S19: Run D.B.C

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ABSTRACT

The RUN-D.B.C project, involves the design and construction of an autonomously navigating RC car. Development of the R.C car's subsystem modules will be divided amongst and performed by seven team members. Each team member will lead or significantly contribute to the development of at least one subsystem.

INTRODUCTION & OBJECTIVES

RC CAR OBJECTIVES

  • Successfully detect and avoid obstacles
  • Autonomously navigate to a fixed destination, from a fixed starting location; based on feedback from a GPS
  • Integrate communication between the RC car's master controller and an Android device, using Bluetooth
  • Integrate system hardware communication using a PCB


TEAM OBJECTIVES

  • Strive to learn as much as possible, in order to develop a professional product
  • Establish and enforce professional software design standards
  • Establish and enforce professional hardware design standards
  • Achieve 100% code coverage, during unit testing
  • Carefully document and track all bugs encountered and patched, during development
  • Clearly communicate the development of all modules of the RC car


CORE MODULES OF RC CAR

  • Android Mobile Application
  • Bridge Controller
  • Geographic Controller
  • Master Controller
  • Motor Controller
  • Sensor Controller
  • Hardware Integration PCB
  • Wiring Harness


PROJECT MANAGEMENT ADMINISTRATION ROLES

  • Team Lead
  • Finance Manager
  • Git Repository Manager
  • Wiki Report Manager
  • Gantt Chart Manager
  • Bill of Materials Manager
  • Project Presentation Manager


TEAM MEMBERS & RESPONSIBILITIES

Team Members

Administrative Roles

Technical Roles

  • Tristan French
  • Team Lead
  • Git Repository Manager
  • Finance Manager
  • Master Controller (Lead)
  • Hardware Integration PCB
  • Wiring Harness
  • Ryan Zelek
  • Testing and Integration (Lead)
  • Master Controller
  • Motor Controller
  • Samir Mohammed
  • Wiki Report Manager
  • Gantt Chart Manager
  • Bill of Materials Manager
  • Android Mobile Application & Bridge Controller (Lead)
  • Hardware Integration PCB
  • Wiring Harness
  • Vignesh Kumar Venkateshwar
  • Project Presentation Manager
  • Motor Controller (Lead)
  • Android Mobile Application & Bridge Controller
  • Bharath Vyas Balasubramanyam
  • Geographic Controller (Lead)
  • Motor Controller
  • Nuoya Xie
  • Sensor Controller (Lead)
  • Geographic Controller
  • Kelvin Cheong
  • Sensor Controller
  • Geographic Controller


SCHEDULE

TEAM MEETING DATES & DELIVERABLES

Week#

Date Assigned

Deliverables

Status

1 2/16/19
  • Share team contact information
  • Create Git Repository (Tristan)
  • Set up Slack
  • Invite Preet to Slack
  • Establish Code Guidelines and Standards
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
2 2/24/19
  • (1/2 team) Share research of past projects
  • Establish ownership of Administrative and Technical Project Modules
  • Establish weekly team meeting time
  • Establish Team Slack usage Guidelines and Standards
  • Received CAN Transceivers
  • Create a Gantt chart to track project progress (Samir)
  • Create Git directory structure (Tristan)
  • Create a Bill of Materials (Samir)
  • Select and order an RC car (Bharath)
  • Push a file to Git Repository
  • Conduct research of project modules (based on ownership/sub-team)
  • Invite Preet to Gitlab
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
3 3/3/19
  • (2/2 team) Share research of past projects
  • Explore using Splitwise for managing project finances
  • Explore using Taiga.io for project management (Samir/Tristan)
  • Sub-teams share research and findings with each other and the team
  • Start planning what parts need to be ordered and update BoM
  • Email Preet regarding LCD screen for Bridge Controller
  • Interface with the HC05 Bluetooth module
  • Research frameworks for Android App development
  • Research GPS modules
  • Create a high-level system block diagram and control scheme
  • Develop a high-level plan interfacing with speed controller and servo controller
  • Select a PCB design tool (develop a sample board in KiCAD)
  • Test performance/specs of current Ultrasonic sensors and research others
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
4 3/10/19
  • Each team create a schedule for sub-system development and send to Samir
  • Set up Cygwin on Windows (and configure) Mac machines for auto-formatting
  • Finalize and purchase LCD screen for Bridge Controller
  • Learn to develop in Android Studio (watch tutorials and begin developing Android App)
  • Purchase Adafruit Ultimate GPS module
  • Selected KiCad as PCB design tool (develop sample PCB to help learn how to use software)
  • Purchase long-range distance sensors and select bump sensors
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
5 3/17/19
  • Established Git Repository Structure
  • Completed PCB design requirements
  • Selected PCB manufacturer
  • Completed high-level system block diagram
  • Complete
  • Complete
6 3/24/19
  • Ordered PCB
  • Successfully unit tested a JAVA module with JUnit (JAVA unit test framework)
  • Choose Android mobile phone/OS to load app onto
  • Interface with GPS and compass modules
  • Finalize high-level system block diagram and control scheme
  • Record how servo and DC motors react to RC Transmitter and Receiver feedback
  • Interface with with speed controller and servo controller
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
7 3/31/19
  • All parts have been ordered
  • Create button to launch mobile application
  • Integrate Google Maps into mobile application
  • Use feedback from GPS and compass to calculate bearing angle
  • LPC 1758 responds to feedback from motor speed sensor (reports RPM of wheels, when a PWM signal is applied)
  • Complete DBC CAN message format
  • Complete DBC CAN message format
  • LPC 1758 responds to feedback from bump sensor
  • LPC 1758 responds to feedback from Ultrasonic sensors (reports distance of objects in their detection radius)
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
  • Complete
8 4/7/19
  • Successfully get starting and destination coordinates
  • Transmit latitude and longitude coordinates as CAN messages to master controller
  • Master controller can send/receive CAN messages to/from all other controllers on CANbus
  • Complete sensor module code and push final revision to GitLab
  • Angle wheels left/right/straight based on CAN feedback from master controller
  • Complete
  • In Progress
  • In Progress
9 4/14/19
  • All modules have been fully assembled
  • Successfully integrate checkpoints into mobile app
  • Transmit heading and bearing angle as CAN messages to master controller
  • Completed implementation of speed control algorithm
  • Implement obstacle avoidance algorithm
  • In Progress
10 4/21/19
  • Complete first vehicle test drive
  • Send starting/destination coordinates to bridge controller
  • Send starting/destination coordinates as CAN messages from bridge controller to master controller
  • Design a feed back mechanism to adjust speed of DC motor using RPM sensor values for vehicular movement on the slope
11 4/28/19
  • Achieve full communication between all subsystems on the CANbus
  • Use GPS feedback to govern (motor behavior) car movement
12 5/5/19
  • RC car has been fully assembled and modules have been integrated
  • Complete integration of PCB and wiring harness


