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Round-a-Bot: ME552 Final Presentation

The document summarizes a student project to design and build an inverted pendulum robot called Round-a-Bot that can transport a person safely indoors while balancing on a single ball. Key components fabricated for the robot include plates, bearings, wheels, and motor mounts. Assembly and testing of electronics, drive train, and balancing mechanisms was completed. Safety features like casters, charge indicators, and shields were incorporated. Next steps involve further sensor testing and control system development.

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217 views21 pages

Round-a-Bot: ME552 Final Presentation

The document summarizes a student project to design and build an inverted pendulum robot called Round-a-Bot that can transport a person safely indoors while balancing on a single ball. Key components fabricated for the robot include plates, bearings, wheels, and motor mounts. Assembly and testing of electronics, drive train, and balancing mechanisms was completed. Safety features like casters, charge indicators, and shields were incorporated. Next steps involve further sensor testing and control system development.

Uploaded by

kimdl5
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Round-a-Bot

Holonomic Inverted   Pendulum Robot


 

 
Jeff Fletcher 
Sung-Tu Ho
Jason Kloess 
Ranjit Raj 
Steve Vozar 

ME552 Final Presentation


 
13 December 2010

roundabot.wordpress.com
[BallP Robot, ieeespectrum.org]
Project Summary
Round-a-Bot: Holonomic Inverted Pendulum Mobile
Robot

• Project Objective:
o Design and build an inverted pendulum robot riding on a
single ball capable of transporting a person safely in an
indoor environment.
DR3 -------> Final Presentation
• All components from bill of materials ordered & obtained
• All fabricated components have been machined
• All electronic circuits tested
• The cRIO has been tested
• Assembly of the Round-a-bot completed
• Testing
o Electronics Function Verification
 Motors speed up/down and change direction
 Current sensors change with motor current
 Encoders output position and velocity
Outline
• System Modeling
• Fabrication
• Assembly
• Testing
• Safety Features
• Conclusion
Final CAD model The Round-a-bot
Major Design Modifications after DR3:

• New aluminum plate


o Aluminum plate covers motor
controller
o Protects the controller
• Base Plate and Top electronics Plate
o Stool a bit smaller than expected dimensions
o Base plate and top plate made smaller accordingly
o Hole pattern changed accordingly

• Bearing Mount holes


o Bearing Dimension did not include mounting holes
o Hole dimensioned differently from CAD file

• Wire size
o wire size changed to 14 AWG for motor controllers
o mainly because terminals are very small

•  Motor Controller/cRIO
o Change in the signal type used for control 
 
Major Fabricated Components
• Top Electronics Plate
o .25" thick ABS plate
o Laser cut 
• Base Plate
o 0.5" thick 6061 aluminum plate
o Water jet cut
o Outer diameter change to fit on new stool dimensions
• Bearing Supports
o 1/2" thick 6061 aluminum plate
o Water jet cut
•  Omni-wheel slug
o 12L15 steel
o Turned on lathe, keyways cut with mill and broach
o  Removed second outer keyway
Major Fabricated Components (cont.)
• Caster slug
o 12L15 steel
o Turned on lathe
o Diameter change to fit with new stool dimensions
• Motor controller mount plate
o required dimension and hole pattern saved as CAD file
o Laser cut
 
(total image)
Testing
• Actuators
o Motors
 Two FIRST CIM motors were ordered
  First tested on 'no-load'
 The current required matched data sheet (3-3.5 A)
 The current with gearbox load was lower than expected
(4-4.5 A)
 Motors are capable of handling the high torque
o Gearboxes
 Two P80 gearboxes were ordered
  Gearbox along with motor handled high load and
torque(rotating medicine ball) 
• Drive-train
o Omni-wheels 
 Six omni-wheels purchased
 All omni-wheels assembled according to design
 Omni-wheels able to handle balls weight
 Omni-wheel surface provide good grip with ball
surface  
o  Drive and Idler shafts
 1/2" chromium alloy steel
 Idler: Standard size 5.5" (came with gearbox)
 Drive: Long size 7.5" (ordered additionally)
 
Power Supply
o Sealed Lead Acid Battery 12V 3.5 Ah
 Two batteries => 24V
 Discharge rate meets calculations

o Sealed Lead Acid Battery 12V 12 Ah


 one battery purchased
 Discharge rate meets calculations
Structural
o Chicago Bar Stool
 Frame was shipped dissembled
 Good structural rigidity
 Dimensions slightly smaller than expected  
 two rings strong enough and support top & bottom plates
o Balancing Ball: 
 8 lb rubberized medicine ball purchased
 can easily support a person's weight
 deflects very slightly on the application of load
 good surface texture, good grip
 
MISC.
o Caster wheels 
 Four caster wheels purchased
 Machined to fix on four legs of stool
 In case of emergency,ie, when robot falls from ball,
caster wheels can easily support robot
 
Individual Electronic components check
o  NI cRIO 9004
 LabVIEW real time module originally missing
 Analog and Digital modules work
 Testing diagnostic program and total system program
flashed
Pololu High-Power Motor Driver
• High current needed to handle torque of balancing.
• Digital PWM input to control motor
• Can drive motors from battery
• At high enough frequency, behaves as current  
Sensors
• IMU
o The IMU was tested using a Labview module.
o It worked perfectly in all the 5 DOF (X, Y, Z,
X_rate, Y_rate )
•  Current Sensor
o The hall effect current sensor tested during
motor controller tests using LabVIEW
o Tested to check the motor current
o Output at low current minimal but improves for
high current.
 Used as high low switch in LabVIEW
• Encoder
o Digital input into cRIO works well for both motors
and directions
Electronics Circuit Check
o Battery Charge-Indicator circuit 
 LED in circuit lights up when battery discharged below a
set value
 Two circuits: 24V controller battery, 12V drive battery
 Circuit designed, soldered and checked
o Motor Controller Circuit
 Direction and current control verified
Assembly:
• General Procedure
o Structural Assembly
 All components screwed and bolted
 No other methods used (eg welding)
o Electronics circuit assembly
  All connections done on Printed Circuit Boards
  All connections soldered
• Major Assembly Modules
o  Base Plate Assembly
 Motor shaft stack, bearn mounts, batttery mounts, motor
controller plates
o Top Plate Assembly
 cRIO
 PCB boards
 IMU
Safety Features:
• Caster Wheels
o In case balancing mechanism fails, caster wheels would
support to keep robot vertical, and rider safe.
• Battery Charge indicator circuits 
o LED lights up when battery discharges below a certain
point
• Electrical Fuses
o Fuses at appropriate points in the electrical circuit
o Prevent unexpected excess flow of current
• Heat sinks & Stand-offs
o Electrical circuit boards placed on insulating stand-offs
o Heat sinks used with electrical components
•  Plastic Shield
o Keeps rider safe from touching any components
Next Steps

• Order new IMU ($44.91,   $48.83 left)


• Finish electronic component testing (eg IMU)
• Fix close-loop control VI

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