Testing Readiness Review March 3, 2014 - University of ... Readiness Review March 3, 2014 Ben Azlein, Chris Bennett, Kara Bongiovanni, Eric Brenner, Lea Harris, Austin Kootz, Stephanie

Testing Readiness Review

March 3, 2014

Ben Azlein, Chris Bennett, Kara

Bongiovanni, Eric Brenner, Lea Harris,

Austin Kootz, Stephanie Oij, Jason Schelz

Customer: Barbara Streiffert, JPL

PAB Advisor: Dr. Nabity

Project Overview

Test Readiness

Schedule

Budget

3/3/2014 ASEN 4028: TRR 2

Project Overview Test Readiness Schedule Budget

3/3/2014 ASEN 4028: TRR 3


The goal of DARE is to design and build a Child

Rover (CR) that is capable of deploying,

communicating, and docking with the

previously designed TREADS Mother Rover

(MR), while also being able to ascend and

descend slopes between 30o and 70o. These

slopes will replicate a sandstone surface found

when exploring canyon walls, craters, and

caverns on Earth.

4 3/3/2014 ASEN 4028: TRR References: 3


After deploying from the MR and travelling a maximum of 20m across flat ground, the CR will ascend and/or descend a slope of 30o to 70o, then return to the MR

The CR will travel up to 20m on level terrain

The CR will communicate with the MR and the Ground Station (GS)

The CR will capture color images

The CR will be capable of docking and deploying with the TREADS MR

The CR will determine its position relative to the MR to within ±1m and its elevation angle to within ±5o

5 3/3/2014 ASEN 4028: TRR References: 3, 4


Legend

Blue = Critical to Project

6 3/3/2014 ASEN 4028: TRR


Fan Assembly Electronics

3/3/2014 ASEN 4028: TRR 7


Drivetrain

Wheels/Cogs

Motors

Rubber Skirt

Chassis

Suction Fan

RoboVero

Microcontroller/

FireSTORM COM

Motor Controllers Electronic Battery

Fan Battery

Encoders

Caspa FS Camera

Ground

Station

CR Ascends

then Descends

CR Descends

then Ascends CR Approaches

Slope

8

MR CR

CR Returns

to MR

NOTE: Images not to scale.

20 meters

3/3/2014 ASEN 4028: TRR

Legend

GS to CR

MR to CR

GS to MR

Descending slopes

30 – 70o Rover takes a

picture

3/3/2014 ASEN 4028: TRR 9

Suction Fan Status Update

Suction fan shall provide 955 Pa pressure differential over

a 0.1 m2 area. Fan assembly tested: ~3000 Pa

pressure differential possible Seal design shall maintain an inlet volumetric flow rate of

63 cfm while at required pressure differential.

Drivetrain Status Update

Chassis shall support loads caused by suction fan and

motors. 1. Chassis supports fan load

2. Motors match expected torque

at acceptance

3. Planning to complete

drivetrain assembly test ~3/7

Motors shall be able to provide a continuous torque of 4.3

Nm and a burst torque of 5.1 Nm.

Wheels shall remain in contact with the surface.

Software Status Update

The software shall allow the user to operate the pressure

fan, locomotion, and capture images. 1. Software allows user to

command the RoboVero

microcontroller and Faulhaber

motor controllers

2. Software provides meaningful

feedback to the user

The software shall provide meaningful feedback to the

user of position, status, images, and history.

The software parses information from GS to MR to CR, as

well as GS to CR.


