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Senior Design I Report - University of Central Florida

1. 15 3 1 3 Customer Review 8 Feasibility maaa 16 3 1 4 Objective and Specification ModificatioOn a 18 3 2 Electrical System Research oooooooWoWoWoWoWoWoWoWo Wo Wo WWW 18 32A GONE ri E eae nee eee 19 3 2121 OUIPUL Systems san Akan aie tata ARA td 19 3 2 11 1 DG Motors seen An ias 20 01011 1 2 Motor Drivers A A NE UR RN ARIS 26 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 32 12 Input System Ann AA anna ias 32 EN RE ENT UNE ER 3 2 1 2 2 Hardware Gensors AAA 37 3 2123 COMMONER pita ib ia 39 3 2 1 3 1 MiCrOprocesSorS aah EA ea ana 39 3 2 1 4 Control Theory 8 Application ooooWooWoWoWoWoWooW 41 SE 42 3 0 1 4 2 Rolling EA LE 42 3 2 1 4 3 Value Binning 4 onani aini 43 A an NN mna 43 01212 We AR LEAN AR NN NE NN anna 44 3 2 2 1 1 Non Rechargeable o oocoooo o oommmannaa 44 3 2 2 1 2 RechargeabIe mmm oa 45 AAA n NG Gan 45 3 2 2 1 4 Lithium lon Polymer ico 46 3 2 2 1 5 Nickel Metal Hydride aaa 47 3 2 2 1 6 Alkaline cti AS Nata 48 3 2 2 2 Battery MONITOR citas Atina 48 d PRODUCTION eege 51 4 1 Electronic KEEN e 51 ATT POB el it 51 4 1 2 Layout amp Rules of Thumb mm WWW anna 53 4 1 3 Connectors Cabl
2. Light Weight Thin layers can be dented Impact resistant Complications in joining the material Carbon Fiber 37 Pros Cons Extremely light Most expensive Strongest material being considered Can crack or fracture Best at absorbing shock The stiffness is depended on design Moldable to any type of design Not as readily available compared to other materials Acrylonitrile Butadiene Styrene ABS 38 Pros Cons Very sturdy and hard material Made out of oil and is damaging to the environment Very high melting point Very limited to weather resistance Very long lifespan High cost to print Easiest material to use in designing Not as strong when compared to other materials considered for this project Table 8 Pros amp Cons of Considered Frame Materials 64 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 5 DETAILED DESIGN CONTENT 5 1 Mechanical System Design After investigation the design team has narrowed the project design to two major designs The design team believes that it is best to investigate both designs feasibility and functionality In order to increase productivity both designs are nearly identical in regards to its electrical system This will allow a modular system in the subsystem components After investigation the design team can easily incorporate the electrical system on either mechanical
3. 39 40 41 42 43 44 45 46 47 48 49 50 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Firgelli Linear Actuators Minature Linear Motion Series L12 Online Available http www firgelli com Uploads L12_datasheet pdf Accessed 27 April 2014 D2826 6 2200kv Outrunner Motor hobbyking com Online Available http www hobbyking com hobbyking store 12919 d2826 6 2200kv outrunner mo tor html Accessed 27 April 2014 Tenergy Li lon 18650 14 8V 2000mAh PCM Protected Rechargeable Battery Pack with 22AWG Bare Leads all battery com 2014 Online Available http www all battery com li ion18650148v2600mahrechargeablebatterypackpcbprotectionwith22awgbareleads aspx Accessed 27 April 2014 Wikipedia org g force Wikipedia the free encylopedia 23 April 2014 Online Available http en wikipedia org wiki G force Accessed 27 April 2014 Wikipedia org Standard Gravity Wikipedia the free encylopedia 5 April 2014 Online Available http en wikipedia org wiki Standard_gravity Accessed 27 April 2014 G E amp Students Acceleration That Would Kill a Human 2004 Online Available http hypertextbook com facts 2004 YuriyRafailov shtml Accessed 27 April 2014 C Norton Formula One drivers feel the G force The Telegraph 10 May 2010 Online Available http www telegraph co uk motoring motorsport 7681665 Formula One
4. 96 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih BuidA o ONg suasAs ayajduo 7 209 youeasay Ya a ajdwoy 1 Pop SUID yoday 180438 HOUVISIY vonel8a u Wayshs SWiasis oh uge Suunseayy Koay jonuo sallayeg 9 JAMOd SINT S nn 9 JOJO A SIDEN Buidiyopo1g awe 4 pidey ugisag awel4 suSISag out HIS WI Wu W Wi BOE DE m JOG NT DI Du m ou Uef 97 tt Judy IEN pm fuginuer Figure 45 Spring 2014 Timeline amp Schedule 97 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih ei Apeay udisag D 1209 n o DEL Wl IT dk unf uSisag jemu avedaug Im unf ST aunf Unf 8 unf T Ney 9z AGI An An Jeu dud NOLLVINISINA 140438 TWNId 9N830 8 1531 dd JEMpIEH ea Je MPAeH jeURYIAN ae E EMYS wash Auaneg 9 Jamog swajsAs Juawaunsea SNIN Y OO swalSAs 0 Sjene 9 usisaq ave ONIdALOLOYd Figure 46 Summer 2014 Timeline 8 Schedule 98 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 7 2 Milestones amp Timeline A millstone of the project was also crafted in order to bring a sense of clarify to all the members of the group The milestone would help to quantify the goals in a timely fashion so as make sure that no part of the project gets left behind or not given an appropriate amount of time Figure 45 and Figure 46 on the previous page will depict the expect time that each step of the pr
5. 5 1 2 Design B One of the mechanical designs that the design team wishes to investigate revolves stability through the use of a rotational gimbal system This system design focuses on eliminating optical jitter that is introduced by human instability While vertical turbulence can be mitigated through mechanical isolation this design technique cannot compensate for vibration frequencies that are caused by human fatigue To compensate for these vibrations the mechanical design is comprised of two main components the gimbal mounting and the vertical handle grip The first major component is the gimbal mounting system The camera will be mounted to a roll and tilt axis gimbal system Two brushless DC motors will be mounted to the gimbal system for axis control Each motor will use an independent brushless DC motor driver that will be controlled through the main microprocessor Input sensors will be attached to each motor for independent control The control will be determined by input data received from the inertial measurement unit Both acceleration and gyroscopic data will be used so the pan and stabilizer motors will maintain stability The gimbal mounting system will be attached to a horizontal isolation platform The platform has two purposes Its first purpose as the name might suggest provides vibration isolation The platform is comprised of two horizontal plates with rubber damping isolators Their purpose is to help absorb vibrations
6. 3 2 1 4 1 PID Due to the troubleshooting involved with tuning a PID controller the team will most likely employ a PID if all other methods fail or heavy use of brushless DC motors are used 3 2 1 4 2 Rolling Average The rolling average method is very similar to discrete convolution except that the sums of the rolling window are divided by the number of elements that are examined within the rolling window The data used in the following experiments will be the magnitude of acceleration of each trial The number of samples used for the rolling window width will be 1 raw data 2 5 10 20 50 100 and 500 samples Each sample represents roughly 2 ms of acceleration data No Sampling Raw Data 2 Samples 5 Samples No Sampling Raw Data 2 Samples 5 Samples 3 3 3 3 5 3 3 3 22 2 2 22 2 2 ER 1 WT ER 1 Ida alba ag Lupita E S lt 0 50 100 0 50 100 0 50 100 lt 0 50 100 0 50 100 0 50 100 Time seconds Time seconds 10 Samples 20 Samples 50 Samples 10 Samples 20 Samples 50 Samples 3 2 2 2 2 2 2 A AA A A A UE E 0 50 100 0 50 100 0 50 100 0 50 100 0 50 100 0 50 100 100 Samples 200 Samples 500 Samples 100 Samples 200 Samples 500 Samples 3 3 3 3 2 2 2 2 2 2 1 1 1 1 1 1 P E 0 50 100 0 50 100 0 50 100 0 50 100 0 50 100 0 50 100 Figure 20 Rolling Filter Brick Road Trials 1 am
7. 93 6 4 1 Initial Manual Excerpt 5 moon Sneak En Bana 93 Te e UV ae ea EN in ILIR BER KA ALAS ROARS Ana 95 7 1 Team EE e ET EE 95 7 2 Milestones amp TIMEIIN6 mio iaa 99 7 3 Budget amp EISE Sean an aa aman 99 Appendix A Permissions ini mendes ala Ia mba kana a Appendix B DataSh6etS coo g Appendix C Works Cited EE h SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 1 EXECUTIVE SUMMARY This senior design research paper is for a handheld camera stabilizer intended for videography in personal aircraft and personal use Included are the product motivation and objectives specifications and requirements research and investigation design content project quality plan and acceptance test plan This project is coordinated by electrical engineering students Thomas Mizell Alex Pennock and Ahmed Salih University of Central Florida Funding and guidance is provided by Professor Michael Young George Mason University Project approved by Dr Samuel Ritchie University of Central Florida SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 2 INTRODUCTION 2 1 Motivation The intention of this senior design project is to allow electrical engineering students to showcase the skills learned in college The students will plan manage research test des
8. angles were detected the servo motors moved causing the camera mount beam to move as well The motors continue to move in a direction until the angles of the slider arms have been adjusted to the appropriate angle resulting in camera stabilization 3 1 3 Customer Review amp Feasibility Each of the previous decisions were presented to the customer for review Due to various issues with each design the customer did not approve the development of any of the designs The design team was forced to modify and review their design approach Based on further feedback provided by the customer it was noted that the ideal method for their satisfaction would be a design that closely resembled a vertically positioned linear actuator As a result linear actuators were researched as a possible output to drive the mechanical system As the design process continued members of the design team questioned the feasibility of the customer request The primary concerns were regarding the product s weight vertical stabilization and response time Previous products researched were advertised as lightweight yet most contained a weight range of two to six pounds This was nearly four times the customer specifications of only nine ounces Due to lack of technical experience with mechanical systems the design team sought guidance from several engineers with relatable experience to the design team s project Guidance included a spacecraft systems engineer f
9. SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Figure 10 GWS 3000kV Inrunner Brushless DC Motor There are several reasons why brushless motors have become popular over brushed motors One the most important reasons is the fact that brushless motors are much more efficient then brushed motors Brushless motors have very good electronic communications which can be attributed to the addition of the Hall Effect sensor These sensors have higher accuracy in determining the position of the permanent magnet rotor Signals are then sent from the Hall Effect sensors to the electronic drives The drives can then determine which phase to pass current through in order to appropriately allow continuous movement of the rotor 13 Figure 11 Turnigy D2826 10 1400kV Outrunner Motor Not being mechanically limited by the brushes also leads to several benefits as well There is no voltage drop to account for in the brushes which increases the efficiency of the device and also the power output per frame size is much greater in brushless motors This gives an advantage of limiting power consumption in order to allow the battery to last a minimum of 30 minutes on a single charge Although selecting brushless motors may lead to better performance the drawbacks also have to be weighed in Once important factor is the cost Brushless motors and their drivers do cost more than brushed motors would In designing the prototype there are
10. SPRING 2014 TEAM 3 Mizell Pennock Salih Inertial Measurement Unit Linear Actuator PWM ER dk Embedded Controller Feedback Motor PWM Microcontroller NN Motor el Driver BEMF Feedback Analog In Normal Power Signal Low Power Signal On ott Switch ao TA Power Status LED Battery Figure 31 Design A Block Diagram Measurement Unit I y Motor1 PWM Motor A Driver LV f LV BEMF Feedback Analog In Microcontroller PWM Motor Driver Motor2 ita Limit Switch 1 Optional Pan System i sam Limit Switch 2 A Digitalin Pan Mot H Analoga Joystick pg ns Motor Digital Out Driver gt Normal Power Signal Low Power Signal On Off Switch Power Status LEO Battery Figure 32 Design B Block Diagram It can be seen that the two designs are nearly identical Both designs will use the same microcontroller inertial measurement unit and power devices In both designs the main stabilizer outputs will be controlled using pulse width modulation channels In all cases motors used will be brushless DC motors and therefore all corresponding drivers will be for BLDC motors Each brushless motor will have a 76 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih closed loop control using BEMF feedback The only difference is the use of a linear actuator compared to an additional
11. The combination of the photosensitive film and bare copper board will be referred to as the developer board After a developer board is prepared a red light source is the only light that should be initially exposed to the developer board A simple picture frame can be used to keep the printed circuit design on the board The transparency containing the circuit layout must be taught Place the developer board with transparency under a desk lamp for about 8 minutes the circuit board is to be exposed to any regular study lamp keeping a distance of about 6 inches between the board and the lamp A solution of water and positive type developer is placed on any Pyrex dish The printed circuit board is placed into the Pyrex dish that contains the developer solution and the dish is rocked back and forth The procedure continues until it is clear that there is no signs of resist coating on the circuit board The board is then rinsed in cold water In order to properly etch the circuit board a solution of ferric chloride and water is poured onto the Pyrex dish The circuit board is once again dipped into the dish that is agitated for about 30 seconds The printed circuit board is left in the solution for roughly 20 minutes After which the PCB at this point can have all its component holes drilled Attaining a printed circuit board in this fashion can often times be a faster approach rather than waiting for a manufacturer to send one Also it is mo
12. accelerometer as well as the data logging and computations that would be needed for the accelerometer This was one of the more difficult aspects towards the camera stabilizer and would be delegated towards one of the members of the group to research and write about This member through their experience with internships with various internships as well as being currently employed as an engineer seemed to be most suited to spearheading the research on the accelerometer Another of the main components was the research needed for electric motors and the batteries that would needed to supply power to the camera stabilizer The electric motors and power supply are critical towards the project and as such have been delegated to specifically be address by one of the members of the group to properly document The member of the group that was tasked to write about these topics was concentrating on power systems and electric machinery in school and naturally was very interested in researching and writing about the electric motors and power supply The last of the main components would be research and documentation towards the microcontroller as well as the appropriate sensors and motor drivers needed The three main components that were previously mentioned obviously would not be sufficient material to research and document on Other topics such as writing about existing projects and design concepts would have inputs and documentations by all members of the group
13. and direction reversal The ESC controls motor velocity by varying the amount of time the motor is on and off Regarding brushless DC motors the ESC performs the necessary phase inversions to maintain a rotating motor This greatly simplifies the complexity of the project s motor control system Most ESC incorporate a battery eliminator circuit which eliminate the need for a power supply for motor output and a power supply for the circuit functionality While the ESC simplifies the circuitry required it limits the design versatility of a custom built control circuit Usually ESC are designed by manufacturers for their specific motor brand In addition a unique ESC is usually needed for different rated motors To diminish the amount of required programming required by the hobbyist 31 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih only a few operating conditions can be modified The ESC may be useful in design its corresponding hobbyist brushless DC motor can be found Otherwise a custom controller circuit should be created The design team has many choices regarding the motor driver Therefore it is best to determine which driver criteria are most fundamental to the decision of the project design First and foremost the type of driver circuit required will depend on the motor decision Each type of motor requires a different method of driving power Once the type of motor is chosen a comparison of the products previousl
14. contained within table 14 are the maximum and minimum values of acceleration in g of the different axis and magnitude maximum and mean values The z axis has mean values listed due to interest in changes in vertical motion 83 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Trial X Axis g Y Axis g Z Axis g Magnitude Time max min max min max min mean max mean see 1 1 93 1 74 1 87 1 99 1 96 1 93 0 94 3 19 0 98 106 2 2 1 89 1 99 1 93 1 99 1 75 1 99 0 94 3 14 0 98 127 4 3 1 93 1 81 1 93 1 99 1 94 1 80 0 94 2 65 0 99 115 2 4 1 95 1 79 1 81 1 99 1 94 1 99 0 95 2 77 0 99 23 93 5 1 75 1 92 1 87 1 99 1 87 1 87 0 94 2 99 0 99 105 1 6 1 87 1 85 1 95 1 93 1 87 1 87 0 94 3 20 1 00 85 6 Table 14 Brick Road Acceleration Testing The results seem very consistent meaning that the average magnitude value of each trial is nearly 1g with maximum magnitude values all above 2 65g Luckily the maximum magnitude values are less than the designed lower airplane load limit of 3 8g Also the z axis measurements are consistent with maximum and minimum values ranging around 2g and a mean of 0 95g This information indicates that the design team needs to find a major axis motor to be most efficient around 1g worth of force This will allow the design team to ex
15. for smaller components Visually inspect the populated PCB for correct component placement and that all pins are padded Preheat the toaster oven to 350 F and gently place the populated PCB into the heating chamber Make sure that the board rests level so that excess solder doesn t slide onto nearby pads Allow the populated board to cook for seven to nine minutes then turn off the heating element and allow the board to cool Once the board is cool enough to touch take it out of the heating chamber scrub the board with a toothbrush and deionized water and allow the board to air dry Some components cannot be pasted on so hand solder where appropriate 61 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Like any project cut the leads visually inspect the populated PCB for shorted pads and correct component alignment and test connections are proper with a multimeter Fortunately the University of Central Florida s Robotics club offers free soldering lessons Also as part of taking on the assignment of the camera stabilizer from Professor Young A specialized soldiering class will be offered by Professor Young These various resources will be help in perfecting the soldering techniques that will be used to complete the electrical system Wave Soldering Another method of PCB construction is wave soldering Wave soldering can only be used on single sided PCBs with through hold components The producer takes the PC
16. DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih x axis y axis A Acceleration o o al Acceleration g LA 5 10 15 20 5 10 15 20 Time seconds Time seconds z axis Magnitude o o Acceleration q mb o mb Acceleration q N mb un N oi o Un 5 10 15 20 10 15 20 Time seconds Time seconds o Figure 40 Trial 4 Brick Road Acceleration Testing x axis y axis Acceleration q eb o a Acceleration q al 0 50 100 0 50 100 Time seconds Time seconds z axis Magnitude Acceleration g da o ak Acceleration g o N nn on N Ka 50 50 100 Time seconds Time seconds o o o o Figure 41 Trial 5 Brick Road Acceleration Testing Figures 37 through 41 are shown to ensure that the statistics in table 14 are accurate and consistent upon visual inspection Figures 37 through 41 show that the x and y axis acceleration does not sway from Og often and that the z axis and magnitude acceleration does not sway from 1g often This verifies that though there is much acceleration in all directions the majority of the force is in the z axis 86 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih x axis y axis Acceleration g 0 20 40 60 Time seconds z axis o Acceleration g mb 0 20 40 60 Time seconds Acceleration g 80 Acceleration g 80 o i mb 0 20 40 60 Time seconds
17. Magnitude 80 w N eh 0 20 40 60 Time seconds 80 Figure 42 Trial 6 Brick Road Acceleration Testing After FFT analysis of the data there seemed to be no overpowering frequency leaking out of the system that could be dampened As prototyping evolves FFT analysis will persist to ensure stability and understanding in the design Axis Maxg Ming Mean g X 1 95 1 99 0 00 Y 1 95 1 99 0 11 Z 19 1 99 0 94 Magnitude 3 20 0 18 0 99 Table 15 Overall Brick Road Testing Values Table 15 are the grand statistics of the brick road trials Again the data is consistent since all values are close to the values found in table14 Again the primary forces are in the z axis yet sidewall maximums and minimums float around 29 Testing Conclusion Overall all of the data has shown that the majority of force during simulated turbulence is in the z direction with a mean of 1g and a consistent sidewall maximum minimum acceleration of 2g and a maximum magnitude acceleration of 3 29 87 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Conclusion The worrisome data found in table 15 is the maximum magnitude of 3 20g This will be a design constraint and challenge for keeping the frame rigid yet light We ll have to investigate as to what construction techniques and materials to employ for such quick and high forces The killer of stability are small changes in
18. Mizell Pennock Salih the operation of the Turnigy is a maximum of 11v and 21A current Unlike other motor drivers the A3930 device does not require a secondary power supply This will greatly help power consumption and simplify the system s circuit design The device also has low current sleep mode is capable of producing 5V hall sensor power and uses PWM current control The peak load current limit can be set through voltage input referencing In addition the PWM frequency can be set but user set external RC timing networks This functionality allows speed and torque control If required this provides the design team with the capacity to enable coasting and braking functionality If incorporated this has the potential to greatly help tuning motion profiles within the control system The device comes in a quad flat package thus meeting the surface mount requirements previously established One disadvantage of the product is its cost Through the supplier Newark Element 14 the cost without shipping is 5 03 This is rather expensive for a single IC component The cost is also multiplied as one device is needed for each motor control However the design team feels this is a minimal expense for using such a valuable component 5 2 1 2 Input System With the motor output system selected the feedback input system must be evaluated During initial design investigation the design team felt that it was critical to determine the main sensor input
19. NH Smaller package footprint than THT mM Less resistance through the soldered joints than THT Cheap MH Great for heat dissipating components 58 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih CONS E Hard or impossible to hand solder m Can be too small to hand solder mM Repair and reworking of component is difficult E Alignment issues Figure 26 Surface Mount Technology reprinted with permission 4 1 5 Soldering Methods The final and perhaps the most important step in producing the electrical system is soldering all the various components on to the printed circuit board This can be a rather delicate step in the process Finalization of the camera stabilizer may be set back for quite a bit of time if damaged is caused to the PCP due to poor soldering Hand Soldering The equipment that will be needed to solder is a temperature adjustable soldering iron a damped sponge solder wire wire cutters liquid flux needle nosed picks and tweezers toothbrush isopropyl alcohol deionized water and lastly safety glasses for the operator that will be soldering on the PCB and trimming of the leads First the PCB is wiped clean of oils and contaminants with isopropyl alcohol and allowed to dry Drying should take a maximum of three minutes Next the soldering iron is plugged into a power outlet and left to heat up for about two minutes or a temperature of 650 F Generally a medium chisel tip is best for
20. Pennock Salih 2 2 Objectives The following is a list of the general objectives and character of the HCS system mM Provide enhanced videography WR Stabilizing against user motion mM Primary rotational compensation via electronic system NH Secondary linear vertical compensation via mechanical system The design team s goal is to provide a simple to use battery powered handheld camera stabilizer for amateur aerial videography using higher quality digital single lens reflex DSLR cameras such as the Nikon 1 Canon Rebel or Pentax K series The primary objective of the project is to design a handheld camera stabilizer that will compensate for video disturbances that are introduced by human fatigue The HCS system must provide stable video quality for 1080HD filming eliminating mechanical blur and refocus error 2 3 Specifications amp Requirements 2 3 1 Customer Specifications The following is a list of requirements that was commissioned by Professor Young s Single Axis Camera Stabilizer 2 handout The handout quoted below are the desired goals for the project these goals are not definite E Single handheld device E Must hold vertical position y axis to within 1 8 with vertical transient jumps as much as at least 6 m Response time must be quick enough so as to eliminate all vertical movement as seen by the camera Must have a standard camera mount Supports the weight of a Nikon 1 camera as well as smaller ca
21. SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih The structural materials of the base and arms were to be constructed of lightweight composite materials The main body of the Arm Cuff HCS AC HCS would be a composite base with arm cuffs grip and grip mounted ON OFF button The PCB and rechargeable battery would be attached to the underside of the main body Two control arms of adjustable length were attached to the base at a single pivot point At the pivot point a motor would control major axis motion illustrated on the right side of Figure 5 The control arms would be guided by fixed rails attached to one of the arm cuffs The motor would provide vertical translation for the camera mount On the opposite ends of the control arms the camera stage would contain the camera mounting The camera stage would contain another point of angular motion termed as the minor axis The minor axis angle would be manipulated with another motor or gimbal To control the AC HCS accelerometers would be placed in various places the camera stage control arms and base Feedback would be sent to a microcontroller unit MCU The MCU would take the accelerometer information and maintain minimum and equal acceleration on two accelerometers found on the camera stage A maximum swing allowance would ensure that the AC HCS does not go beyond the maximum vertical translation range ensuring the arms do not accidently injure the user This des
22. The Brick Road Test will be presented in the Project Quality Plan section of this document 3 2 1 2 2 Hardware Sensors In order to obtain reliable and efficient results data measurements are usually required Based on the expected output performance data feedback will definitely be required to complete the design project The feedback can be broadly categorized into two parts the hardware feedback system that will control the mechanical performance of the project and the electronic monitoring system that will be used to control any processes required by the internal electronic circuitry Regarding the mechanical input sensor system probably the most crucial component is the inertial measurement unit The main expected external forces that act on the system will be in the form of vertical accelerations However for reliability and safety purpose other sensor devices must be incorporated into the final design The most significant system that must be properly sensed is the motor output system It is absolutely necessary to obtain proper feedback regarding the motor s status There are several methods that can be incorporated to obtain motor information The motor s rotational position speed current back EMF direction can all be evaluated In order to generate a closed loop motor system at least one of these sensor systems must be investigated and implemented For more reliability and precision performance more sensors could be inc
