Multidisciplinary Senior Design
Project Readiness Package
Project Title: / ShingleBot: Mechanical Enhancements and Power SystemsProject Number:
(assigned by MSD) / 17211
Primary Customer:
(provide name, phone number, and email) / Mark Underhill (see below)
Sponsor(s):
(provide name, phone number, email, and amount of support) / Mark Underhill, (716) 957-4525,
Labor/advisory support: 8 hrs./week
Funding: up to $10K
Preferred Start Term: / Fall 2016
Faculty Champion:
(provide name and email) / Dan Kaputa
Other Support:
Project Guide:
(assigned by MSD)
Bryan Mah updated by EWCH 12 Aug 2016 / 7 July 2016
Prepared By / Date
Received By / Date
Items marked with a * are required, and items marked with a † are preferred if available, but we can work with the proposer on these.
Project Information
* Overview:
Roofing material removal is presently performed in a labor intensive manner using standard hand tools (roofing shovels, claw hammers, etc.). While there are some improved tools available, these tools require that human beings operate them while on the roof. This presents significant safety and liability concerns and costs.
Advancements in technology, particularly computer vision and the availability of low cost electronics capable of supporting computer vision, have made it possible to automate the shingle removal process. The goal of this project is to demonstrate an effective autonomous shingle removal robot prototype. Ideally, the completed project would include an effective removal mechanism, an integrated vehicle (rover) to transport and apply the mechanism, the electronics and controls to power the vehicle and mechanism, a vision system used to both identify shingles and to navigate the vehicle, and an appropriate user interface.
While such a system will not completely eliminate the need for laborers on the roof, it can act as a force multiplier, effectively reducing the number of workers exposed to the risks. Detailed interviews with potential lead users also suggest that, by reducing the level of physical labor required, roofing contractors will be able to hire a more sophisticated, career oriented laborer rather than requiring young, physically fit laborers whose roofing employment is generally short term.
* Preliminary Customer Requirements (CR):
Current State of Project:
A preliminary removal mechanism is in the design phase at this time; its prototype is scheduled to be assembled by the beginning of the fall semester. This mechanism will be tested and optimized on a mock up “roof”; such a facility will be available at the sponsor’s site in West Falls, NY or could potentially be set up in a facility at RIT if a space is made available.
Customer requirement #1: Provide a method to remove nails and other similar objects.
• Proposed design must consider the existing lift mechanism and related hardware.
• The shingle/nail lift mechanism will be designed to accommodate a removable “tooth plate”
• The “tooth plate” must allow for the removal of nails with maximum efficiency and minimum debris entanglement
• This project will require iterative design and test
• There are several potentially useful approaches
• Testing will be performed by ARM using the prototype mechanism and test roof
•
Customer requirement #2: Customer Testing is expected to identify performance shortfalls. Team will work with customer to Address some of the performance shortfalls that are identified during the lst wave of testing of the ShingleBot.
Similarly, a robotic vehicle (rover) is in the design phase, and will likely be ready for integration with the mechanism in the early fall. The rover will need to be tested and optimized, then integrated with the mechanism and tested as a system. Again, a mock up roof will be used for testing.
Customer requirement #3: Customer would like the MSD project team to research, design, propose, build, test and implement a prototype electrical power and control design. The proposed design should use as much commercially available hardware as possible (particularly for the computing platform). However, the power subsystem and a variety of signal interfaces will likely require a modest PC board design.
Follow on project Work: This will address the system software and the computer vision software that will need to be adapted from the software presently provided by RIT Associate Professor Dan Kaputa. This software, which integrates Open CV (with Python bindings) and a rover navigation system, needs to be modified to accept on site navigational cues and to recognize the particular roof’s shingle pattern.
Finally, an appropriate user interface should be developed. Conceptually, a set of high definition digital images gathered either by drone or using a telescoping camera mount will be used to set boundary way points, determine keep out zones, and to signal the shingle pattern. At present, it is assumed that this will be done using a remote device. Since only a rough outline of the user interface design has been conceived at this time, this area will afford the student a significant degree of freedom in design.