3/3/2014 ASEN 4028: TRR 10

Legend

Make

Done

In-Progress

Future Work

Procure

On-hand

On order

Future Purchase


3/3/2014 ASEN 4028: TRR 11


Navigation

Communication

Mission Validation

Acceptance Tests Integration Tests System Test

Final Validation Fan Assembly Fan

Drivetrain

Motors

Motor Controller

Electronics/ Software

Robovero (Microcontroller)

CASPA FS

(Camera)

FireSTORM

(COM)

Battery Discharge

3/3/2014 ASEN 4028: TRR 12

LEGEND

Planned

Completed

In Process

Critical

LEGEND

Planned

Completed

In Process

3/3/2014 ASEN 4028: TRR 13

Results

Expected Can receive signals and return

digital output

Actual Passed

Impact

Verifies board is functional and

ready for programming and

integration

Results

Expected Match supplier specifications

Actual Passed

Impact

Verifies the motors can be

controlled and provide necessary

torque

Results

Expected Fan can maintain 955 Pa on

prototype base

Actual 1400 Pa

Impact Verifies fan design

Validates design concept

Results

Expected Determine battery discharge profile

Actual In progress

Impact Verifies sufficient power for mission

duration

3/3/2014 ASEN 4028: TRR 14

LEGEND

Planned

Completed

In Process

Results

Expected Fan can maintain 955 Pa on actual

base

Actual ~3000 Pa

Impact Verifies fan/seal design

Validates design concept

3/3/2014 ASEN 4028: TRR 15

Test Overview

Purpose

Ensure drivetrain assembly can

deliver expected torque without

deforming

Equipment Motors, motor controllers,

power supply, torque gauge,

Method Static torque measurements

Expected

Results

Continuous torque of 4.1 Nm and

burst torque of 5.3 Nm

Impact Verifies meet drivetrain

requirement

LEGEND

Planned

Completed

In Process

3/3/2014 ASEN 4028: TRR 16

User

gsmain

GS computer

Port

Communication

MR computer

Port

Communication

mrmain

MR computer

Port

Communication

CR FireSTORM COM

Firestorm Library

RoboVero

RoboVero Library

robomain

Encoder1

Encoder2

Camera

Motorcontroller1

Motorcontroller2

Fan

Legend

Software

Hardware

Firmware


CR RoboVero

3/3/2014 ASEN 4028: TRR 17

Legend

Software

Hardware

Firmware

3/3/2014 ASEN 4028: TRR 18

Test Overview

Purpose Command fan and receive fan status

Equipment Fan, Power Conditioning Circuit,

RoboVero, FireSTORM, GS

Method Ensuring code output corresponds to

physical state of fan

Expected Results Fan turns on and off, fan status is

accurately provided upon request

Impact Fan can be controlled and system is

ready for next level integration

Legend

Software

Hardware

Firmware

3/3/2014 ASEN 4028: TRR 19

Legend

Software

Hardware

Firmware

Test Overview

Purpose Capturing images upon user

command

Equipment GS, RoboVero, FireSTORM,

Caspa FS

Method Command camera and

validate image on GS

Expected

Results

Camera captures and

communicates image to GS

Impact

Camera can capture and

communicate images for

science

Test Overview

Purpose Obtain Distance Traveled

Equipment Encoder, GS, RoboVero

Method Manually roll wheels over

measured distance

Expected

Results

Distanced traveled and

software output matched

within ± 1 m

Impact CR is capable of meeting

navigation requirement

3/3/2014 ASEN 4028: TRR 20

Legend

Software

Hardware

Firmware

3/3/2014 ASEN 4028: TRR 21

Legend

Software

Hardware

Firmware

3/3/2014 ASEN 4028: TRR 22

Legend

Software

Hardware

Firmware

Test Overview

Purpose Command and Status update of Motors

Equipment GS, FireSTORM, RoboVero, Faulhaber, Motors

Method Send command or status check

Expected Results Motors rotate intended linear distance, status is clearly