23. The first step was the matter of delegating which member of the group was going to write what part of the documentation Having these meetings benefited the group in a multitude of ways As the group meet to discuss what was needed in the group lots of times the person who suggested something be added or placed would also be very comfortable with writing about the topic and thus adding to the documentation page count needed Another very important point is the fact that the group wanted to insure that there was no overlap The last thing anyone would want is for two members of the group writing about the same exact topic at same time Meeting with the group and discussing about what was written also insured that everyone on in the group would agree on what one member suggested they would write about in order to insure a high level of quality Throughout the course of this project a constant and clear form of communication was made between the members of the group in several ways First of all any and all writings where shared on a google drive that was accessible to all members of the groups This would insure that at any given time a group member can access a writing about a particular topic to review it and discuss with the group if any edits were needed to the documentation The group would have anywhere between two to four meetings throughout the course of the week Two of the meetings would be held prior to the start of the senior design class and
24. aide in insuring the device meets the specifications of at least 30 minutes of power supply A second point of advantage for non rechargeable batteries over rechargeable batteries is the fact that non rechargeable batteries cost less This something that will not only help in keeping the budget down for the project but it also may be a point of interest for the user Since the shelf life is very good on non rechargeable batteries the user isn t expected to have to replace the batteries to often but even when it comes time to replace the batteries there won t be financial burden since the price of the battery is very low 44 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 3 2 2 1 2 Rechargeable Although non rechargeable batteries have a longer shelf life the rechargeable batteries rechargeable batteries will last longer This simply means that the user will be able to recharge the power supply and continue operating the device rather than having to always purchase new batteries then the charge is depleted This leads up to the following point that even though non rechargeable batteries cost much less the rechargeable batteries the rechargeable batteries are more cost efficient Because of the fact that rechargeable batteries will last longer than then means the user will not buy as much batteries in a time frame and therefore this becomes cost efficient The primary factor that will lead in deciding which type of t
25. an unsteady shot Most modern MEMS based gyroscopes are designed around the idea of the Coriolis vibratory gyroscope CVG a term coined and standardized by the IEEE Method of Operation The CVG primarily uses measurements of the Coriolis force as means to measure radial velocity The CVG also uses a double test mass setup known as the tuning fork configuration In the tuning fork configuration the two equal valued test masses are tethered together with a spring with a known spring constant The two test masses are never at rest and constantly oscillate in opposite directions as seen by a reference point found at the center of inertia of the system F coriolis 2M2 X V Equation 2 Coriolis Force 34 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih AC Ap F AC 0 F Coriolis Figure 19 Coriolis Force on Tuning Fork Gyroscope reprinted with permission Since the test masses are moving at nearly constant speeds the linear velocity vector for equation 2 is known When the system rotates about the center of mass is a z wise direction as seen in figure 19 a Coriolis force is produced The Coriolis force is measured in a similar manner found in the accelerometer a square wave pulse in sent through a differential capacitor where one set of plates is attached to the side of the test mass Since the Coriolis forces and linear velocity is known the analog signals can be converted to digital information sent
26. are typically broken up into mechanical hydraulic pneumatic piezoelectric and electromechanical actuators The only type of linear actuator that will be considered for the camera stabilizer will be the electro mechanical actuator Linear actuators are typical comprised of a ball screw or rollers screw and an electric motor that moves the screw The principle in the linear actuator design is that there is a concept of threads on lead screws that will become a ramp A rotational force will be used to move a load in a linear direction in two directions based on whether there is clockwise or counterclockwise rotational force The overall performance of a linear actuator appears to have some of the highest level of accuracy for motion speed and force control Linear actuators are available in brushed dc stepper or servomotors The operations that result from using linear actuators have shown to be very and quite Looking from the standpoint of strictly controlling where the camera stabilizer needs to be linear actuators have a good advantage of most of the motors on the market Figure 13 Miniature Linear Actuator permission requested 25 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih One of the biggest disadvantages seen in most linear actuators is the simple fact that they are not very fast at all In fact of the first linear actuators that were looked into for the camera stabilizer it would appear that even though t
27. at 24V It contains a 3 3V 10mA built in low drop out LDO regulator The device has the functionality for the use of low side current sensing of each half H Bridge The device is primarily used to drive a single brushless DC motor but has the capacity to drive a BDC motor and one additional unipolar device The DRV10866 5V three phase sensorless brushless DC motor driver is the last product choice provided by Texas Instruments The input voltage range is 1 65V to 5 5V It provides a 680 mA peak output current and runs in a 5 pA standby mode 30 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih It is developed for a back EMF control scheme PWM inputs are allowed in the range of 15 kHz to 50 kHz The MCP8063 three phase brushless sinusoidal sensorless Motor Driver is an 8 pin device produced by Microchip It supports 180 sinusoidal drive and power supplies ranging between 2V to 14V It requires no external tuning and speed control can be generated either using power supply modulation PSM or PWM signal It generates a 23 kHz PWM output frequency It also contains built in overcurrent limitations and thermal shutdown protection The device is optimized for notebook cooling fan systems but also provides precision speed control in closed loop applications The MCP8024 three phase brushless DC motor gate driver with power module is a 40 pin device Its peak output is 500mA at 12V It contains three operational amplifiers
28. attached to the PCB and off board rerouting of lines for components on the PCB Many considerations come into play when choosing connector type such as Maximum current Cost Thermal capacity Junction resistance PCB footprint Connection strength and durability 53 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Wires Materials Historically electrical wiring has been made of mostly copper metal due to its conductance properties thermal stability and flexibility At times in the United States there have been shortages in copper wire and aluminum wiring used as a replacement Aluminum is not an appropriate wiring material due to its sensitivity of conductance from changes in heat R l Eguation 3 Resistance of a Conductor Diameter Diameter is a major contributor to the overall resistance of the wire Diameter is directly proportional to the cross section area of the wire with eguation 4 A x XA Equation 4 Area of a Circle The consideration with resistance within the wire as found in equation 3 Thus as the diameter of the wire increases the cross sectional area increases and the resistance of the wire decreases For higher current applications you want to have the least amount of voltage drop across the wire to have a high efficiency power transfer Increasing the resistance will drop the power transferred from the source to the powered device Length Due to maintaining simplicity in the
29. camera that was not stabilized Also if the camera stabilizer continues to functions properly for the entire duration of the test without having to recharge the battery then that would show that the power supply would meet the requirements of lasting at least 30 minutes This test will also have 3 trials 6 3 3 Test 3 Road Test This test was previously mentioned in the Battery Life section For this test the camera stabilizer will be operated by a user that will be in car that is driven on a very bumpy road The road would ideally be a dirt road but can also be a brick road The reasoning behind this test is to simulate an in an environment similar to that of being on a plan that may experience turbulence The constant vibration caused by driving on the car will help in measuring the devices performance The videos taken from this test will be compared to another video taken from a camera that was not stabilized Also the video will be compared to the images taken from the previous tests Another observation will be made to see how accurate the camera stays within 1 8 of its original position Due to the fact that roads will be bumpy the device will more than likely have to constantly stabilize the camera This test may be one of the best test for the battery Having the device to constantly work on stabilizing the camera on a single charge for at least 30 minutes would support the idea that the power system is cable of meeting the desired s
