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P08201: - 10kg Robotic Platform
A. Electrical Test Plan
I. Motor Control Board (H-Bridge and Logic)
1. Verify Circuit PCB’s
* Requires: One operator, schematic
a) Check layout patterns with schematic
b) Inspect boards for manufacturing defects
c) Note results in test log
2. Connect H-Bridge board to power supply
* Requires: One operator, DC power supply, meter/scope
a) Connect Ground to J1 Pin #1
b) Connect +5VDC to J1 Pin #2 current limited to 200mA
i. Verify current does not reach limit
ii. Note measured current value in test log
c) Connect +24VDC to J1 Pin #3 current limited to 200mA
i. Verify current does not reach limit
ii. Note measured current value in test log
3. Connect Logic board to power supply
* Requires: One operator, DC power supply, meter/scope
a) Connect Ground to J1 Pin #1
b) Connect +5VDC to J1 Pin #2 current limited to 200mA
i. Verify current does not reach limit
ii. Note measured current value in test log
4. Test Board Function
* Requires: One operator, DC power supply, function generator, multi-meter, IR or Thermocouple temperature sensor
a) Verify correct Boolean logic levels by selecting inputs and monitoring outputs
a. Apply 5VDC to J2 Pin #2
i. Verify J3 Pin #5 and J4 Pin #5 are 5VDC +- 0.2V
ii. Note measured voltage value in test log
b. Apply 0VDC to J2 Pin #2
i. Verify J3 Pin #5 and J4 Pin #5 are 0VDC +- 0.2V
ii. Note measured voltage value in test log
c. Apply 5VDC to J2 Pin #3
i. Verify J3 Pin #8 and J4 Pin #8 are 5VDC +- 0.2V
ii. Note measured voltage value in test log
iii. Verify J3 Pin #9 and J4 Pin #9 are 0VDC +- 0.2V
iv. Note measured voltage value in test log
d. Apply 0VDC to J2 Pin #3
i. Verify J3 Pin #8 and J4 Pin #8 are 0VDC +- 0.2V
ii. Note measured voltage value in test log
iii. Verify J3 Pin #9 and J4 Pin #9 are 5VDC +- 0.2V
iv. Note measured voltage value in test log
e. Apply 5VDC to J2 Pin #4
i. Verify J3 Pin #3 and J4 Pin #3 are 5VDC +- 0.2V
ii. Note measured voltage value in test log
iii. Verify J3 Pin #4 and J4 Pin #4 are 0VDC +- 0.2V
iv. Note measured voltage value in test log
f. Apply 0VDC to J2 Pin #3
i. Verify J3 Pin #3 and J4 Pin #3 are 0VDC +- 0.2V
ii. Note measured voltage value in test log
iii. Verify J3 Pin #4 and J4 Pin #4 are 5VDC +- 0.2V
iv. Note measured voltage value in test log
b) Load H-Bridge
a. Attach drive motor to J3
b. vary PWM from 0 – 100% in forward direction (10% increments)
i. Measure voltage at motor and be sure it tracks from 0 – 24 Volts with PWM percentage
ii. Voltage must be within 0.5V of 24V multiplied by PWM percentage
c. Reverse drive motor direction and vary PWM from 0 – 100%, (10% increments)
i. measure voltage at motor and be sure it tracks from 0 – 24 Volts with PWM percentage
ii. Voltage must be within 0.5V of 24V multiplied by PWM percentage
d. Attach steering motor to J4
e. vary PWM from 0 – 100% in forward direction, (10% increments)
i. measure voltage at motor and be sure it tracks from 0 – 24 Volts with PWM percentage
ii. Voltage must be within 0.5V of 24V multiplied by PWM percentage
f. Reverse steering motor direction and vary PWM from 0 – 100%, (10% increments)
i. measure voltage at motor and be sure it tracks from 0 – 24 Volts with PWM percentage
ii. Voltage must be within 0.5V of 24V multiplied by PWM percentage
c) Monitor temperature of MOSFETS under load for 20 minutes, ie. Connect 10 ohm resistor for 20 minutes at
both 50% and then 100% duty cycles
a. Repeat test (I – 3 – b) monitoring temperature instead of voltage ensuring temperature remains
under 120 ºF
5. Test H-Bridge and logic boards on robotic platform
* Requires: One operator, DC power supply, multi-meter, function generator
a) Power boards with full power and run for 30 min
b) Check temperature using a thermocouple or IR thermometer to verify boards do not overheat (exceed
120ºF). Note temperatures in test log.