received by GS

Impact CR is capable of traveling

3/3/2014 ASEN 4028: TRR 23

Legend

Software

Hardware

Firmware

3/3/2014 ASEN 4028: TRR 24

Legend

Done

In-Progress

Future Work

Software Environment Configuration

Communication with GS to FireSTORM

Wi-Fi Communication GS to FireSTORM

Command_motor

Read_motor

Command_camera

Command_fan

Read_fan

Read_encoders

Wi-Fi Communication GS to MR to FireSTORM

System Integration Test


3/3/2014 ASEN 4028: TRR 25

LEGEND

Planned

Completed

In Process

3/3/2014 ASEN 4028: TRR 26

Test Overview

Purpose Ensure GS can communicate

with CR

Equipment RoboVero, FireSTORM, GS

Method Place CR up to 20m away from

GS and send commands

Expected

Results

Exact distance at which CR

can maintain communication

Impact Validate communication

objective

Test Overview

Purpose Ensure navigation is within

required accuracy

Equipment RoboVero, Encoders,

FireSTORM, GS

Method Compare software results with

physical

Expected

Results

Position known within ±1 m and

± 5o

Impact Verify navigation meets

requirements

LEGEND

Planned

Completed

In Process

Purpose Validate CR is able to complete simulated mission

To investigate the capability of the complete rover system

Assure all systems are compatible with each other

All requirements validated except R.5.4, R.11, R.16 Test surface is not large enough to meet range

requirements R.11 and R.16

R.5.4 will be met in communication component testing

Expected Results Performance map of capabilities to compare to

objectives

3/3/2014 ASEN 4028: TRR 27


Shorten mission distance to make testing

feasible

Two methods will be used to account for the

reduced mission length

1. Perform mission at 10 m circuit test length

Extrapolate to 80 m length

2. Perform 80 m mission in consecutive 2.5 m

segments

Add data segments to form data set for complete

80m mission

3/3/2014 ASEN 4028: TRR 28


3/3/2014 ASEN 4028: TRR 29

30𝑜

50𝑜 70𝑜

2.5 m Level Platform

Rover takes

a photo and

transmit


RECUV lab

Vicon optical positioning system

Infrared imaging

Precise position data

Indoor facility

Controlled environmental conditions

Safety Concerns

Battery electric shock to people and components

Improper set up of testing ramp

Particles ejected at high velocity from exhaust

Improper handling of the CR

3/3/2014 ASEN 4028: TRR 30


3/3/2014 ASEN 4028: TRR 31


3/3/2014 ASEN 4028: TRR 32

= Assembly

= Test = Software = Procurement

Legend

= Baseline


3/3/2014 ASEN 4028: TRR 33


3/3/2014 ASEN 4028: TRR 34


CDR Proposed

Budget ($) TRR Expenses ($)

3202.11 4059.78

Primary extra expenses: Spare Chassis Spare Batteries Spare Machining Metal Power Conditioning Board

Remaining Budget: $840.22

Parts Expected Cost ($)

Current expenditure 4059.78

Misc. Nuts and Bolts 100.00

TOTAL 4,159.78

[1] STARR Project Team. “Spring Project Review: STARR: Sample Targeting and Retrieval Rover.” University of Colorado. April 2012.

[2] TREADS Project Team. “Spring Project Review: RADS: Rover Acquisition & Deployment System.” University of Colorado. 23 April 2013.

[3] DARE Project Team. “Project Definition Document: DARE: Descending/Ascending Rover for Exploration.” University of Colorado. September 2013.

[4] DARE Project Team. “Conceptual Design Document: DARE: Descending/Ascending Rover for Exploration.” University of Colorado. 30 September 2013.

[5] DARE Project Team. “PDR”. University of Colorado. 10/2/13.

[6] Murray, Michael et al. “STARR Critical Design Review.” 05 Dec. 2011. University of Colorado at Boulder AES. 12 Oct. 2013.