30. design Design A focuses on camera stability via linear actuator and vertical translation correction Design B instead employs a two axis gimbal system to reduce vibrations introduced as a result of human interaction 5 1 1 Design A An initial design was based about stabilization in the z axis or as Professor Young calls the y axis in the Single Camera Stabilizer handout The emphasis of the motion stabilization was in the z axis to prevent the bumps and peaks experienced when flying above the clouds in a passenger aircraft The main vertical translation of Design A will be caused from a swinging arm and a fast yet accurate linear actuator The inspiration for the design came from the main hinge from a backhoe digger A backhoe digger uses a pneumatic piston to rotate a load bearing arm up and down This piston does the majority of heavy lifting Figure 28 Design A Illustration Design A will consist of a pistol style grip with a backwards pointing arm offset Within the pistol grip will be the motor housing of the linear actuator When the videographer s hand moves up the accelerometer will detect the upward acceleration talk with the processor then the processor will compensate the motion with a constriction of the linear actuator The Brick Road Test Apparatus has a similar shape to Design A If more stability is needed on the end of the arm where the camera housing is then the addition of a brushless DC motor will be im
31. design team was previously aware of development kits that had the devices as their main processor This would allow for easy testing and evaluation of the components The initial components were the ATmega2560 ATmega328 MSP430G2553 and MSP430G2333 The table 4 provides a quick comparison of specifications the design team researched on each component 40 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih ATmega2560 ATmega328 MSP430G2553 MSP430G2333 Architecture bits 8 8 16 16 Frequenc MHz y 16 20 16 16 Max Operating 5 5 5 5 3 6 3 6 Voltage V Program creel KB 256 32 16 4 RAM KB 8 2 0 5 0 25 USART SPI 4 5 1 1 1 4 3 12C 1 1 1 3 I O Pins 86 23 24 140 Analog to Digital 16 10bit 8 10bit 8 10bit 8 10bit Convertors Development Arduino Arduino Uno EEL4750Kit Launchpad oard Mega Table 4 Possible Processors For testing purposes the design team chose to work with the ATmega2560 Several members had an Arduino Mega development board and therefore the most work could be collectively produced using this development board It provided acceptable PWM control of servos and 5v brushed motors However the ATmega2560 will not be used for the final design as the design team wanted to maintain a 16 bit architecture that would allow the best data resolution provided by the MPU 6050 inertial measurement unit The design team soon found that none of the processors would provide the performance to
32. drivers feel the G force html Accessed 27 April 2014 P Tyson NOVA All About G Forces PBS org 1 November 2007 Online Available http www pbs org wgbh nova space gravity forces html Accessed 27 April 2014 Nikon Nikon Imaging Products Specifications Nikon 1 V1 Nikon 2014 Online Available http imaging nikon com lineup acil bodies v1 spec htm Accessed 27 April 2014 Microchip Motor Control and Drive Microchip 2014 Online Available https www microchip com pagehandler en us technology motorcontrol Accessed 6 March 2014 Microchip Brushless DC Motor Control Made Easy 2002 Online Available http ww1 microchip com downloads en appnotes 00857a pdf Accessed 28 Feburary 2014 Microchip Sinusoidal Control of PMSM Motors with dsPIC30F DSC 2005 Online Available http ww1 microchip com downloads en AppNotes 01017A pdf Accessed 27 April 2014
33. execute the project control Upon suggestion from Professor Michael Young George Mason University the design team investigated Microchip s PIC controllers Members of the design team were familiar with programming PIC controllers Because of this familiarity the design team focused on an acceptable Microchip product Microchip s website had provided documentation and recommended products for motor control Because advanced closed loop control will be reguired the design team chose to research Microchip s dsPIC33E family of digital signal controllers The family is energy efficient incredibly powerful and contains high performing peripherals In addition Microchip provides a vast amount of documentation including complete user manuals software libraries and application notes of motor control 3 2 1 4 Control Theory amp Application The following experiments in control theory use only the MPU 6050 accelerometer data from the Brick Road Trials that was previous discussed Since the team has 41 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih not built any stabilizer yet feedback cannot be used to measure the performance of such control methods Rather the following experiments are used to smooth out any extreme changes in the sensor data acquisition and to give an idea or clue as to what effect and to what scale the following methods may be used This is a practice in control simulation and not control itself
34. expected to be lots of trial and errors which may lead to constantly having to try different motors and using brushless motors may drive up 22 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih the cost of this project if great caution isn t taken into account Also the addition of the electronic devices causes the complexity of the controller This is biggest dilemma with choosing the brushless motor as lots of time and effort will be delegated to control If control is not properly design the results can be very detrimental to performance of the camera stabilizer Stepper Motors Stepper motors often referred to as the baby of the motor family are brushless DC motors that have a unique construct from other motors with respect to the rotor The permanent magnets are placed on the rotor in a fashion that causes the rotor to be magnetized axially as opposed to most other motors that will have the rotor magnetized radially Another unique feature about stepper motors is the fact it has a doubly salient design in other words both the rotor and the stator have protruding structures or teeth One advantage for using a stepper motor is that they are well known for giving very good position control Also stepper motors can hold their position once they are set through open loop constant current This feature of the stepper motor can prove to be quite useful for the camera stabilizer The stepper motor would be able to provide acc
35. further assistance Have a great day Best Regards Taylor Iversen Customer Service Representative SparkFun Electronics Kew sparkfun com x 303 945 2984 x 09 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Figure 26 Surface Mount Technology reprinted with permission aaa 59 SparkFun Customer Service cserice sparkfui Mar 18 amp to me Hello Tom Yes absolutely Thank you for asking Please just be sure to check out the guidelines for doing such a thing You can find these guidelines HERE Please let me know if can be of further assistance Have a great day Best Regards Taylor Iversen Customer Service Representative Sparkfun Electronics mew sparkfun com x 303 945 2984 x609 Figure 29 Easy Gimbal Mechanics permission pending oooWoooWoooc 68 Hi Michael My name is Alexander Pennock I m an electrical engineering student at UCE I m working on a design project regarding camera stabilization noticed your EasyGimbal Kickstarter Project was hoping to use one of your images as a reference within the report The particular image is shown below After quite a bit of research am thoroughly impressed by your product hope this really takes off Thank you for your support and good luck https s3 amazonaws com ksr assets 000 850 543 5c08d40bdd259a5c56c579680817a491_large jpg 13771704 15 e Your message will go to Michael s Other folder because y
36. general soldering due to their larger surface area The tip of the soldering iron is wiped on the damped sponge to insure that it stays clean Also if using ROHS solder soldering must take places in locations with open ventilation as to insure that the operator doesn t breath in the solder fumes The only vapor from leaded solder is water from the flux core Tinning is then performed on the soldering iron Tinning can be described as adding a lit bit of solder to the tip of the iron in order to prevent the tip of the soldering iron from oxidizing Wipe away excess solder on the dampened sponge 59 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Gather your components to be soldered liquid flux solder picks and tweezers Drop a very small amount of flux on the pads to be soldered Then the component is placed on to the printed circuit board and heat is then applied to the component and pad using the chisel tip Solder is then applied not to the iron tip but rather the heated pad and or the component Allow the solder to cool and settle Generally smaller the pin pitch on components the smaller diameter solder is to be used After all soldering is finished wet the toothbrush in deionized water and scrub away any excess solder and allow the board to air dry You can use bathroom hand dryers or hair dryers on low heat to speed up the drying process Wire cutters are used to cut any excess leads left from the compone
37. in a similar fashion to a spring suspension This will mimic the mechanical isolation technique mentioned within the design research on a smaller scale The second purpose of the platform is to increase the strength and balance of the gimbal system mounting to the vertical handle grip The isolation plate increases the gimbal system s moment of inertia about the handle grip By doing so it will decrease the gimbal system s tendency to roll The surface area will be increased as a result of the 67 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih horizontal plates This will allow a larger attachment area to the handle grip thus reducing forces and stress on the joint location The other major component is the vertical handle grip The vertical handle grip has several functional purposes Embedded within the top of the handle grip will be one additional brushless DC motor Its purpose will be to provide the user with manual control of camera pan functionality The pan motor will be directly mounted to the bottom of the horizontal isolation platform As a result the entire gimbal system will be capable of rotating about the vertical axis In addition the handle grip will house the necessary battery power supply Embedded within the grip will be all necessary user interfaces including the power switch pan control and power indicator light If time permits the design team would like to further isolate vertical vibrations by inc
