All current is sourced through pin 5 of the current sensor

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Power Management Schematic (cont.)

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Power Management Schematic (cont.)

• Low current will be passed through the circuit → Low power dissipation

• Potentiometer is used to tune the divider

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Power Management Schematic (cont.)

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Power Management Schematic (cont.)

Rail # of outputs24Vu 55V 83.3V 3GNF 20TX 1RX 1

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Power Management Pin Allocations

ATMEGA328 Serial Communication ISP Sampling Crystal Total Analog DigitalInput 1 4 2 2 9 3 6

Output 1 1 1 0

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RISKS

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System Risks

Risk SeverityOccurrence Probability Mitigation Owner

1Staffing/engineering

ability 4 1

Consultation with advisor/customerScale back of scope Nico

2 Budget 5 1

Consultation with advisor/customerScale back of scope Wes

3 Machine setbacks 3 1 Plenty of lead time Wes4 Shipping setbacks 3 1 Plenty of lead time Nico5 Part setbacks 3 1 Plenty of lead time Jared

6Incorrect Engineering

Analysis 2 3Thorough verification of analysis

Per subsystem

7 Ordering errors 3 3 Thorough verification of BOM Nico

8Catastrophic prototype

failure 5 1

Proof of conceptsSmall scale tests before large scale tests Chris

9 Time constraints 2 4

Consultation with advisor/customerScale back of scope Jared

10 Hardware failure 3 4Thorough design verificationSpare components Chris

11 Mechanical failure 3 4Thorough design verificationSpare components Wes

12 Software failure 3 4Thorough design verificationSpare components Sean

13 Environmental factors 1 5 Review weather conditions Jared14 Technological limits 3 1 Review current technologies Sean

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Mechanical Risks

Risk SeverityOccurrence Probability Mitigation Owner

1

Unstable control of the robot while it's hanging from straps connected to mini-crane 5  0

Consultation with advisor/customerScale back of scope  Wes

2Module being dropped 5 2Reinforced chassis and shock absorption  Wes

4

Lose control of vehicle while it's descendingfrom the ramp 5  1 

Manual brakes/emergency brakesLimited/no power to the motors ->-> "coasting function" or clutch  Wes

4Limited slip to turn 5  3Make sure motors are powerfulenough to cause slipping  Wes

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Electrical Risks

Risk SeverityOccurrence Probability Mitigation Owner

1

Visual inspection of robot isnot adequate in identifying

all malfunctions  5  2Perform electrical self tests to identify other malfunctions  Nico

2 Battery short circuits  5 1 Fuse to break circuit  Chris

3 Emergency stop malfunction  5 1  It doesn't.  Chris

4 Electrical noise in the system 4 1 Proper signal conditioning and isolation  Nico

5 Packet loss 5  5 Apply failsafe  Sean

6 Lighting malfunction 2  1  Infrared / additional backup  Jared

7 Faulty IMU readings 4 1  redundant IMU  Jared

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Software Risks

Risk SeverityOccurrence Probability Mitigation Owner

1 Packet loss 5   5 Apply software failsafe  Sean / Jared

2Wheel slippage causesbad odometry readings 3   4

Use GPS / Inertial sensors to correct odometry readings  Jared

3Poor / Unavailable GPS

connectivity 3   3Fall back on inertial sensors / odometry alone  Jared / Sean

4 Faulty IMU readings 4 1  redundant IMU  Jared5 Unstable control loop 5  1 Vigorous control loop testing Nico

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Safety Risks

Risk SeverityOccurrence Probability Mitigation Owner

1Weight consideration when lifting the

robot 5  1>1 person is used to lift the robot  Chris

2

Unstable control of the robot while it'sit's hanging from straps connected to

mini-crane 5  1

There needs to be 3 hook pointsin order to safely move the robotusing a crane  Wes

3 Safety to personnel 5 3 Needs to meet military safetystandard MIL 883E  Chris

4

Lose control of vehicle while it's descending

from the ramp 4  1 

Manual brakes/emergency brakesLimited/no power to the motors ->-> "coasting function" or clutch  Wes

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Schedule

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To be accomplished

• EMF interference mitigation• Further node deployment development

® Prototyping• Schematic and PCB design• Full BOMs• Detailed Design Review Slideshow• Final Detailed Design Review Slideshow• Continued EDGE Updates

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Questions