35 3/3/2014 ASEN 4028: TRR

36 3/3/2014 ASEN 4028: TRR

37 3/3/2014 ASEN 4028: TRR

38 3/3/2014 ASEN 4028: TRR 4 References: 1,2

Developed:

• 3rd generation CR

• Sample

identification

based on color

• CR sample

collection and

retrieval

2008 - 2009 2009 - 2010 2010 - 2011 2011 - 2012

Developed:

• 1st generation

Mother Rover (MR)

• Optical navigation

system

Purchased:

• 2 COTS Child

Rover (CR)

Developed:

• 1st generation CR

• 2nd generation MR

• 2D ultrasonic

“cricket”

navigation system

• CR imaging

system

Developed:

• 3rd generation MR

• Deployable MR

ramp

• Enhanced relay

COM system

• 2nd generation CR

• CR rocker-bogie

suspension

2012 - 2013

Developed:

• 4rd generation MR

• Sample storage

• Multiple CR storage

• Retractable ramp

• Driving

• LEDs for

deployment and

retrieval of CRs

The legacy Mother Rover (MR) and Child Rover (CR) developed for JPL by CU.

3/3/2014 ASEN 4028: TRR 39

robomain

parse

Status or

Command

Motor,

Encoder,

or Fan

Fan,

Camera,

or Motor?

read_motor

read_encoder

read_fan

command_camera command_fan

command_motor

Status

Command

Fan Camera

Motor

Fan

Encoder

Motor

Project Overview Schedule Manufacturing Budget

3/3/2014 ASEN 4028: TRR 40

Project Overview Schedule Manufacturing Budget

User

gsmain

GS computer

Port

Communication

FireSTORM COM

Firestorm Library

RoboVero

RoboVero Library

robomain

Legend

Software

Hardware

Firmware

parse Status or

Command

Command

Status

command_motor

RoboVero

RoboVero Library

Motor1 Motor2

read_motor

RoboVero

RoboVero Library

Motor1

Motor2

Motorcontroller1

Faulhaber Library

Motorcontroller2

Faulhaber Library Motorcontroller1

Faulhaber Library

Motorcontroller2

Faulhaber Library

3/3/2014 ASEN 4028: TRR 41

R.1) The CR shall fit within the TREADS MR docking bay.

R.1.1) The CR shall have an area no greater than 0.457 m x 0.457 m

R.1.2) The CR mass shall not exceed 8 kg.

R.5) The CR shall communicate with the MR.

R.5.1) The CR shall transmit images to the MR.

R.5.2) The CR shall receive commands from the MR.

R.5.3) The CR shall transmit telemetry data to the MR.

R.5.5) The CR shall be capable of transferring 10kbps

R.16.1) The CR shall communicate with the MR while within the maximum range of 40 m

from the MR

R.6) The CR shall perform navigation.

R.6.3) The CR shall know the distance travelled before the ascent or descent.

R.13.1) The CR shall know its relative position to the MR to within ±1 m.

R.13.2) The CR shall know its elevation angle to within ±5o.

R.17.1) While within a 1m radius from the MR ramp, the CR shall know its relative

position to within 25 cm.

R.7) The CR shall capture color images.

R.7.1) The image shall have a resolution of at least 160x120 pixels.

R.10) After ascending or descending a slope the CR shall return to within 1 m of the MR.

R.12) The CR shall communicate with the GS.

R.12.1) The CR shall receive commands from the GS.

R.14) The CR shall travel a maximum of 20m from the MR prior to descent or ascent.

R.15) The CR shall descend or ascend a slope.

R.15.1) The CR shall descend a slope of 30o for 20 m.



R.15.4) The CR shall ascend a slope of 30o for 20 m.



Legend

Blue = Critical to Project

References: 3, 4, 5

*Refer to backup slides 59-61

for tiered requirements

3/3/2014 ASEN 4028: TRR 42

Minimum Level of Success R.1) The CR shall fit within the TREADS MR docking bay.

R.1.1) The CR shall have an area no greater than 0.457 m x 0.457 m

R.1.2) The CR mass shall not exceed 8 kg.

R.2) The CR shall travel a maximum of 5 m from the MR prior to descent or ascent.








R.5.1) The CR shall transmit images to the MR.

R.5.2) The CR shall receive commands from the MR.

