Difference between revisions of "HANcoder/Training Material/Highwaysurfer"
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− | [[file:Components_diagram.jpg|right|300px|Click | + | [[file:Components_diagram.jpg|right|300px|Click to enlarge image]] |
'''General overview'''<br> | '''General overview'''<br> | ||
A car runs on a conveyor belt and can run on three different lanes. <br> | A car runs on a conveyor belt and can run on three different lanes. <br> | ||
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the housing components, the lane change mechanism and the conveyer belt. <br> | the housing components, the lane change mechanism and the conveyer belt. <br> | ||
− | [[file:Electric_diagram.jpg|right|300px|Click | + | [[file:Electric_diagram.jpg|right|300px|Click to enlarge image]] |
'''''Electrical:'''''<br> | '''''Electrical:'''''<br> | ||
The electrical components are connected by soldering and screw terminals.<br> | The electrical components are connected by soldering and screw terminals.<br> | ||
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stepper-motor and the ultrasonic sensors.<br> | stepper-motor and the ultrasonic sensors.<br> | ||
− | [[file:Software_diagram.jpg|right|300px|Click | + | [[file:Software_diagram.jpg|right|300px|Click to enlarge image]] |
'''''Software:'''''<br> | '''''Software:'''''<br> | ||
The software is also divided into 3 separate systems: the input, algorithm and output.<br> | The software is also divided into 3 separate systems: the input, algorithm and output.<br> | ||
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==Introduction== | ==Introduction== | ||
− | The HAN-AR have two model based development tools, HANcoder and HANtune, that they would like to promote. In order to do this a new demonstration model was required. This is what the project team '''Highway Surfer''' has created. The model will showcase the abilities of the tools and will act as an eye catcher at tech fairs and conferences that the HAN-AR attends. With the help of this document people who are interested in recreating this project or start their own projects will be able to see what the steps involved are, the materials required and the capabilities of the tools, [[HANcoder]] and [[HANtune]]. | + | The HAN-AR have two model based development tools, HANcoder and HANtune, that they would like to promote. In order to do this a new demonstration model was required.<br> |
+ | This is what the project team '''Highway Surfer''' has created. <br> | ||
+ | The model will showcase the abilities of the tools and will act as an eye catcher at tech fairs and conferences that the HAN-AR attends.<br> | ||
+ | With the help of this document people who are interested in recreating this project or start their own projects will be able to see what the steps involved are,<br> | ||
+ | the materials required and the capabilities of the tools, [[HANcoder]] and [[HANtune]]. | ||
This project was started with the help a template. This template can be downloaded from the following link: | This project was started with the help a template. This template can be downloaded from the following link: | ||
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− | On this wikipage, you can find the building process for the mechanical parts, the wiring and other processes for the electronics, and the logic for building the software algorithm. To make it easy for the consumer, we have an easy to understand order list with relevant links. | + | On this wikipage, you can find the building process for the mechanical parts, the wiring and other processes for the electronics, and the logic for building the software algorithm.<br> To make it easy for the consumer, we have an easy to understand order list with relevant links. |
==Materials Required== | ==Materials Required== | ||
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The process can be seen in Figure 3. We chose this option to get a cleaner finish. Of course, there are other ways to get the panels to the right dimensions. | The process can be seen in Figure 3. We chose this option to get a cleaner finish. Of course, there are other ways to get the panels to the right dimensions. | ||
− | [[file:LaserPro_X500.jpg|200px| | + | [[file:LaserPro_X500.jpg|200px|Click to enlarge image]] [[file:Corel_Draw_X8.jpg|200px|Click to enlarge image]] [[file:Laser_cutting.jpg|200px|Click to enlarge image]] |
====L-profile’s and drilling==== | ====L-profile’s and drilling==== | ||
− | The following L-profiles need to be cut [[file:L_profile.jpg|250px|right| | + | The following L-profiles need to be cut [[file:L_profile.jpg|250px|right|Click to enlarge image]] |