Summarizing, the customer requirements are as follows:
1. Test, analysis, and optimization of the machine’s removal mechanism function.
2. Test, analysis, and optimization of the machine’s rover.
3. Electrical design of the machine’s power and computing electronics. This will likely include a modest PC board layout.
Follow on Team will address:
4. Modification of the present software design to tailor it to the mechanism and rover and to discern navigation way points, keep out zones, and shingle patterns.
5. An appropriate user interface using a remote device (tablet or phone preferred).
* Preliminary Engineering Requirements (ER):
Include both metrics and specifications. Each ER should map to one or more CRs (see above).
Metrics: what quantities will be measured in order to verify success?
Specifications: what is the target value of the metric that the team should design to?
1. Mechanism
a. Weight < 65 lbs.
b. Rate of removal roughly equivalent to a laborer (2 square per hour) or greater
c. Removal of multiple nails simultaneously
2. Rover
a. Weight < 35 lbs.
b. Safety: Failsafe brake system
c. Propulsion: sufficient torque and speed to traverse a 45 degree incline @ > 1 ft/sec
d. Ability to raise or lower the mechanism in 5 seconds or less
3. Electronic design
a. Support control electronics power supplies and sensor interfaces
b. Battery management
c. Motor drive design (multiple low voltage motor drive stages)
4. Software design
a. Adaptation of navigation software to interface with the rover design
b. Shingle discernment using computer vision (Open CV baseline)
c. Coordination of mechanism and rover during the removal process (includes motor control loop closure)
* Constraints:
List any external factors that limit the selection of alternatives, e.g., allowable footprint, budget, required use of legacy hardware/software.
1. The end item must weigh no more than 100 lbs. total, with a goal of 80 lbs. or less
a. The mechanism and rover designs as delivered will provide a baseline design; significant change will be limited if it works properly
2. The control software must use Python as the primary language
3. All purchases of material must be approved in writing or via email by Mark Underhill
* Project Deliverables:
Minimum requirements:
· All design documents (e.g., concepts, analysis, detailed drawings/schematics, BOM, test results)
· working prototype
· technical paper
· poster
· All teams finishing during the spring term are expected to participate in ImagineRIT
† Budget Information:
List major cost items anticipated, and any special purchasing requirements from the sponsor(s).
The initial prototype mechanism and rover will contain most of the expensive items associated with the project, and are expected to be available at the beginning of the project or shortly thereafter (i.e. they will be furnished). However, it is anticipated that at least some changes will be required after test and analysis, or perhaps a superior approach will be developed.
The electronics approach utilizes inexpensive, commercially available electronics as much as possible. However, it is expected that at least one custom PC board will be required.
Finally, it is expected that the software developer(s) will need a development platform apart from the actual prototype. These will be provided as necessary.
Because this project is being solely funded from the sponsor’s personal funds, all purchases must be approved in writing by the sponsor or will be made by the sponsor.
* Intellectual Property:
Describe any IP concerns or limitations. Is there patent potential? Will confidentiality of any data or information be required?
The initial concept for this project is described in US Patent 15198737, filed on Jun-30-2016, and previously covered by US Provisional Patent application number 62189876, filed July-08-2015. That said, since this project represents a convergence of many technologies only recently available, it is possible that additional patents may be generated as the project is realized. It is assumed, for the purposes of this project, that any patents developed as a result of this project will be usable by Mark J. Underhill at no cost. However, as a holder of multiple patents assigned to my employer, I am sensitive to the restrictive nature of this policy and am open to an alternative so as long as the aforementioned use clause is maintained.
I do not anticipate a need to restrict access to the data generated by the project. It would be preferred to not share the software on a casual basis, but other than that, no restrictions are envisioned.
Project Resources
† Required Resources (besides student staffing):
Describe the resources necessary for successful project completion. When the resource is secured, the responsible person should initial and date to acknowledge that they have agreed to provide this support. We assume that all teams with ME/ISE students will have access to the ME Machine Shop and all teams with EE students will have access to the EE Senior Design Lab, so it is not necessary to list these! Limit this list to specialized expertise, space, equipment, and materials.