c) Inspect battery health and note power level in test log.
d) Verify control by microprocessor
i. Test all directions under 50 and 100% duty cycles
1. Drive Forward / Reverse
(Pass = correct direction, Fail = no movement or wrong direction)
2. Steer Left / Right
(Pass = correct direction, Fail = no movement or wrong direction)
3. Repeat for all motor module channels
II. Battery Monitor Board
1. Verify Circuit PCB’s
* Requires: One operator, schematic
a) Verify boards against schematic and layout patterns
b) Inspect boards for manufacturing defects
c) Note results in test log
2. Connect board to power supply
* Requires: One operator, DC power supply, multi-meter
a) Connect ground to J1 Pin #2
b) Apply 12VDC with a 10mA current limit from a power supply to J1 Pin #1
i. Verify current limit is not reached
ii. Note measured current value in test log
3. Test Onboard Power Regulation
* Requires: One operator, DC power supply, multi-meter
a) Verify regulator outputs 5VDC (+- 0.2V) on pin 7 of LT1765
b) Note measured voltage value in test log
c) Sweep input from 0 to 12.6VDC
i. Verify indicator LEDs illuminate in the proper order from 9.5V to 12.6V
1. First red LED – Always on
2. All other LED’s turn on by 12.6V
ii. Note results in test log
iii. Verify indicator LED’s turn off as voltage is decreased from 12.6V to 9.5V
1. LED’s turn off starting with green and ending with 2 nd red
2. First red LED – Always on
iv. Note results in test log
1.
4. Implement Battery Monitor boards on robotic platform
* Requires: One operator
a) Verify indicator LEDs illuminate when connected to robotic platform
b) Note result in test log
III. Power Distribution Board
1. Layout Design, fabricate boards
* Requires: One operator, schematic
a) Verify boards against schematic and layout patterns
b) Inspect boards for manufacturing defects
c) Note results in test log
2. Connect board to power supply
* Requires: One operator, DC power supply, multi-meter
a) Connect Ground or power supply channel 1 to J1 pin #1
b) Apply 12VDC from power supply channel 1 to J1 pin #2 with a 400mA current limit
i. Verify current limit is not reached
ii. Note measured current value in test log
c) Connect Ground of power supply channel 2 to J1 pin #4
d) Connect 12VDC from power supply channel 2 to J1 pin #5 with a 400mA current limit
i. Verify current limit is not reached
ii. Note measured current value in test log
3. Test on Board Power Regulation
* Requires: One operator), DC power supply, multi-meter
a) Verify regulator outputs of 9VDC (+- 0.2V) on pin #1 of U1
b) Note measured voltage value in test log
c) Verify regulator outputs of 5VDC (+- 0.2V) on pin #1 of U2
d) Note measured voltage value in test log
e) Verify regulator outputs of 3VDC (+- 0.2V) on pin #1 of U3
f) Note measured voltage value in test log
g) Apply 50 ohm load resistor to regulated voltages and check voltage levels using an oscilloscope
h) Apply load resistor, up to 400mA to 9V power supply and ensure voltage does not change by more then
0.2V
i) Note measured voltage change in test log
j) Apply load resistor, up to 250mA to 5V power supply and ensure voltage does not change by more then
0.2V
k) Note measured voltage change in test log
l) Apply load resistor, up to 250mA to 3V power supply and ensure voltage does not change by more then
0.2V
m) Note measured voltage change in test log
4. Attach Power Distribution Board to robotic platform
* Requires: One operator, DC power supply, multi-meter
a) Repeat Section III-3-(a, b, c)
b) Attach other electrical components to power distribution board and test operation as each device is
connected
i. Attach Battery Monitors – See Section (II – 4 – a)
ii. Attach PWM Logic Boards – See Section (I – 5 - c)
iii. Attach H-Bridge Boards – See Section (I – 5 – c)
iv. Attach Microprocessor and wireless module; verify proper operation as described in section (C-II-4)
B. Mechanical Test Plan
I. Frame
1. Rectangular Frame (Specification 10kg)
a) Apply weight to frame in 5kg increments until 20kg has been applied or until failure occurs. Record max
loading capacity (20kg minimum, including the weight of all electronic components)
b) Remove weights and inspect frame for any visual deformation of the members or connectors. If any
noticeable deformation or failure occurs record failure reason or failed parts for improvement and redesign.