:* 2x540mm 5 holes per plane | :* 2x540mm 5 holes per plane | ||
:* 4x100mm 2 holes per plane | :* 4x100mm 2 holes per plane | ||
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====Assembling==== | ====Assembling==== | ||
− | [[file:Assembly_L-profile.jpg|250px|right| | + | [[file:Assembly_L-profile.jpg|250px|right|Click to enlarge image]] |
Place the plates with the L-profile against each other and mark the holes.<br> | Place the plates with the L-profile against each other and mark the holes.<br> | ||
Do not forget witch L-profile you use, every profile is slightly different even with the best measurements. <br> | Do not forget witch L-profile you use, every profile is slightly different even with the best measurements. <br> | ||
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</tr> | </tr> | ||
<tr> | <tr> | ||
− | <td>[[file:Exploded view roller tensioning side.jpg|300px| | + | <td>[[file:Exploded view roller tensioning side.jpg|300px|Click to enlarge image]]</td> |
− | <td>[[file:Exploded view roller powerd side.jpg|300px| | + | <td>[[file:Exploded view roller powerd side.jpg|300px|Click to enlarge image]]</td> |
</tr> | </tr> | ||
</table> | </table> | ||
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</tr> | </tr> | ||
<tr> | <tr> | ||
− | <td>[[file:Roller-end_for_powered_side.jpg|300x200px| | + | <td>[[file:Roller-end_for_powered_side.jpg|300x200px|Click to enlarge image]]</td> |
− | <td>[[file:PVC_EPDM.jpg|300x200px| | + | <td>[[file:PVC_EPDM.jpg|300x200px|Click to enlarge image]]</td> |
</tr> | </tr> | ||
</table> | </table> | ||
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</tr> | </tr> | ||
<tr> | <tr> | ||
− | <td>[[file:Drill for roller-blocks.jpg|300x200px| | + | <td>[[file:Drill for roller-blocks.jpg|300x200px|Click to enlarge image]]</td> |
− | <td>[[file:Bearingblock unmachined.jpg|300x200px| | + | <td>[[file:Bearingblock unmachined.jpg|300x200px|Click to enlarge image]]</td> |
− | <td>[[file:Bearingblock_machining.jpg|300x200px| | + | <td>[[file:Bearingblock_machining.jpg|300x200px|Click to enlarge image]]</td> |
</tr> | </tr> | ||
</table> | </table> | ||
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===Conveyor belt=== | ===Conveyor belt=== | ||
− | [[file:Conveyerbelt.jpg|250px|right| | + | [[file:Conveyerbelt.jpg|250px|right|Click to enlarge image]] |
Items needed: | Items needed: | ||
:* 1500*450 [mm] strong and bendable fiber (this demo: 80%PVC and 20% polyester) | :* 1500*450 [mm] strong and bendable fiber (this demo: 80%PVC and 20% polyester) | ||
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</tr> | </tr> | ||
<tr> | <tr> | ||
− | <td>[[file:Ultrasonic_sensor_bracket.jpg|250x200px| | + | <td>[[file:Ultrasonic_sensor_bracket.jpg|250x200px|Click to enlarge image]]</td> |
− | <td>[[file:Ultrasonic sensor bracket complete.jpg|750px| | + | <td>[[file:Ultrasonic sensor bracket complete.jpg|750px|Click to enlarge image]]</td> |
</tr> | </tr> | ||
</table> | </table> | ||
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</tr> | </tr> | ||
<tr> | <tr> | ||
− | <td>[[file:20x20 profile.jpg|250x200px| | + | <td>[[file:20x20 profile.jpg|250x200px|Click to enlarge image]]</td> |
− | <td>[[file:Bridge_cover_assembly.png|250x140px| | + | <td>[[file:Bridge_cover_assembly.png|250x140px|Click to enlarge image]]</td> |
</tr> | </tr> | ||
</table> | </table> | ||
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</tr> | </tr> | ||
<tr> | <tr> | ||
− | <td>[[file:Lane_change_mechanism_bracket.jpg|250x200px| | + | <td>[[file:Lane_change_mechanism_bracket.jpg|250x200px|Click to enlarge image]]</td> |
− | <td>[[file:Top_view_potentiometer.jpg|250x120px| | + | <td>[[file:Top_view_potentiometer.jpg|250x120px|Click to enlarge image]]</td> |
</tr> | </tr> | ||
</table> | </table> | ||
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</tr> | </tr> | ||
<tr> | <tr> | ||
− | <td>[[file:Exploded_view_lane_change_mechanism.jpg|600x150px| | + | <td>[[file:Exploded_view_lane_change_mechanism.jpg|600x150px|Click to enlarge image]]</td> |
− | <td>[[file:Treaded bushing.jpg|600x150px| | + | <td>[[file:Treaded bushing.jpg|600x150px|Click to enlarge image]]</td> |
− | <td>[[file:Chain_link_clamps.jpg|600x150px| | + | <td>[[file:Chain_link_clamps.jpg|600x150px|Click to enlarge image]]</td> |
− | <td>[[file:Assembelt_belt-clamp.jpg|600x150px| | + | <td>[[file:Assembelt_belt-clamp.jpg|600x150px|Click to enlarge image]]</td> |
− | <td>[[file:Car construction.jpg|600x150px| | + | <td>[[file:Car construction.jpg|600x150px|Click to enlarge]]</td> |
</tr> | </tr> | ||
</table> | </table> | ||
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====The switches==== | ====The switches==== | ||