38. is pe e e EEE A E RE E E e TE ETA FE on AE E eee ee E TEEN e e an rm TEE A ne Ka ai napaan oe EPA PI AR ER EE fg Figure 15 Accelerometer Structure a dana makananenak 32 SparkFun Customer Service cserice sparkfui Mar18 x A to me Hello Tom Yes absolutely Thank you for asking Please just be sure to check out the guidelines for doing such a thing You can find these guidelines HERE Please let me know if can be of further assistance Have a great day Best Regards Taylor Iversen Customer Service Representative SparkFun Electronics Xew sparkfun com x 303 945 2984 x609 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Figure 19 Coriolis Force on Tuning Fork Gyroscope ooWoooWooW Waka 35 Images and other media See also Commons Reusing content outside Wikimedia While in principle Wikipedia s text is subject to the Creative Commons Attribution ShareAlike License and generally the GNU Free Documentation License and can be used free of charge for any purpose so long as licensing terms are met other media including images are sometimes identified as being subject to other licenses Each media file has its own information page which includes source and licensing information Clicking on the media file will lead to this information page Many media files are free to use as long as you follow the terms of the licenses applied to them From the information page to download a
39. pan control motor If the linear actuator is used a controller is not required as all feedback sensing is embedded within the actuator The design team will just have to send appropriate PWM signals If the optional pan motor is incorporated then three additional inputs will be required The two corresponding limit switches and a user thumb joystick As a result the pan motor will not need closed loop feedback No BEMF input is required and it can be controlled with constant output signals 5 3 2 Electronic Parts List Because of the variations between the two mechanical designs the design team chose to develop a comprehensive quantity list of all major electrical components required The list is maximized for both designs meaning that the list includes all unique electronic components that may be used in the circuit design dsPIC33EP128GM306 1 System Control MPU 6050 1 Rocker Switches DPST 16A Tenergy 18650 1 Power HSMF C15x 1 Management L4931 1 Turnigy D2826 10 2 A3930 2 Stability System L12 Firgelli Linear Actuator 1 Turnigy D2826 10 1 A3930 1 Pan 311SM702 2 System COM 09032 1 Table 12 Major Parts Listing 77 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 5 3 3 Design A amp B Schematics Schematic for Design A Figure 33 Design A Schematic 78 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 2 E 3d Sc
40. quality of work on the project Luckily the group has been able to meet the overall majority of the millstones and objectives that had been laid out at the start of the senior design class Professor Young s constant attention to how the members of the senior design group worked on the camera stabilizer helped to insure that not only the individual members where always meeting deadlines that he set but that also there was never a compromise on the quality of the work that was documented and built 102 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Appendix A Permissions Figure 2 Stedicam Harness and Stabilizer reprinted with permission Lam a student and would like to use one of your articles in my research project Can have your ermission to do so We are happy to grant permission to use our material for noncommercial nonprofit educational purposes We ask that you not alter the images or content from the way they appear on our site and that you cite HowStuffWorks as your source Figure 3 Fig Rig Camera Stabilizer permission requested y H d have permission to use o in the following page beep to us Lig rig video camera stabilizer This is for an academic paper Thank you Tom Name Email Phone Type X essage M I m an electrical engineering a student at the University of 8 Central Florida and was wondering if I could have permission to use this following photo for a
41. stability conditions The user will simply hold the camera stabilizer and begin to move the device in an upward and downward motion Data will be collected from this test to see how quickly the motor moves the device as well as how much torque will be produced 91 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih The video images taken from this test are then compared to video images taken from another camera performing the same movements but without being connected to the stabilizer An arrow will be placed on a wall with another arrow placed on the camera As the device is moving an observation will be taken to see how the far the arrow on the camera is moving away from the arrow on the wall This observation will aide in determining wither or not the device can keep the camera within 1 8 of its original position This test will have three trials 6 3 2 Test 2 30 Minute Stair Climb This test was previously mentioned in the Battery Life section The second test of the camera stabilizer will not only test stability but will also aide in testing the performance of the power supply An individual will begin to climb up and down a flight of stairs Once that person begins to feel fatigue they will pass the device to another person to continue climbing up and down the flight of stairs This test will continue to run for about 30 minutes The images from the camera stabilizer will be compared to that of images taken from a
42. that the senior design group will face is designing a rigid light and functional frame that will be used to house the camera printed circuit board the dc brushless motors and other materials as well The reason behind the struggle with regards to frame design is due to the fact that this is considered to be more of a mechanical engineering aspect of the design rather than an electrical engineering one The frame work is very important considering that it will be a camera housing cage to hold the camera and might possibly be a swinging arm that connects the motor to the camera stage 4 2 1 Materials The purposed materials for the frame include aluminum carbon fiber and Acrylonitrile Butadiene Styrene Acrylonitrile Butadiene Styrene also referred to as simply ABS is the plastic material used by 3D printers The material will have to be stiff and rigid enough for impacts above 3g able to withstand torque ranges around 5 foot pounds lightweight easy to cut drill and replaceable in case of damages The cutting and manufacturing will most likely be done by UCF s manufacturing lab found in ENGR2 101 Table 28 gives a good illustration between the benefits and concerns of each of the materials that will be used 63 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Aluminum 35 36 Pros Moldable into any shape Cons Difficult to reshape if damaged Very Strong Can be sharp if not properly cut
43. unnecessarily complicating the control design DC motors appear to satisfy all the reguirements that are needed for the camera design in terms of power and torgue and offer a simpler controller design then that of AC motors Therefore DC motors will be chosen over AC motors moving forward 3 2 1 1 1 DC Motors Brushed vs Brushless Brushed motors have been the standard for motors historically for quite a while however brushless motors started to immerge and dominate a good part of industry A look into what distinguishes these types of motors as well as the pros and cons between brushed and brushless motors will be required to determine what would be more advantages to use in the design of the camera stabilizer Brushed Motors Within the confines of a brushed DC motor there is the armature commutator and a permanent magnet 10 The armature is made up of a set of wire coils that rotate and becomes an electromagnet with two poles The commutator is a mechanical rotary switch that causes direction of electric current to be reversed about twice every cycle When current starts to pass through the armature the poles of the electromagnet will push and pull against permanent magnets As the poles of the electromagnet pass the poles of the permanent magnet the commuter steps in to 20 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih cause an instantaneous change in polarity The inertia of the motor allows for the motor t
44. used for motor phase current and position monitoring lts operation voltage range is 6V to 40V The device is capable of driving a three phase brushless DC motor a comparator voltage regulator power monitoring system over temperature sensor and motor current monitoring system The system uses PWM speed control using either fast decay chop chop method or slow decay chop coast The last device available through Microchip is the MTD6501C three phase brushless DC sinusoidal sensorless fan motor driver The device comes in either 8 pin or 10 pin packaging It supports voltage power supplies between 2V and 14V Speed control is achieved through Pulse Amplitude Modulation PAM or PWM The device has maximum current outputs of 800MA and 500mA and PWM output frequencies of 23 kHz and 20 kHz for the 8 pin and 10 pin package respectively The device also features a frequency generator function thermal shutdown lockup protection and automatic restart and a boost mode An alternative option to designing a custom controller circuit is to purchase an electronic speed controller ESC ESC are available for both brushed and brushless motors however they are generally purposed for brushless DC motors as they mitigate the complexity of brushless DC motor control ESC devices are usually found on hobby models such as radio controlled cars and aerial vehicles Many ESC provide the hobbyist the ability for programmable modes to mimic coasting acceleration
