HANcoder/Training Material/Highwaysurfer
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.
In this document, 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
- 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
- Gears and belts, for the drivetrain and lane change mechanism
- Axes
- Bearings
- End pieces’ roll
Electrical
- Transformer
- Wall socket
- Transistor
- Female power connector for Olimexino
- Screw terminal block 1.50 [mm²]
- Mini fuse holder
- Mini fuse 1 [A]
- Mini fuse 7.5 [A]
- Resistor 10 [KΩ]
- Resistor 1 [KΩ]
- Capacitor 0.33 [μF]
- Capacitor 4 [μf]
- Capacitor 22 [μf]
- Zener diode 18 [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.
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. (INSERT PICTURES FROM WIKI DOCUMENTATION FILE)
L-profile’s and drilling
The following L-profiles need to be cut
- 2x540mm 5 holes per plane (ADD PICTURE FROM WIKI DOCUMENTATION)
- 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. (ADD PICTURE FORM DOCUMENTATION)
Rollers
To build the rollers the following parts are needed:
- PVC pipe Ø 80 [mm]
- Treaded rod M10 for axles ~ 600 [mm]
- Wood ~ 40 mm thick enough for 4 blocks
- Bearings 2x: inner-Ø 10mm, outer-Ø 22mm
- Tooth wheel (powered side), ABS-ring (tension side).
- Some strips of rubbery material (EPDM) the get the friction needed for the belt.
(ADD EXPLODED VIEWS FROM WIKI DOCUMENTATION)
Assembling
Cut 2 pieces of PVC to a length of 450mm. (3x PICTURES FROM WIKI DOCUMENTATION) Drill the 4 roller blocks and put them into the lathe to machine them to their final form as seen on the drawings. (3x PICTURES FROM WIKI DOCUMENTATION) When that is finished place the bearings in the blocks and glue the blocks into the PVC pipe. For the powered side the tooth wheel is pressed in and for the tension side the ABS-ring is pressed around it. For friction between the belt and PVC pipe a couple of strips of rubbery material (EPDM) are glued around it. (2x PICTURES FROM WIKI DOCUMENTATION)
Conveyor belt
Items needed:
- 1500*450 [mm] strong and bendable fiber (this demo: 80%PVC and 20% polyester)
- Thread and a needle or a sewing mill
Test fit the conveyor belt around the rollers which are placed at a minimum width. Mark some spots on the overlapped part which you can see circled in picture(?). Remove the conveyor belt and align it back on the spots so you can stitch it together with a needle or a sewing mill. (ADD PICTURE OF BELT