− | [[file:Switch.jpg|200x150px|right| | + | [[file:Switch.jpg|200x150px|right|Click to enlarge image]] |
We have attached an emergency button and on off switch to the ground of the. Both of the buttons power a coil what opens a relay.<br> | We have attached an emergency button and on off switch to the ground of the. Both of the buttons power a coil what opens a relay.<br> | ||
The emergency button relay is closed by default, while thee on off switch is open by default.<br> | The emergency button relay is closed by default, while thee on off switch is open by default.<br> | ||
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====The stepper motor==== | ====The stepper motor==== | ||
− | [[file:steppermotor.jpg|200x150px|right| | + | [[file:steppermotor.jpg|200x150px|right|Click to enlarge image]] |
The PM engine will be controlled by a H bridge, in our case the “Ardumoto - Motor Driver Shield”. <br> | The PM engine will be controlled by a H bridge, in our case the “Ardumoto - Motor Driver Shield”. <br> | ||
The reasoning we chose for an H-bridge is that the PM needs to be controlled in two directions, an H-bridge can change the direction by switching the poles easily.<br> | The reasoning we chose for an H-bridge is that the PM needs to be controlled in two directions, an H-bridge can change the direction by switching the poles easily.<br> | ||
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====The conveyor belt motor==== | ====The conveyor belt motor==== | ||
− | [[file:Conveyerbelt motor.jpg|200x150px|right| | + | [[file:Conveyerbelt motor.jpg|200x150px|right|Click to enlarge image]] |
The PM motor is being controlled by the micro controller with PWM duty cycle. We used a P channel MOSFET to switch the motor on and off again.<br> | The PM motor is being controlled by the micro controller with PWM duty cycle. We used a P channel MOSFET to switch the motor on and off again.<br> | ||
To protect the MOSFET we used a 1kO resistance. To manage outflow in case the MOSFET is turned off we used a high 10kO resistance. | To protect the MOSFET we used a 1kO resistance. To manage outflow in case the MOSFET is turned off we used a high 10kO resistance. | ||
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====Ultrasonic sensors (SR04)==== | ====Ultrasonic sensors (SR04)==== | ||
− | [[file:Ultrasonic sensors.jpg|200x150px|right| | + | [[file:Ultrasonic sensors.jpg|200x150px|right|Click to enlarge image]] |
The Ultrasonic sensors are connected to the micro controller twice, once for the micro controller to trigger the sensors and for the sensor output.<br> | The Ultrasonic sensors are connected to the micro controller twice, once for the micro controller to trigger the sensors and for the sensor output.<br> | ||
To protect the circuit from voltage peaks from electromagnetic waves caused by the transformer filtering techniques are used. <br> | To protect the circuit from voltage peaks from electromagnetic waves caused by the transformer filtering techniques are used. <br> | ||
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====VR sensor and DNF10 chip==== | ====VR sensor and DNF10 chip==== | ||
− | [[file:VR sensor.jpg|200x150px|right| | + | [[file:VR sensor.jpg|200x150px|right|Click to enlarge image]] |
The configuration of the chip has been given, and the values of R8, R9 and C7 are in the specifications.<br> | The configuration of the chip has been given, and the values of R8, R9 and C7 are in the specifications.<br> | ||
The configuration converts a sinus wave into a block wave. It only has one output towards the micro controller. | The configuration converts a sinus wave into a block wave. It only has one output towards the micro controller. | ||
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===Installation=== | ===Installation=== | ||
− | [[file:Electric scheme.jpg|400x300px|right|Click | + | [[file:Electric scheme.jpg|400x300px|right|Click to enlarge image]] |
Different electric schemes for each of the components are being used in this chapter. The main scheme can be found above.<br> | Different electric schemes for each of the components are being used in this chapter. The main scheme can be found above.<br> | ||
For clarification, some pictures are mirrored to make them correspond with the pictures from the back side.<br> | For clarification, some pictures are mirrored to make them correspond with the pictures from the back side.<br> | ||
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</tr> | </tr> | ||
<tr> | <tr> | ||
− | <td>[[file:Connection diagram.jpg|600x250px| | + | <td>[[file:Connection diagram.jpg|600x250px|Click to enlarge image]]</td> |