Faculty list individuals and their area of expertise (people who can provide specialized knowledge unique to your project, e.g., faculty you will need to consult for more than a basic technical question during office hours) / Initial/dateDaniel S. Kaputa – computer vision, software design, user interface design
Environment (e.g., a specific lab with specialized equipment/facilities, space for very large or oily/greasy projects, space for projects that generate airborne debris or hazardous gases, specific electrical requirements such as 3-phase power) / Initial/date
A roof mock up measuring up to 24’long, 8’wide, and up to 8’ high will need to be housed in an appropriately lit facility. If RIT cannot provide an area for such a setup, the students will need to periodically visit the test facility in West Falls, NY (about 1.5 hr. drive from RIT).
Equipment (specific computing, test, measurement, or construction equipment that the team will need to borrow, e.g., CMM, SEM, ) / Initial/date
A portable oscilloscope, basic multimeters, and typical electronic items like jumpers, soldering irons, etc. will be required. Basic hand tools (wrenches, screwdrivers, etc.) will also need to be available.
Materials (materials that will be consumed during the course of the project, e.g., test samples from customer, specialized raw material for construction, chemicals that must be purchased and stored) / Initial/date
It is expected that many shingles and shingle nails will be expended; these will need to be disposed of.
Other / Initial/date
† Anticipated Staffing By Discipline:
Indicate the requested staffing for each discipline, along with a brief explanation of the associated activities. “Other” includes students from any department on campus besides those explicitly listed. For example, we have done projects with students from Industrial Design, Business, Software Engineering, Civil Engineering Technology, and Information Technology. If you have recruited students to work on this project (including student-initiated projects), include their names here, as well!
Dept. / # Req. / Expected ActivitiesBME
CE / 1. .
EE / 3 / 1. Assist in the design and test of the machine’s electrical system which includes power distribution and some operational controls for rover movement and shingle and nail removal
2.
ISE
ME / 3 / Analyze, test, and optimize the machine mechanism and rover. Redesign portions as necessary in concert with the sponsor.
Other
Bryan Mah (’17) is expected to fulfill an EE role.
* Skills Checklist:
Indicate the skills or knowledge that will be needed by students working on this project. Please use the following scale of importance:
1=must have
2=helpful, but not essential
3=either a very small part of the project, or relates to a “bonus” feature
blank = not applicable to this project
Mechanical Engineering
/ ME Core Knowledge / ME Elective Knowledge /1 / 3D CAD / 2 / Finite element analysis
2 / Matlab programming / Heat transfer
2 / Basic machining / 1 / Modeling of electromechanical & fluid systems
2D stress analysis / 2 / Fatigue and static failure criteria
2D static/dynamic analysis / 2 / Machine elements
Thermodynamics / Aerodynamics
Fluid dynamics (CV) / Computational fluid dynamics
LabView / Biomaterials
Statistics / 2 / Vibrations
1 / Materials selection / IC Engines
2 / GD&T
3 / Linear Controls
Composites
2 / Robotics
Other (specify)
Electrical Engineering
/ EE Core Knowledge / EE Elective Knowledge /1 / Circuit Design (AC/DC converters, regulators, amplifies, analog filter design, FPGA logic design, sensor bias/support circuitry) / 2 / Digital filter design and implementation
1 / Power systems: selection, analysis, power budget / 2 / Digital signal processing
2 / System analysis: frequency analysis (Fourier, Laplace), stability, PID controllers, modulation schemes, VCO’s & mixers, ADC selection / Microcontroller selection/application
1 / Circuit build, test, debug (scope, DMM, function generator / Wireless: communication protocol, component selection
2 / Board layout / Antenna selection (simple design)
2 / Matlab / Communication system front end design
3 / PSpice / 2 / Algorithm design/simulation
2 / Programming: C, Assembly / 2 / Embedded software design/implementation
Electromagnetics: shielding, interference / Other (specify)
Industrial & Systems Engineering