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Multidisciplinary Engineering
Senior Design
Project 05400
Construction of 3-D Objects and Displays
using Swarms of Intelligent Microsystems
Preliminary Design Review
May 11, 2005
Brian Saghy (CE) Team Leader & Programming Lead
Alejandro Lam (EE) Integration Lead
Nathan Pendleton (EE) Electronics Lead
Brian Payant (EE) E&M Lead
Gaurav Patel (ME) Mechanical Lead
Presentation Overview
•
•
•
•
•
•
•
•
•
•
•
Introduction
Past Work
Detailed Description Gen1b
Problems with Gen1b
Critical Parameters
Requirements
Project Plan
Redesign Concepts, Ideas, and Feasibility Assessments
Future Considerations
Summary
Questions
Project Introduction and
History
Swarms of small,
intelligent objects
can form a large
shape.
Future MEMS technology
could make for
microscopic robot.
Market
• Rapid-prototyping & Simulating
• 3D displays
• Advertising
Previous Work
Inertial Drive
Does not work due
to lack of static
friction in fluid, and
symmetric design.
Previous Work
Magnetic Field Propulsion
•Tank has six high power magnetic coils on each
side
•Chunxil drives itself by turning on internal coils
to attract it to the desired wall
•Chunxil is able to determine location in tank by
the strength of the EMF fields induced by the
external coils
•Control Problems
Timing Diagram
North AC Signal Asserts Interrupt,
Begin GETAC routine
DELD2 used here
DELAC used here
DELDC used here
Wake Up Signal
Post Wake Up Delay
Sleep Timer Running
N S E W F B
N
600ms
S
E
2000ms
W
F
B
W
1200ms
1000ms
DELD2 used here
E
N
S
E
W
F
S
E
W
F
B
W
F
B
B
N
E
F
N
N
S
E
N
S
E
W
F
S
E
W
F
B
W
F
B
B
B
N
S
N
N
N
S
S
E
Proteus 1B
Demonstration Video
Considerations and
Objectives
•Our main goal during this term is the control of the
Chunxil
•Secondary goals include assembly ease,
modularity, programmability and charging ease.
•Start with small steps, rather than trying to tackle
the whole project at once. Start with 1 Dimension.
•Utilize improvements over the last few years in
microcontrollers and batteries
Critical Parameters
1
2
3
4
5
6
7
8
9
10
11
ABSOLUTE IMPORTANCE
RELATIVE IMPORTANCE
mm Gauge
mA turns
mm Gauge
mA turnsin
10
3 8
8 8 3 8
8 8 7
5 5
7 9
8
8
8
10
in
8
Waterproofing
Straightness of Field Lines
Chunxil Dimensions
Chunxil Shape
Tank Dimensions
External Coil # Turns
External Coil Current
External Coil Gauge
External Coil Size
External Coil Shape and Uniformity
Internal Coil # Turns
Internal Coil Current
Internal Coil Gauge
Internal Coil Size
Chunxil Redesign Rev1C
CUSTOMER REQUIREMENTS
mm mAhV hr mA mm mA V Hz bits
Run Time
6
10 6
4
6 6
Speed
4
Reliability and Control
10
3
3
4 8
Small Chunxil Size ( < 1")
8 7
7
Large Tank Size
4
Chunxil can move in three dimensions2
8 9
System Operation Power Usage
3
2 2
Safe to operate
4
Chunxil is easily visible
8
Nesting of Multiple Chunxils
2
Sustainability/Upgradability
10
8
8
10
Internal Coil Shape and Uniformity
Microprocessor Re-programability
Microprocessor A-D resolution
Microprocessor Speed
Microprocessor Voltage
Microprocessor Current
Microprocessor Size
Maximum Battery Current
Battery Charge Time
Battery Voltage
Battery Life
Battery Size
RELATIVE IMPORTANCE*
-----------------ENGINEERING CHARACTERISTICS-------------------
degrees
7
2 10
10
10
3
10
10
8 9
7
7
10
7
4
5
5
5
9
56 170 42 86 54 56 36 36 56 98 100 62 146 12 92 96 82 234 88 98 32 124 100 178 170 150
0.2 0.7 0.2 0.4 0.2 0.2 0.2 0.2 0.2 0.4 0.4 0.3 0.6 0.1 0.4 0.4 0.4 1 0.4 0.4 0.1 0.5 0.4 0.8 0.7 0.6
* 10 = ABSOLUTELY ESSENTIAL, 7 = VERY IMPORTANT, 5 = MODERATLY IMPORTANT, 3 = NOT VERY IMPORTANT, 1 = UNIMPORTANT
** 10 = CR DRIVEN BY THIS PARAMETER, 5 = CR MODERATELY INFLUENCED BY THIS PARAMETER, 1 = CR NOT SIGNIFICANTLY INFLUENCED BY THIS PARAMETER
Requirements
High-level Objectives
•
An small intelligent robot, called a Chunxil, shall be designed to navigate to a
predetermined position within somewhere in a constrained 3-D space, most
likely ocupied by a fluid.