− | <td>[[file:Ground and source star.jpg|600x250px| | + | <td>[[file:Ground and source star.jpg|600x250px|Click to enlarge image]]</td> |
</tr> | </tr> | ||
</table> | </table> | ||
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====The transformer==== | ====The transformer==== | ||
− | [[file:Transformer.png|200x250px|right|Click | + | [[file:Transformer.png|200x250px|right|Click to enlarge image]] |
To connect the transformer there are 5 wires what need to be connected. The first three wires are from the plug.<br> | To connect the transformer there are 5 wires what need to be connected. The first three wires are from the plug.<br> | ||
Connect them according to the symbols on the transformer or according to the picture above. | Connect them according to the symbols on the transformer or according to the picture above. | ||
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====The Zener-diode==== | ====The Zener-diode==== | ||
− | [[file:Zenerdiode.jpg|600x150px|right|Click | + | [[file:Zenerdiode.jpg|600x150px|right|Click to enlarge image]] |
Following the source wire from the transformer, the next component is the Zener diode. This diode is there to protect the system from voltage peaks.<br> | Following the source wire from the transformer, the next component is the Zener diode. This diode is there to protect the system from voltage peaks.<br> | ||
It’s switched parallel directly with the transformer. Because a PCB is being used, all the connections are made with screw blocks.<br> | It’s switched parallel directly with the transformer. Because a PCB is being used, all the connections are made with screw blocks.<br> | ||
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====The switch==== | ====The switch==== | ||
− | [[file:The_switch.jpg|600x150px|right|Click | + | [[file:The_switch.jpg|600x150px|right|Click to enlarge image]] |
The switch in the electric scheme is shown as a parallel on/off button with a coil and a relay in series.<br> | The switch in the electric scheme is shown as a parallel on/off button with a coil and a relay in series.<br> | ||
The on/off button and its electric coil are built into the component what is being used.<br> | The on/off button and its electric coil are built into the component what is being used.<br> | ||
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====The high frequency filters==== | ====The high frequency filters==== | ||
− | [[file:High frequency filter.jpg|600x150px|right|Click | + | [[file:High frequency filter.jpg|600x150px|right|Click to enlarge image]] |
All the long wires in our system function as antenna’s that are exposed to the EMI (Electromagnetic interferance)from the transformer.<br> | All the long wires in our system function as antenna’s that are exposed to the EMI (Electromagnetic interferance)from the transformer.<br> | ||
To filter these frequencies a combination of resistances and capacitors is used. Using a PCB for these resistors and capacitors is convenient. <br> | To filter these frequencies a combination of resistances and capacitors is used. Using a PCB for these resistors and capacitors is convenient. <br> | ||
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====The low voltage circuit==== | ====The low voltage circuit==== | ||
− | [[file:Low voltage circuit.jpg|600x150px|right|Click | + | [[file:Low voltage circuit.jpg|600x150px|right|Click to enlarge image]] |
The second PCB is mostly used to supply the components that run under 4 V instead of 12 V. These are the Ultrasonic sensors and the DNF10 chip.<br> | The second PCB is mostly used to supply the components that run under 4 V instead of 12 V. These are the Ultrasonic sensors and the DNF10 chip.<br> | ||
The DNF chip is connected due the max 9240 specifications. The [-] screw block is connected to the ground while the [12V PS] is connected to the power source.<br> | The DNF chip is connected due the max 9240 specifications. The [-] screw block is connected to the ground while the [12V PS] is connected to the power source.<br> | ||
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====The micro-controller==== | ====The micro-controller==== | ||
− | [[file:Microcontroler.jpg|600x150px|right|Click | + | [[file:Microcontroler.jpg|600x150px|right|Click to enlarge image]] |
The microcontroller is directly connected with the ground and source stars with an extra fuse in series for protection. | The microcontroller is directly connected with the ground and source stars with an extra fuse in series for protection. | ||
Revision as of 07:32, 19 June 2017
General overview
A car runs on a conveyor belt and can run on three different lanes.
When an obstacle is detected in the path of the car,
the car will switch a lane to avoid a collision.
