Round-a-Bot

Holonomic Inverted Pendulum Robot

Jeff Fletcher
Sung-Tu Ho
Jason Kloess
Ranjit Raj
Steve Vozar

ME552 Design Review 3

23 November 2010

roundabot.wordpress.com
[BallP Robot, ieeespectrum.org]
La Formule

Amuse-bouche Project Summary

Hors d’œuvre Technical Specifications
Potage Physical Design
Entree Mathematical Model
Relevee Major Modules
Legumes Component Verification
Entremets Bill of Materials
Cafe Engineering Drawings
Project Summary
Round-a-Bot: Holonomic Inverted Pendulum Mobile
Robot

Project Objective:
Design and build an inverted pendulum robot riding on
a single ball capable of transporting a person safely in
an indoor environment.
Technical Specifications
Ball size: 8.5 - 10" diameter (soccer - basket ball sized)
Robot Height: 2.5 - 3 ft (table-top height)
Cost: $1500
Human transport only
Operational Environment: Indoors
Temperature: 15 - 25 ºC
Surfaces: Tile, Carpet, Concrete, Brick, etc.
Able to traverse slopes up to 10º
Reject disturbances caused by small (~1cm) bumps
Operational Range: ~1 hr continuous battery life with ability to
easily recharge (AC outlet)
Operational Speed: 2-3 mph translational (safe walking speed)
Safety Features: Thermal/Over-current protection, training wheels,
foot support, etc.
Physical Design (3D CAD)

Total height = 31in

Transparent Items:
Shielding panels
Base plate, Top Plate
Top and Bottom Ring
 Physical Design (3D CAD)
OMNIWHEEL-to-SHAFT CONNECTION (ADAPTER HUB)

Stock omniwheel
Dinner = 22.225mm
Wkey = 6.6mm
Skey = 2.75mm
Shaft size
Dinner = 1/2" -0.0005 -0.0025
Wkey = 1/8" +0.002"
Skey = 1/16" +0.002"
Physical Design (3D CAD)
MOTOR SHAFT STACK

Overall 3D model
Shaft section
Physical Design (3D CAD)
LOWER HALF ASSEMBLY (BASE PLATE)
Physical Design (3D CAD)
FRAME STRUCTURE (CHICAGO BAR STOOL)

Base plate mounting

Top plate mounting
Protective siding
Training Casters
Swivel Seat
Physical Design (3D CAD)
ELECTRONICS MOUNTING PLATE (TOP PLATE)

IMU mounting
cRIO, H-Bridge servos, and PCB mounting
Wire pass through slot
Mathematical Modeling
Mathematical Modeling

Taking the Lagrangian yields:

Linearization
We then Linearize the model around (0,0,0,0) to obtain the
state-space equations for creating a state feedback controller.
(Mi is from corresponding entry of the Mass Matrix)

Comparison for a step response to ball torque:

Mathematical Modeling - Controller

Controller Design
LQR controller
High emphasis on cylinder position
Low emphasis on ball position

3000 0 0 0 cylinder angle

0 0.003 0 0 ball angle

0 0 300 0 cylinder velocity

0 0 0 300 ball velocity

Mathematical Modeling - Controller

Disturbances
Passenger movements modeled as disturbance
Constant lean: step disturbance in torque
Sine or ramp function initially to better represent human
motion
Mathematical Modeling - Controller

Issues
Size of motor deadband has substantial impact on
controller performance
Sensor noise does not affect ability to balance much but
does increase control effort
Control effort is related to frequency of disturbance
Future work
Actual controller will be designed once we have run
system ID on the motors
If needed, an inner loop will be added to control motor
speed
Simulink Model
Nonlinear Dynamic System
Actuator Model
Sensor Model
Controller Simulations

Step Response
Offset Response

Disturbances
Push
Grade
Controller Simulation
Step Response to 10° user lean

9 rad/s = 5.1 mph

Controller Simulation
Initial 10° Cylinder offset
Controller Simulation
Disturbance Response to 7.5° floor slope
Controller Simulation
Response to small bump disturbance on ground while
moving
Controller Simulation
Response to 200N shove at CoM from rest
Major Modules

Overview:
Chassis
Drivetrain
Power Supply
Sensors
Microprocessor
Chassis
Stool Requirements
Comfortable height to sit (2.5-3 feet, ball+robot)
Not too heavy, can support 200lb person

Chicago Bar Stool

Height: 30", Base: 16x16"
Weight:16 lbs
Additional Features:
Two support rings
lower ring: base plate
upper ring: electronics plate
Swivel Seat
 Electronics Plate
Supports the cRIO, IMU, H-bridge controller
and the PCB voltage converter

Rectangular PVC plate selected:

Light weight(4 lbs, size:24x12x.25")
Cheaper compared to a square plate
Bolted to the upper ring