R.5.3) The CR shall transmit telemetry data to the MR.


from the MR

R.5.5) The CR shall be capable of transferring 10 kbps




R.6.3) The CR shall know the distance travelled before the ascent or descent.

R.7) The CR shall capture color images.

R.7.1) The image shall have a resolution of at least 160x120 pixels.

3/3/2014 ASEN 4028: TRR 43

2nd Level of Success R.8) The CR shall travel a maximum of 10 m from the MR prior to descent or ascent.











from the MR

R.12) The CR shall communicate with the GS.

R.12.1) The CR shall receive commands from the GS.




3/3/2014 ASEN 4028: TRR 44

Optimal Level of Success R.14) The CR shall travel a maximum of 20 m from the MR prior to descent or ascent.










from the MR


R.17.1) While within a 1 m radius from the MR ramp, the CR shall know its relative

position to within 25 cm.

Initial specification verification

Replicated previous experiment to get new

measurements for purchased vacuum assembly

3/3/2014 ASEN 4028: TRR 45

Test Needed Measured

Volume Flow 63 cfm 58.7 cfm

Pressure Differential 955 Pa 1350-1450 Pa

Volume Flow Test Pressure Differential Test

3/3/2014 ASEN 4028: TRR 46

DARE Rover

Drivetrain

Front Drive

Motor System

Motor

Gearbox

Encoder

Controller

L-bracket Al 6061

Front Wheel Assy

Front Wheel Al 6061

Tread

Cog Lock

Cog Tube Al 6061

Cog

Front Shaft 316L St.

Chain

Rear Drive

L-bracket Al 6061

Rear Shaft 316L St.

Rear Wheel Assy

Rear Wheel Al 6061

Bearings x2

Cog Tube Al 6061

Cog

Cog Lock

Tread

Fan Assembly

Fan

Chassis

Fan Mounts Al 6061

Foam Core

Edge Trim

Skirt

Rubber

Bristles

Silicone Caulking

Skirt Mount Plexi-glass

Silicone Caulking

Electronics

FireSTORM

Caspa FS

RoboVero

EPS

Fan Battery Circuit

Fan Battery

Power Circuit

Electronics Battery Assembly

Electronics Battery

Power Conditioning Circuit

Board Mounts

Standoff Plate Delrin

Standoffs

Baseplate Plexiglass Motor Controllers

Software

Software Development Environment

Install drivers

Install Client Libraries

Install git

Communication with Electronics

RoboVero

Caspa FS

Motorcontrollers

FireSTORM

GS to CR

GS to MR to CR

Data Receiving and Handling

Mission Class

Status Class

History Class

Guidance User Interface main.cpp

CDR Components CDR

Cost ($)

Electronics Boards:

RoboVero, Overo,

Caspa 387.25

Testing Materials:

Wood, Poly, Nails,

Screws 241.74

Vacuum Motor 140.00

Vacuum Battery 71.93

Chassis 186.77

Motor, Motor

Controller, Gearbox 1868.40

Wheel Tread 36.80

Metal for Machining 104.92

Suction Components 23.32

Other Mechanical

Components 140.98

TOTAL 3202.11

3/3/2014 ASEN 4028: TRR 47

TRR Components TRR

Cost ($)

Printing 19.08

Electronics Boards 408.13

Vac Motor 140.00

Chassis 186.77

Wheel Tread 36.80

Metal for Machining 102.76

Suction Components 28.87

Motor, Motor Controller, Gearbox 1864.45

Power Supplies 423.27

Testing Materials 131.81

Spare Metal 190.07

Spare Chassis 187.22

Spare Power Supplies 184.50

Other Mechanical Components 156.05

TOTAL 4059.78


Documents

Testing Readiness Review March 3, 2014 - University of ... Readiness Review March 3, 2014 Ben Azlein, Chris Bennett, Kara Bongiovanni, Eric Brenner, Lea Harris, Austin Kootz, Stephanie