It is possible to block all three lanes, but then the car will stop.
This demo is built up from different subsystems.
The mechanical, the electrical and the software.
All these systems are also divided into the sub-components.
Mechanical:
The construction of the total demo assembly is divided in 3 separate sub-assembly’s:
the housing components, the lane change mechanism and the conveyer belt.
Electrical:
The electrical components are connected by soldering and screw terminals.
The power supply from the wall socket goes directly into the transformer
that generates the correct power supply for the components such as the H-bridge
that controls the conveyer belt motor, the microcontroller,
stepper-motor and the ultrasonic sensors.
Software:
The software is also divided into 3 separate systems: the input, algorithm and output.
The input gives the values that the algorithm need to create the output.
The algorithm decides what happens with the belt. When there is an obstacle the car will switch lanes,
if all 3 lanes are blocked the belt will stop.
Introduction
The HAN-AR have two model based development tools, HANcoder and HANtune, that they would like to promote. In order to do this a new demonstration model was required.
This is what the project team Highway Surfer has created.
The model will showcase the abilities of the tools and will act as an eye catcher at tech fairs and conferences that the HAN-AR attends.
With the help of this document people who are interested in recreating this project or start their own projects will be able to see what the steps involved are,
the materials required and the capabilities of the tools, HANcoder and HANtune.
This project was started with the help a template. This template can be downloaded from the following link:
On this wikipage, you can find the building process for the mechanical parts, the wiring and other processes for the electronics, and the logic for building the software algorithm.
To make it easy for the consumer, we have an easy to understand order list with relevant links.
Materials Required
In the Appendix, a detailed order list has been attached. However, a simple list is added in each subchapter to tender to specific parts.
Hardware parts
Local hardware store:
- 5.5 [mm] multiplex
- Aluminum L-profile 20X20 [mm]
- Bolts, nuts
- PVC tube (80mm diameter x 1m length)
- Grip material for the PVC tubes
- Conveyor belt
- Axes
- End pieces’ roll (wood)
Online webshop:
- Bearings
- Gears/pullies and belts, for the drivetrain and lane change mechanism:
Electrical
Online webshop:
- Olimexino STM-32 board
- Stepper motor-driver
- Ardumoto - Motor Driver Shield
- Transformer
- Transistor 7805
- Female power connector for Olimexino
- 6x Screw terminal block 1.50 [mm²]
- Mini fuse 2 [A]
- Mini fuse 5 [A]
- Resistor 10 [KO]
- Resistor 1 [KO]
- Capacitor 0.33 [µF]
- Capacitor 4,7 [µF]
- Capacitor 22 [µF]
- Zener diode 18 [V]
- Wall socket (220 ~ 230 [V])
Sensors
Actuators
Software
- MatLab-Simulink
- HANcoder
- HANtune
HANcoder and HANtune are available at OpenMBD. (On the website is a download manual for all the software.)
Mechanical
For the mechanical design the dimensions can be found in the CAD 2D drawings, which can be downloaded from the website [link here]. When all the parts are cut, they can be assembled. In the exploded views in this document the exact order of assembly is explained.
Conveyor belt base
Housing
To build the housing of the conveyor belt you need following items:
- 3x multiplex plates of 1220x610mm with a thickness of 5,5 [mm].
- Blueprints of the individual panels for the dimensions.
- Saw or something to cut the wood.
- Bolts(m5)
- L-profile(3000x20x20 [mm])
- Measuring tape
- Wood drill
Cutting
To get the right dimensions for this DEMO a LaserPro X500 was used which can be seen in figure 1.
The Solid Works drawings of all the wooden parts are send to a device that runs 'Corel Draw X8' which can be seen in figure 2.
The process can be seen in Figure 3. We chose this option to get a cleaner finish. Of course, there are other ways to get the panels to the right dimensions.
L-profile’s and drilling
The following L-profiles need to be cut- 2x540mm 5 holes per plane
- 4x100mm 2 holes per plane
- 2x460mm 3 holes per plane
- 10x50mm 2 holes per plane
Some holes need to be drilled in the L-profiles to match the bolts, for this DEMO 5mm. Be aware that the holes in the two planes are not on top of each other, see figure 4.
Assembling
Place the plates with the L-profile against each other and mark the holes.
Do not forget witch L-profile you use, every profile is slightly different even with the best measurements.
Continue by drilling the marked holes in the wood and assemble the parts with bolts and nuts. Start from the bottom and work all the way up.