Components:
The cRIO, PCB mounted voltage
controller and the H-bridge controller
bolted to the top surface of the plate.
The IMU bolted to the bottom surface
exactly at the center
Lower base plate
Square Aluminum Plate (18x18x0.25")
supports
batteries
Net weight of the batteries:15.7 lbs
drive-train
Motors, omni-wheels and gearboxes
Requirements:
capable of supporting the high loads
Sufficiently strong and light
Mounting:
Aluminum plate bolted to the lower ring
Motors, Omniwheels bolted to bottom of the base plate
Batteries bolted to the top part
Drive-train
Bearing: Flanged open ball bearing(Material:Steel)
ID: 0.5", OD: 1.375",width:0.5"
Dynamic radial load = 450 lbs
number of bearings =6
Total load on the bearing= 58.68 lbs
Bearing load rating C = 1437.25lbf
Number of cycles = 441134
Omni-Wheels:Rotacaster
Number of omni-wheels = 6
Diameter = 4.92 "
Width = 1.06"
Bore = 0.875"
Load Capacity =110 lbs
Power Supply
Motor Battery Selection:
PowerStar 12V 15 A-hr battery:
Type : Sealed Lead Acid Battery
Current: 210 A(peak)
Weight: 9.26 lbs
Size: 5.95x3.86x3.98"
Aux Battery Selection:
PowerStar 12V 3.5 A-hr battery(2 Nos):
Type: Sealed Lead Acid Battery
Current:52.5 A(peak)
Weight: 2.98 lbs
Size: 5.28x2.64x2.62"
Wiring Practices
Twisted pair, shielded cables
Signal wires from controller to motor controller
Sensor wires
Motor cable is separated from controller wiring and signal
wiring
Single ground to eliminate ground loops
Wire gauge
AWG gauge Max amps for chasis Max amps for power
6 wiring
101 transmission
37
7 89 30
8 73 24

Table come from Handbook of Electronic Tables and

Formulas for American Wire Gauge
Choice:8-Gauge Stranded THHN Cable
Cost is:$0.31/ft
Sensors(IMU)
5 Degrees of Freedom IDG500/ADXL335
Cost: $44.95
Output type: Analog
Dimension: 20*23(mm)
Sensitivity: 300mV/g and 2mV/degree/sec
Bias voltage: 1.5V and 1.35V

Sensors(Encoder)
US Digital: E7P
Cost: $57.42
CPR: 180 to 720
Number of channel: 2(A,B)
Fits shaft diameter: 3 to 10mm
Emergency stop
Cost:$29.56
Dimension Of Button: 22mm
Voltage Regulator
Type:
78L05(5V)
LP2950(3.3V)
Max output current:
100mA
Input voltage range:0 to 30V
Purpose:
Transform 24V battery voltage to 5
and 3.3V
Printed Circuit Board
Matching Printed Circuit Borad with 550
Connect Points
Cost:$2.99
Circuit diagram
Battery Capacity Measuring Circuit

The voltage for turn on the led will be 24V and 12V
Circuit on PCB
Sensor Filter

To be implemented in Labview
Based on previous M-Way team's experiences
Will adjust values once we have confirmed our sensor's
performance
Microprocessor - cRIO

Power Consumption:
24 V recommended power supply
2 A continuous

Dimensions:
7 in x 3.5 in x 3.5 in
Microprocessor - cRIO

Main Tasks
Control algorithm
Sensor feedback
PWM generator
Accelerometer / gyro filter
Microprocessor - cRIO

Modules:
NI cRIO 9004: Controller
NI 9401: Digital I/O
NI 9201: Analog Input

NI 9401 NI 9201
Motor Controllers

Simple H
H bridge circuit for 1 - 2 motor control
5 to 25 V range
1.3 oz
2.5 in x 2.25 in x .75 in (with fan)
Current Sense: Vc = I*0.075
 Motor Controllers

Full Bridge Half Bridge, 2 Motors Ganged Half Bridge

Continuous Current 25 A 25 A 48 A

Peak Current 45 A 45 A 70 A

Voltage Range 5 - 24 V 5 - 24 V 5 - 24 V
Component Verification: IMU
Accelerometer test
Component Verification: IMU
Gyroscope test
Component Verification:
Microprocessor
Getting started tutorials performed with cRIO
Plan for Thanksgiving Break:
Create controller VI
Interface with Simulink model
Test controller performance w/ Simulink
Bill of Materials

Round-a-Bot BOM
Engineering Drawings

Round-a-Bot Drawings
Conclusions

All major and minor component and material selections

have been made
Bill of Materials completed
Fabricated parts have been designed
Engineering Drawings completed
Mathematical model and controller confirm feasability of
proposed system
Preliminary component verification and testing underway
and will continue through the next week
Ready to place orders pending feedback from this review