13 5/12/19
  • Resolve any remaining bugs or concerns
14 5/22/19
  • DEMO


BILL OF MATERIALS (GENERAL PARTS)

MICRO-CONTROLLERS

PART NAME

PART MODEL & SOURCE

QUANTITY

COST PER UNIT (USD)

  • Micro-controller
  • LPC 1758 (Purchased from Preet Kang)
  • 5
  • $80.00


RC CAR

PART NAME

PART MODEL & SOURCE

QUANTITY

COST PER UNIT (USD)

  • RC Car
  • 1
  • $205.99
  • Lithium-Ion Battery
  • 1
  • $74.95
  • Battery Charger
  • 1
  • $47.95


HARDWARE INTEGRATION PCB

Hardware Design

RUN DBC PCB LAYOUT.jpg


The hardware integration PCB was designed with two goals:


1. Minimize the footprint of the onboard electronics
2. Minimize the chances of wires disconnecting, during drives


To accomplish these goals, all controllers were directly connected to the board's 34 pin header arrays, while all sensors were connected to the board, using ribbon cables and locking connectors. The master controller's header pins were inverted and then connected to a header array on top of the PCB, while the other controllers were mounted to the bottom. This guaranteed secure power and signal transmission paths, throughout the system.


The board consisted of 4 layers:


Signal
3.3V
5.0V
GND

Technical Challenges

Design

  • Balancing priorities between HW design and getting a working prototype
  • Finalizing a PCB design, when some components and module designs are not nailed down

Assembly

  • DB-9 connector for CAN dongle was wired backwards in the PCB design. Because there are several unused pins, we were able to just.
  • Spacing for headers with clips were not accounted for properly in the design. two of them are very close. It's a tight fit, but it should work.
  • Wireless antenna connector on master board not accounted for in footprint, it may have to be removed to avoid interference with one connector.


Bill Of Materials

HARDWARE INTEGRATION PCB

PART NAME

PART MODEL

QUANTITY

COST PER UNIT (USD)


WIRING HARNESS

Hardware Design

<Picture and information, including links to your PCB

Bill Of Materials

WIRING HARNESS

PART NAME

PART MODEL

QUANTITY

COST PER UNIT (USD)


CAN NETWORK

<Talk about your message IDs or communication strategy, such as periodic transmission, MIA management etc.>

Hardware Design

<Show your CAN bus hardware design>

DBC File

<Gitlab link to your DBC file> <You can optionally use an inline image>


ANDROID MOBILE APPLICATION

<Picture and link to Gitlab>

Hardware Design

Software Design

<List the code modules that are being called periodically.>

Technical Challenges

<Bullet or Headings of a module>

Bug Tracking

<Problem Summary> <Problem Resolution>

Bill Of Materials

ANDROID MOBILE APPLICATION

PART NAME

PART MODEL

QUANTITY

COST PER UNIT (USD)