•
As a method of control, only 1-dimensional positioning will be required for
the scope of this project.
•
If One-Dimension is attained, then multiple dimensions will be explored,
given appropriate amount of time.
•
The Chunxil should be designed with nano-technology limits in mind. Extra
hardware should be avoided if possible, considering the possibility of placing
the entire chunxil in a system-on-chip configuration for future generations. The
less things used in the Chunxil, the more feasible it would be to get them to a
very small size at a low production cost.
Size and Shape
a. Tank
•
The Tank size shall remain the same as before, a cube, 6"x6"x6" +- 0.5".
b. Chunxil
•
The Chunxil's weight, height, nor depth shall excede 1" in dimension.
•
The Chunxil shall be a regular shape such that it can nest, or at least sit
plush with another Chunxil.
•
The Chunxil enclosure should be designed for relatively easy replication,
allowing for multiple Chunxils to be built for testing.
Requirements
Motion
•
The first revision of this project shall be designed to limit the Chunxil to 1dimension of motion. Should this task be accomplished, then more
dimensions of freedom will be granted.
•
The values should be able to be programmed statically, meaning that
each Chunxil is pre-programed with a pre-determined numeric set of data
corresponding to a location in the tank.
•
The Chunxil shall be able to move to and maintain a position in within
1/4th of the measured diameter of the Chunxil from any starting position within
the given working dimension.
•
Discrete positions shall be defined within the tank,with corresponding
values that should be programmed in the Chunxil to achieve such positions.
•
In one dimension, tilt of axis (spinning and rotation) is not of concern.
However, in two or more dimensions the angle of the chunxil from any wall of
the tank shall not excede 10 degrees.
Weight
a. Distribution
The center of mass of the Chunxil shall be +- 10% of the measured physical
center.
b. Density
The Chunxil shall be neutrally bouyant, +- 10% of the density of the medium
(liquid) in the tank.
Requirements
Power
•
The minimum battery shall be defined as supplying enough energy for the
Chunxil
•
to make 10 round trip cycles from extreme opposite corners of the tank.
•
The battery shall be rechargeable.
•
The battery must conform to the Chunxil Size and Weight requirements.
•
Recharging time should be under 5 hours.
•
Charging nor tank operation shall excede the wall power, voltage or
current
•
specifications defined by RGE and safety regulations.
Visibility
•
The medium (liquid) in the tank shall be transparent.
•
The sides of the tank shall be at least 80% visible, defined by surface area
of visible
•
portion to non-visible portion.
Requirements
Safety
• All external wires on the tank shall be insulated.
• Electrical components shall be isolated from the liquid medium.
• Coil current should be within reasonable specifications for the given
amount of time that they are powered.
• No component shall excede temperature capable of burning human
skin or starting fire. If such a component can occur, it shall be properly
cooled and shielded.
Modularity and Sustainability
• The Chunxil shall be reprogrammible without replacing any physical
parts.
• The Chunxil should not have to be opened for programming,
recharging the batteries, or connecting to a debugger.
• Each Chunxil shall have a standard, compatible method to program,
recharge, and debug so that the same programming and charging
device can be used for all Chunxils.
Project Timeline SD1
Project Timeline Summer
Project Timeline SD2
Our Proposal
Analysis, Improvements, & Ideas to
Control The Chunxil
Force Equations
Internal coil
Z
Y
External coil
X
X2
m 0 * N1 * N 2 * R1 *  * R2 * ( 2 2 2 )
X  Y  Z * di
emf 
2
dt
2( R1  X 2 ) 3 / 2
2
2
With:
R1 = radius of the external coil
R2 = radius of internal coil
N1 = Number of turns of the external coil
N2 = Number of turns of the internal coil
And the distance X, Y and Z:
-3/2 m0 N1 N2 I1 I2 R12 A2 z
Force = --------------------------------(R12 + z2)5/2
Stabilization of Chunxil Axes
1) Widen Tank Coils
Advantages:
Straighten Field Lines Inside Tank.