II. Motor Module
1. Motor Mount
a)
b)
c)
d)
Assemble one full motor mount assembly (excluding motors)
Fully constrain mount rails and apply loading to the flange using weights
Apply load until 10kg is achieved.
Rotate turntable one full rotation and ensure that no binding is experienced
e) Remove weights and inspect frame for any visual deformation. If any noticeable deformation or failure
occurs record failure reason or failed parts for improvement and redesign.
III. Assembled Operations
1. Interchangeability of Motor Modules (Specification – 120s)
*Requires: two operators: (one performing the tests, and the other one record time), Stop Watch, and assembled
robotic platform
a) Use full rectangular assembled frame with attached motor mounts
b) Remove two motor modules from frame.
c) Switch the two motor modules and reattached and secured to frame.
d) Record time for each iteration (Less then 120s)
2. Interchangeability of Electronic Enclosures ( Specification – 120s)
*Requires: two operators: (one performing the tests, and the other one record time), Stop Watch, and assembled
robotic platform.
a) Place power board and attach connectors, and record time.
b) Place logic board and attach connectors, and record time.
c) Place H-Bridge boards and attach connectors, and record time.
d) Place Processor boards and attach connectors, and record time.
e) Place Battery monitor boards and attach connectors, and record time.
f) Place Batteries and connect to power system
g) Record time for each procedure (Less then 120s)
h) Repeat procedures b to h with new operators.
3. Maximum Platform Payload ( Specification – 10 kg)
*Requires: At least one operators (team member). Weights with 2kg intervals.
a) Accelerate unloaded vehicle from a stop
b) Increase payload by 2 kg and repeat (a)
c) Repeat (b) until 20kg of payload is achieved or the platform is incapable of accelerating.
d) Record maximum weight if it is under 20kg(minimum 10kg)
4. Packaging Envelope ( Specification – Must fit in testing Environment)
*Require: One operator, and a measuring tape.
a. Measure width from maximum outer edges of overall frame.
b. Measure length.
c. Measure height from ground up to the top of motor 8020 frame.
d. Ensure that robot is capable of navigating though robotics lab and door w/o getting stuck
5. Tare Weight (Specification – ≤ 40lbs)
*Requires: One operator and a scale which can measure up to 100 lbs or more, scale can be found in the basement
of building 9, or one may use any commonly found bathroom scale.
a. Place un-loaded platform onto scale (Verify platform weighs less than or equal to 40lbs)
6. Turning Radius (Specification – 1m)
*Require: One operator, and a measuring tape.
a) Turn all wheels 90 degrees to the right and drive forward
b) Measure radius of the turn (less then 1m)
c) Note radius in test log
C. Computer System Test Plan
I. Pre-test Configurations: Refer to Manufacturing plan for setup procedure
II. Microcontroller
1. Power consumption
* Requires: At least one operator, DC power supply with current limiting capabilities
a) Connect the current limited (200mA) power supply to the microcontroller and apply 9VDC
b) Note whether the microcontroller powers up with LED indicating there is power (pass).
2. Communication verification
* Requires: At least one operator, Laptop with USB port, 2 TelosB wireless modules, CSM12D microcontroller,
UART/RS232 conversion kit.
a) Download the programs onto the wireless motes.
b) Connect the UART pins on the TelosB mote to the TX & RX pins on the conversion kit.
c) Attach the RS232 connector from the conversion kit to the connector on the microcontroller.
d) Press Up/Down/Left/Right arrow keys to send packets across.
e) Verify that the microcontroller communicates with the TelosB wireless module through RS232/UART.
Note whether the microcontroller is able to enable PWM signal through keyboard control from laptop (pass).