BRIDGE CONTROLLER

<Picture and link to Gitlab>

Hardware Design

RUN DBC PCB Bridge Schematic.jpg

Software Design

<List the code modules that are being called periodically.>

Technical Challenges

<Problem Summary> <Problem Resolution>



Bill Of Materials

BRIDGE CONTROLLER

PART NAME

PART MODEL

QUANTITY

COST PER UNIT (USD)

  • Bluetooth Serial Communication Module
  • 1
  • N/A


GEOGRAPHIC CONTROLLER

Hardware Design

PCB Geo Schematic.jpg

Software Design

<List the code modules that are being called periodically.>

Technical Challenges

<Bullet or Headings of a module>

Bug Tracking

<Problem Summary> <Problem Resolution>

Bill Of Materials

GEOGRAPHIC CONTROLLER

PART NAME

PART MODEL

QUANTITY

COST PER UNIT (USD)

  • GPS
  • 1
  • $69.13
  • Compass
  • 1
  • $32.89


MASTER CONTROLLER

<Picture and link to Gitlab>

Hardware Design

The master controller is primarily interfaced with the other controllers over CAN bus. The other main interface is control of the LCD display for debug data, which communicates over UART.

Software Design

<List the code modules that are being called periodically.>

  • LCD display
  • CAN read and send
  • Navigation
    • obstacle avoidance
    • steer to checkpoint

Technical Challenges

<Bullet or Headings of a module>

Bug Tracking

<Problem Summary> <Problem Resolution>

Bill Of Materials

MASTER CONTROLLER

PART NAME

PART MODEL

QUANTITY

COST PER UNIT (USD)


MOTOR CONTROLLER

<Picture and link to Gitlab>

Hardware Design

Software Design

<List the code modules that are being called periodically.>

Technical Challenges

<Bullet or Headings of a module>

  • We had to change the PWM driver to hard code the sys_clock frequency. We found solution.
  • Original encoder sourced is was designed to be a knob, not a motor encoder. The additional rotational resistance caused vibrations and resulted in it becoming disconnected from the motor shaft several times. The solution was to us a slightly more expensive encoder, designed for higher speed continuous operation on a motor.

Bug Tracking

<Problem Summary> <Problem Resolution>

Bill Of Materials

MOTOR CONTROLLER

PART NAME

PART MODEL

QUANTITY

COST PER UNIT (USD)


SENSOR CONTROLLER

<Picture and link to Gitlab>

Hardware Design

Part Number Quantity Location on Car Range Voltage Requirement Link
MB1000 LV-MaxSonar-EZ0 1 Front - Middle 6 in - 254 in (0.15 m - 6.45m) 3.3V https://www.maxbotix.com/Ultrasonic_Sensors/MB1000.htm
MB1010 LV-MaxSonar-EZ1 2 Front - Left
Front - Right 		6 in - 254 in (0.15 m - 6.45m) 3.3V https://www.maxbotix.com/Ultrasonic_Sensors/MB1010.htm
Infrared Proximity Sensor - Sharp GP2Y0A21YK 1 Back - Middle 10 cm - 80cm 5V https://www.sparkfun.com/products/242

We put in a lot of thoughts on how sensors should be placed on the car. In order to facilitate easy adjustment of sensor direction, we incorporated circular grooves in the sensor bases so the mount left/right direction can be adjusted on the fly. The hinge of the sensor mount also allows sensors to be tiled up and down, together with the sensor mount, offering two degrees of freedom.



Picture on the left shows the hinge of the sensor guard can be adjusted to minimize the amount of interference between sensors. Picture on the right shows the hinge of the sensor mount allows sensors to be tiled up and down.

Software Design

<List the code modules that are being called periodically.>

Technical Challenges

<Bullet or Headings of a module>

Had to change PWM driver for sys_clock, hardcoded number was needed. We found solution.

Bug Tracking

<Problem Summary> <Problem Resolution>

Bill Of Materials

SENSOR CONTROLLER

PART NAME

PART MODEL

QUANTITY

COST PER UNIT (USD)

  • Bumper Sensors
  • 2
  • $18.98
  • Distance Sensors
  • 1
  • $40.17
  • Set Screw Shaft Coupler
  • 1
  • $11.98
  • Encoder
  • 1
  • $26.46


CONCLUSION

<Organized summary of the project>

<What did you learn?>

Project Video

Project Source Code

Advice for Future Students

<Bullet points and discussion>


Grading Criteria

  • How well is Software & Hardware Design described?
  • How well can this report be used to reproduce this project?
  • Code Quality
  • Overall Report Quality:
    • Software Block Diagrams
    • Hardware Block Diagrams
      Schematic Quality
    • Quality of technical challenges and solutions adopted.

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