Increase Visibility
Disadvantages:
Physical Modification of Tank
Invalidate Past EMF Values
Stabilization of Chunxil Axes
2) Simultaneous Activation of Opposite
Coils Inside Chunxil
Advantages:
Greater Resistance to Spin
Opposing Field Directions on Opposite Chunxil Faces
Disadvantages:
Greater Power Consumption in Chunxil
More Complex Circuitry
More Complex Mathematical
Model
1 Coil Chunxil Model
2 Coil Chunxil Model
Stabilization of Chunxil Axes
2) Simultaneous Activation of Opposite
Coils Inside Chunxil
Advantages:
Greater Resistance to Spin
Opposing Field Directions on Opposite Chunxil Faces
Disadvantages:
Greater Power Consumption in Chunxil
More Complex Circuitry
More Complex Mathematical
Model
Stabilization of Chunxil Axes
3) Simultaneous Activation of
Opposite Coils On Tank
Advantages:
Straightens Field Lines Inside Tank
Disadvantages:
Needs Two Coils Inside Coil Activated
Greater Chance of Chunxil Spinning on “Pushing”
Half of the Tank
More Complex Tank Circuitry
More Complex Mathematical Model
Stabilization of Chunxil Axes
Feasibility Assessment
Stabilization of Chunxil Axes
Hybrid Model
Movement
Cycle
West to East - West Side of Tank
1a
1b
1a
1b
West to East - East Side of Tank
External
E
W
+
+
+
+
-
Internal
E
W
On
On
Off
Off
On
On
On
On
+ = “Pulls Toward”
- = “ Pushes Away”
Velocity Control
•
Increase Tank Coil Diameters
•
Decrease Current
•
Lessen # of Turns on Coil
•
Pulse Coils
Electronics Requirements
• The electronics should not take up more than 50%
of the volume of a 1” cube Chunxil.
(Leaving 50% volume for the coils.)
• Chunxils will be pre-programmed to a specific
route, but must be easily reprogrammed.
• The battery must be rechargeable, & able to
recharge in less than 5 hours.
• A Chunxil shall be recharged, reprogrammed &
debugged without being disassembled.
• All Chunxils must conform to a common interface
standard, such that a universal reprogramming,
recharging, and debugging method can easily be
used for all Chunxils.
• A Chunxil must be able to make 10 round trip
cycles across the diagonal of the tank.
Battery Feasibility Assessment
1
2
3
4
5
=
=
=
=
=
much worse than baseline concept
worse than baseline
same as baseline
better than baseline
much better than baseline
Relative Weight
Evaluate each additional concept against
the baseline, score each attribute as:
[Presumed]
Sanyo
CR-1/3N
LIR2032
LIR2430
LIR2450
LIR2477
Weight / Mass (grams)
3.0
3
2
1
1
14%
Size (mm)
3.0
5
4
3
1
25%
Voltage (v)
3.0
4
4
4
4
11%
Normal Capacity (mAh)
3.0
1
1
2
3
18%
Max. Discharge rate [continuous] (mA)
3.0
4
4
5
5
21%
Internal Impedance (ohms)
3.0
4
4
5
5
0%
Average Lifespan (cycles)
3.0
3
3
3
3
4%
Price ($)
3.0
5
5
5
4
7%
Weighted Score
3.0
3.6
3.2
3.2
2.8
Normalized Score
83.2%
100.0%
89.1%
89.1%
78.2%
Battery Specifications
•
•
•
•
LiR2032 Rechargeable Li-Ion coin cell
3.7 V nominal voltage
35mAh nominal capacity
70mA Max. drain current
– Dimensions: 20mm dia. * 3.2mm
thick
• Mass: 3.0 grams
• Unit price: $1.26
Overall re-designed circuit
Re-Designed Op-Amp circuit
Other Improvements
Coil Control Circuit
PIC Choices
Desired Traits:
•Reprogrammable
•Low Power
•Backward compatible with current code
•High Resolution A-D Converter
•Programmable in-circuit
PIC Feasibility Assessment
Evaluate each additional concept against
Current ( PIC16C176)
PIC 16F819
Pic 16F88
Pic 18F1320
TI MSP430F113
Relative Weight
the baseline, score each attribute as: 1
Sufficient Student Skills?