3. Encoder verification
* Requires at least one operator, fully assembled robotic platform, laptop, measuring tape.
a) Run robot in both forward and reverse directions for 5 feet and verify robot reaches the destination.
b) Note whether the robot starts moving within 3 seconds and moves toward target (pass)
c) Verify formulas for steering and drive are calibrated to actual distance turned and traveled
i. Enter coordinates and send robot toward target, adjusting calibration as necessary
ii. Retest after each adjustment to verify calibration (+/- 0.3m of absolute position)
iii. Note the difference between the robot’s target and actual location. Passes if the robot is within
+/-0.3m of the absolute position.
4. Software / Hardware Implementation
* Requires at least one operator, fully assembled robotic platform, laptop, measuring tape, marker
a) Verify proper functionality of Manual Operation (Drive Mode)
Pass – if the robot responses to the correct command.
i. Forward (Up arrow key)
ii. Reverse (Down arrow key)
iii. Left Turn (Left arrow key)
iv. Right Turn (Right arrow key)
v. Stop (Stop button on GUI / ‘X’ key)
vi. Emergency Stop (E. Stop button on GUI / ‘E’ key)
b) Verify proper functionality of Automatic Operation (Navigation Mode)
i. Move to assigned destination by entering coordinates in the table on the GUI
Pass – if robot arrives within 0.3m of the absolute position.
ii. Verify that the platform stops for 10 seconds before it moves to the next coordinate
Pass – if robot stops at coordinate for 10 seconds +/- 2 seconds.
iii. Verify that platform does not respond to directional keyboard responses from user while in
navigation mode
1) Press Up/Down/Right/Left arrow keys while in navigation mode.
Pass – if robot does not follow user input while in navigation mode.
iv. Verify that control is returned to user once the platform escapes from navigation mode.
1) Press Up/Down/Right/Left arrow keys after navigation mode ends.
Pass – if user regains control of robot while it is not in navigation mode.
III. Wireless Remote Control System
1. Wireless module initialization - Refer to Manufacturing plan for setup procedure
2. User input testing:
* Requires at least one operator, Laptop, 2 TelosB wireless motes, microcontroller, at least one motor module.
a) Verify that the wireless module sends out the appropriate signal when keystrokes are entered.
i.
Press Up arrow key and only the Red LED should light up.
ii.
Press Left arrow key and only the Green LED should light up.
iii.
Press Down arrow key and only the Red and Green LEDs should light up.
iv.
Press Right arrow key and only the Blue LED should light up.
v.
Press ‘X’ key and only the Blue and the Red LEDs should light up.
vi.
Press ‘E’ key and only the Blue and the Green LEDs should light up.
Pass – if LEDs lights up for specified commands from the laptop.
b) Verify that the CSM12D microcontroller will only react to the correct keys pressed on the keyboard by
testing other keys that are not linked to directing the platform.
i.
Press Up arrow key and only drive motor should activate with the forward direction.
ii.
Press Down arrow key and only drive motor should activate with the reverse direction.
iii.
Press Left arrow key and only the steer motor should activate and spins counter-clockwise.
iv.
Press Right arrow key and only the steer motor should activate and spins clockwise.
v.
Press ‘X’ key and both the drive and steer motors should ramp down and come to a complete stop.
vi.
Press ‘E’ key and both the drive and steer motors should stop instantly.
Pass – if robot responds to specified commands and does not response to any invalid key presses.
D. Required Equipment
I. Electrical
1. DC Power Supply
i. Current Limiting Capabilities (0 – 1A)
ii. 0 – 24VDC
2. Multimeter
i.
ii.
iii.
Voltage (0 – 24VDC)
Current (0 – 1A)
IR Temperature Sensor or Thermocouple 60 – 150ºF
3. Function Generator
i.
ii.
iii.
iv.
Voltage (0 – 5VDC)
Frequency 2 kHz
Square Wave Output
Variable Duty Cycle
II. Mechanical
1. 50 kg of Weight
2. Scale (up to 100lbs)
3. Measuring Tape (20m in length)
4. Marking Tape
III. Required Software:
1. Obtain VMWare Workstation from the following link:
http://www.vmware.com/download/desktop_virtualization.html
2. Obtain XubunTOS 7.04 ISO Image from the following link:
http://toilers.mines.edu/Public/XubunTOS
3. CodeWarrior (CD Required)