3.0
3.0
3.0
3.0
1.0
2%
Size/Weight/Nano-Feasibility
3.0
3.0
3.0
2.0
1.0
13%
Cost of Chips
3.0
3.0
3.0
2.0
3.0
8%
Cost of Programmer,Burner, and Software
3.0
3.0
3.0
3.0
1.0
3%
Compatible ISA
3.0
2.0
2.0
1.0
1.0
10%
Compatible Pin Layout/Voltages
3.0
2.0
2.0
2.0
1.0
5%
Memory (Flash, Ram)
3.0
4.0
5.0
5.0
5.0
13%
Program in-circuit
3.0
5.0
5.0
5.0
5.0
12%
Sufficient bit-ADC
3.0
4.0
4.0
4.0
4.0
18%
Power Usage
3.0
5.0
5.0
4.0
1.0
15%
Hardware Multiplier
3.0
3.0
3.0
5.0
5.0
3%
Low-Power Programming
3.0
5.0
5.0
3.0
5.0
5%
Weighted Score
3.3
4.1
4.2
3.7
3.1
77.7%
96.8%
100.0%
= much worse than baseline concept 2 =
worse than baseline 3 = same as
baseline 4 = better than baseline 5=
much better than baseline
Normalized Score
88.0% 74.9%
Chunxil Tank
Chunxil Axis Limiter
Chunxil Cube (Encasing)
Relative Weight
Available 1*1*1 inch
Commercially
Existing
than baseline
Prototype 2: Use of
4 = better than baseline 5= much better
Prototype 1: Two
worse than baseline 3 = same as baseline
Sides)
= much worse than baseline concept 2 =
Cube (6 Separate
the baseline, score each attribute as: 1
Current Chunxel
Evaluate each additional concept against
shells put toguether
Cube Feasibility Assessment*
Chunxil Cube Size
3.0
1
5
25%
Inner Space for other components
3.0
2
4
21%
Waterproofing Capabilities
3.0
3
3
18%
Cost of Purchased Components?
3.0
4
2
4%
Everything Inside
3.0
2
4
7%
Modularity of Physical Parameter
3.0
3
3
7%
Nesting Ability
3.0
4
2
4%
Charging and Programming Interface
3.0
5
1
14%
Weighted Score
3.0
2.6
3.4
87.5%
75.0%
100.0%
Ease of Assembly of a Full Chunxil
Normalized Score
Chunxil Cube Inner Assembly
Coil Winding
Future Implementations
& Ideas
• Recharging and Programming using only
inductors (No physical Connection)
• Wireless control of the Chunxil
• Use of multicolor LED’s inside, for color
replications. Will add realism to the shape formed
•Making it smaller and smaller.. nanotechnology
•“Freeze Mode” after Chunxils are all nested
together.
Brief Summary
Questions?
Sneaker Slides
Spiral Development Model*
Wiki
•Online
Collaboration
•Easy to edit
•Accessible from
Anywhere
2 Coil Chunxil Model
Proteus Gen 1B Control Flow Chart
Power On
INIT
RUN
reset sleep timer
calculate target differences
re-enable interrupts
clear flags
reset sleep timer
record NOIZ
wait for int, check flags
interrupt
None
GO FLG
SLP FLG
sleep flag
interrupt
go flag
turn off a-d, etc
save state
clr DCCNT
disable interrupts
disable sleep timer
SLEEP
meas VX,VY,VZ
check alignment
wait for port b sig
calc positon diffs
check source of interrupt
sleep timeout
set SLP flag
other
port b int
set GO flag
disable port b int
reset sleep timer
set move flags
if unaligned, set all move flags
clear flags
enable ints,a-d,etc
reset sleep timer
set drive flags
stall .5 ac cycle
restore state
stall down time
drive flag,DCCNT==1?
stall down time 2
no
stall dc time
clear outputs
++DCCNT
no
DCCNT==6?
yes
drive a coil
Proteus Gen 1B Communications Cycle
North AC Signal Asserts Interrupt,
Begin GETAC routine
DELD2 used here
DELAC used here
DELDC used here
Wake Up Signal
Post Wake Up Delay
Sleep Timer Running
N S E W F B
N
600ms
S
E
2000ms
W
F
B
W
1200ms
1000ms
DELD2 used here
E
N
S
E
W
F
S
E
W
F
B
W
F
B
B
N
E
F
N
N
S
E
N
S
E
W
F
S
E
W
F
B
W
F
B
B
B
N
S
N
N
N
S
S
E
Proteus Gen 1B Navigation Control
Difference = North Voltage – South Voltage
Target: Difference=30mV
D=40mV
D=20mV
10mV
D=30mV
20mV
D=0mV
40mV
50mV
X Position
SOUTH COIL
NORTH COIL
30mV
Initial Battery saver circuit