45. used would be where you need long lengths of wire and want to minimize length during installation such as the electrical grid system Flexible cables are useful for tight packaging spaces moving auxiliary systems and joints Flexible cables also make production easier generally Insulation and Temperature Ratings When you run a current through a material with resistance there will be dissipation of energy in the form of heat This heat dissipation can cause cables to sag material resistance to increase device to device power transfer reduction and possible cable breakdown and fire hazards Generally the higher the current the higher the temperature in the wire the higher the risk of wire failure There are many different type of insulation wrapping made for different temperature ranges Below is table 6 of different materials and temperature ratings 55 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Material Type Operational Temperature Rating C High Molecular Weight 75 Polyethylene HMPE PolyVinyl Chloride PVC 60 75 90 Polypropylene 80 Tefzel 150 Teflon 150 200 Table 6 Temperature Ratings of Wire Insulation Materials Ampacity The National Electrical Safety Codes NESC combines the definitions of electrical resistance frequency of current heat loss insulation temperature rating and outside temperature to determine the maximum current in a wire before fai
46. would roughly last for about 95 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih an hour The main objectives behind these meetings where to recap what each member of the group had already completed towards the writing and also talk about what they would be expected to write throughout the course of the following week The group would also meet regularly every weekend at a coffee shop to discuss important issues relating to the senior design project This served as one of the most beneficial times throughout the course of the project Lots of ideas were bounced around the group and the discussion about the projected would stimulate new design prospects and areas to research The weekly meeting would also serve as a time to allow the group to sit together while the individual members would write about their specific topics Having immediate access to the group members while one is writing a topic towards something like the design would help in insuring no mistakes are made in the writing and that everyone s input can be given in real time The content needed towards documenting the senior design project for the camera stabilizer was broken into several components and proportionally given to the members of the group The bulk of the research that would be needed not only for the documentation but also for the purposes of building the prototype was divided in to three main parts One of the main components of the research was for
47. 0 Peak Power 12NO 11 mm s 23N O 6 mm s 45 N O 2 5 mm s Point Peak Efficiency 6 N 16 mm s 12 N O 8 mm s 18 N 4 mm s Point Max Speed no 23 mm s 12 mm s 5 mm s load Backdrive 43 N 80 N 150 N Force Stroke Option 10 mm 30 mm 50mm 100 mm Weight 28g 34 y 409 56 g Positional 0 1 mm 0 2 mm 0 2 mm 0 3 mm Accuracy Max Side 50 N 40 N 30 N 15N Force Table 9 Firgelli L12 Linear Actuator Options 39 66 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih The Firgelli L12 linear actuator also come equipped with multiple control and output packages ranging from a simple Vin and ground connection a five terminal position feedback system with potentiometers or a fully integrated PWM controlled servo motor controller with its own feedback and correction system The Firgelli L12 linear actuator also comes in compact sizes with the length ranging from 54 5 mm 144 5 mm and a maximum width of 18mm Thus the Firgelli L12 is compact powerful controllable light and quick The downside to the Firgelli L12 is the faster the stroke speed the lower the power a condition not warranted for high impacts and turbulence More than likely the 50 or 100 gearing option with the 50mm stroke and servo controller package will be implemented The team will contact Firgelli about obtaining samples to experiment with The rest of the system will use the same controller IMU and battery package as listed in Design B
48. 2 2 2 2 2 2 15 15 15 15 15 15 1 1 Jovita 5 1 1 7 Morello aa 2 05 05 0 5 3 05 0 5 0 5 lt 0 50 100 0 50 100 0 50 100 lt 0 10 20 0 10 20 0 10 20 Time seconds Time seconds 10 Samples 20 Samples 50 Samples 10 Samples 20 Samples 50 Samples 5 25 25 2 25 25 2 2 2 15 15 15 1 2 1 1 o ES 1 scheiner HE 1 0 5 05 0 5 0 5 0 5 0 5 H 0 50 100 0 50 100 0 50 100 0 10 20 0 10 20 0 10 20 100 Samples 200 Samples 500 Samples 100 Samples 200 Samples 500 Samples 25 25 25 25 25 15 15 15 15 15 15 1 1 1 1 11 A 1 af 05 05 D I 05 05 0 50 100 0 50 100 0 50 100 0 10 20 0 10 20 0 10 20 Figure 21 Rolling Filter Brick Road Trials 3 8 4 3 No Sampling Raw Data 2 Samples 5 Samples 5 No Sampling Raw Data 2 Samples 5 Samples 3 3 3 s25 25 25 5 2 2 2 2 2 8 15 15 15 2 2 84 3 Ma 7 pa a ER 1 TTT 2 05 0 5 0 5 2 2 0 50 100 0 50 100 0 50 100 Zo 50 0 50 0 50 Time seconds Time seconds 10 Samples 20 Samples 50 Samples 10 Samples 20 Samples 50 Samples 25 25 25 3 7 peda 1 4 1 1 1 Ara rio to Berro loros ile erre 0 5 0 5 0 5 0 50 100 0 50 100 0 50 100 0 50 0 50 0 50 100 Samples 200 Samples 500 Samples 100 Samples 200 Samples 500 Samples 25 25 25 5 gt 1 1 1 i e os Jsp Ee 2 0 50 100 0 50 100 0 50 100 0 50 0 50 0 50 Figure 22 Rolling Filter Brick Road Trials 5 amp 6 Lastly one consideration in the importance of choosing a lower sampling size rather than a larger sampling size is an increase in decision speed and decrease in pro
49. 20mA each The Tenergy Lithium lon 18650 battery high energy density can very comfortably meet the requirements of all the electrical components that will be going into the final design of the camera stabilizer Not only can the Tenergy Lithium lon 18650 battery meet the requirements but it can run all the devices while the components are drawing max current at the same time for at least an hour This insures that the thirty minute minimum requirement for the battery to run on a single charge can very easily be provided by the Tenergy Lithium lon 18650 battery 41 Another reason that the Tenergy Lithium lon battery was chosen as the power supply option for the final design of the camera stabilizer project is due to the fact that it is a high quality rechargeable battery pack The battery does not suffer from 74 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih any type of memory effect and has a built in chip integrated circuit chip that protects the battery from overcharge and over discharge which ultimately This particular feature allows the Tenergy Lithium lon 18650 battery to have a very prolonged life The Tenergy lithium 18650 battery if very light weight which comes in handy in keeping the overall device as light weight as possible Table 12 that is proved below gives some of the technical specifications of the Tenergy Lithium lon 18650 battery Technical Specifications Capacity 2600mAh Volta
50. Also as part of taking on the assignment of the camera stabilizer from Professor Young A specialized soldiering class will be offered by Professor Young Solder Pasting The previously mentioned soldering method is great if the soldering technician has a very steady hand or larger pin pitches are used on surface mount and through hole components Unfortunately to reduce component footprint some components have joining pads rather than pins located on the underside of the component Many high output LEDs and thermally active components have this underpad placement 60 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih For the screen soldering method you re going to need a precut metal soldering screen solder paste a stiff metal putty trowel various picks and tweezers double sided Scotch tape and a solder paste oven or modified hacked toaster oven First acquire a metal soldering screen Usually PCB manufacturers or high quality machine shops will be able to take the Gerber file and produce a laser etched solder pad screen If not one can use flat 1 6 mm thick aluminum sheet and manually cut out the solder placement with a hobby knife Before any soldering job always clean the PCB of containments with alcohol and allow to air dry Also wash the solder screen with alcohol and allow to dry Next apply a few strips of double sided Scotch tape to the bottom of the PCB and allow inch long sections of the tap
51. B and places through hole parts in the correct placement and direction then bends and cuts the leads on the bottom of the PCB After populating the board the producer puts a tacky putty like compound to cover any holes needed for post population Then the producer places the populated PCB onto a slightly uphill conveyor belt Within the wave soldering machine is a chamber of heated liquid solder that is rolled over like a wave As the board goes up the conveyor belt the wave of liquid solder splashes on the bottom of the board and adheres solder to any metallurgical junction 34 After the PCBs have passed through the wave soldering machine the boards need to be washed in deionized water dried and the leads clipped and checked for short circuits Afterwards other components such as jumpers surface mount and cabled connectors can be hand soldered onto the PCB ve Figure 27 Wave Soldering Machine self taken photo Wave soldering is efficient for high gross manufacturing The challenges with being able to use a wave soldering machine is to design a single sided PCB and finding all the surface component parts you need lt takes many jumpers and careful placement of the ground plane of the PCB Since this type of PCB manufacturing is only single sided this does not comply with the requirements of the project 62 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 4 2 Frame One of the major obstacles
52. ENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 4 PRODUCTION A significant amount of time and effort has been put towards researching different types of subsystems that will go into the camera stabilizer Once all the appropriate subsystems are chosen and accounted for another integral step to the process must be taken This step is none other than the production of the electrical system as well as the frame that will house varies components It is important to note that having knowledge of the various subsystems that have been researched up to this point does not imply that there is also a knowledge as to how these various components can be properly integrated and housed in a frame Appropriate time and effort also must be taken in order to look into different ways an electrical system can be produced Also research must be made for all the possible options to choose from in deciding how to construct the frame needed for the camera stabilizer 4 1 Electronic Circuitry One of the requirements for any senior design project is to have a double sided printed circuit board PCB as a part of the project The PCB board will house the electrical components and be used to connect the electric motors drivers sensors microcontroller and the power system This is a very sensitive step in the production and requires a great deal of attention as to insure all the various components are properly connected Detail to craft and construc
53. IGN SPRING 2014 TEAM 3 Mizell Pennock Salih Figure 12 Stepper Motor Teeth Diagram reprinted with permission Another area of concern for stepper motors is the fact that they are very underdamped and can have resonance If appropriate measures are not taken into account in the motor control design then any type of noise can increase into the system The results from the increased noise cause stepper motors to behave sporadically and lead to poor position accuracy and jeopardize the video image stability If the motor controller can prevent resonance to appear in the motor and the battery be designed in a way to support the constant current scheme of the stepper motor in a 30 minute interval then stepper motor may very well be a sufficient motor to use the design of the camera stabilizer Servomotors Servomotors are rotary actuators that are coupled with sensors Servomotors do not necessarily distinguish themselves from other types of motors because of any changes in there fundamental operating principles Rather what separates servomotors apart are how they are able to attain close loop control using servomechanism Servomechanisms describe an error sensing negative feedback The servomechanism uses an encoder for sensing feedback data to determine performance correction that is needed for a specific task A servo will measure the difference between the encoder and the desired position and will draw the current needed to mov
54. It must meet many critical specifications The design team has chosen the dsPIC33EP128GM306 device produced by Microchip The device is a digital signal controller that features a 70 MIPS core with integrated digital signal processing and enhanced on chip peripherals The device features minimal operating voltages between 3V and 3 6V and operates with a typical current use is 301A The device definitely meets the design requirements of low power 73 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih consumption It is available in a surface mount packaging with 12mm x 12mm x 1mm dimensions which will be suitable for the design team s PCB board design lt features two IC modules with speeds up to 1 Mbps This will allow direct communication with the MPU 6050 inertial measurement unit The device features 12 PWM outputs which will be just enough for control of two brushless DC motors Each channel has a 16 bit resolution which will provide better response for the motor control Its 128 KB program memory 16 KB RAM and 70 MIPS millions of instructions per second CPU speed will be able to provide the necessary processing required for smooth and quick motor response The device features 53 inputs and outputs Once the PWM outputs are excluded that leaves 41 available I O pins An additional six outputs will be required for the pan motor With all outputs accounted for the design team has 35 pins available for inputs Feedback of the mec
55. N SPRING 2014 TEAM 3 Mizell Pennock Salih mechanically and therefore current switching is not required However because of this BDC motors suffer a lot from wear on the commutator and brushes 14 The purpose of the drive circuit is to vary the current within the windings of the motor The current can be driven through analog control However analog control requires the addition of variable resistance to the motor circuit To obtain better efficiency pulse width modulation PWM will be used to vary the speed of the motor Because the mechanical requires both positive and negative vertical compensation the motor must be driven bi directionally To obtain this characteristic the drive circuit must be designed in a half bridge format The circuit contains two half bridges quadrant 1 quadrant 2 and quadrant 3 quadrant 4 that allow current to flow in either direction of the motor winding The circuit is shown in the figure 14 below Figure 14 Brushed DC Motor Driver with Two Half Bridges reprinted with permission By using this circuit design four modes of operation can be achieved The motor can be placed in a forward reverse coast or brake mode of operation By turning on acombination of the control inputs the MOSFETs will pull one side of the motor to the supply voltage and one side to ground The MOSFET combination for each mode of operation is shown in table 2 below Action Quadrant 1 Quadrant 2 Qu
56. Only the stabilizer motors require precision control and therefore use this BEMF technique The final sensors that must be incorporated into the design are the limit switches for the pan motor Because the pan motor does not have the same compensation requirements are the other motors BEMF sensing will not be mounted to it Control is non essential for the motor since it is manually controlled by the user However the design team agreed that the camera system should be restricted to 120 pan motion The pan motor will be restricted using two limit switches with one at each end of the motion range This will prevent any external wiring from wrapping around the handle grip and tearing components In addition this will keep overuse of the motor to a minimum The major design consideration regarding the limit switches is size constraints The switches should be as small as possible The design team will use the 311SM702 T miniature switch The switch dimensions are 0 50 x 0 25 x 0 80 It has a straight lever that can be bent if required The switch uses a single pole double throw SPDT circuitry which allows for either a normally open or normally closed switch configuration The switch will be wired as normally open When the microprocessor detects a closed input line it will turn off motor output in the switch s corresponding direction 5 2 1 3 Controller Probably the most fundamental component of the control system is the microprocessor
57. SENIOR DESIGN SPRING 2014 TEAM 3 HANDHELD CAMERA STABILIZER Thomas Mizell Alex Pennock Ahmed Salih Report Submitted Project Sponsor Professor Michael Young George Mason University 1 2 3 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih TABLE OF CONTENTS EXECUTIVE SUMMARY en tmn ita 1 INTRODUCTION 2 0 cities adas 3 2 1 MOTO On ee anna E taa 3 2 2 el 4 2 3 Specifications amp Reguirements oooooocoomoWoWoWoWo WWW W W W 4 2 3 1 Customer SPECITICAMONS ane ii nun 4 2 3 2 Pilot 8 Passenger Use of HCS ooooco oWoWoWoWoWoWo WWW WWW W 5 2 3 3 Microcontroller ee ee OR un NN ban 6 2 3 4 EE Len AAA RR DI BAL LN gc edt 6 2 3 02 Motor NEE 6 230 ea Rn na ena ena 6 2 3 7 Power Supply 8 Monitoring ooooWooWoWoWoWoWc WWW 6 2 9 8 Frame Design Ann nn na nahan eld eon aa NA 7 A a 7 RESEARCH 8 INVESTIGATION ooooooooo mna 9 3 1 Mechanical System Research oocoocoooWoWoWoWoWooWcoW WWW WWW 9 3 1 1 Existing Products 8 Designs 9 A an nan 9 311 2 a RIG ae PU o A ANN NAN UE 10 3 1 1 3 Glldecam HD 1000 eegene 11 3 1 2 Proposed Design ta AAA 13 3 1 2 1 Arm Cuff Camera Stabilizer maa 13 3 1 2 2 D Grip Camera StabiliZer tt 14 3 1 2 3 Gyro Based Servo Camera StabiliZeTr
58. acceleration aka jerk 6 1 2 Rapid Prototyping After the team discussed with Dr Ritchie University of Central Florida about the rough draft of the research paper Dr Ritchie gave the team a pair of Futaba S3117 RC car servos to experiment with The team mated a servo with the testing apparatus figure 36 to experiment with stability and feedback The motivation behind this prototype was to understand the ease or difficulty of finding stability in a system The objective of the prototype was to keep a needle attached to the servo motor pointing upwards Now due to the Futaba S3117 servos being limited to 180 range of rotation the counter movement of the needle was limited a MPU 8050 IMU Arduino Mega 2560 Figure 43 Stabilizer Prototype Functional Diagram Servos are very easy to work with Basically there are only three connections power 3 3 5DCV for the Futaba S3117 ground and PWM The PWM connection controls the position of the servo Given the range of motion the duty cycle of the PWM is proportional to where in the range of motion the servo rests at For example the Futaba S3117 servo has a 180 range of motion thus 0 duty cycle relates to the 0 position 25 duty cycle relates to the 45 position 50 duty cycle relates to the 90 position 75 duty cycle relates to the 135 and 100 duty cycle relates to the 180 position Using the Arduino IDE it was simple to take in the raw s
59. ack will be used to control the dynamic behavior of the stabilizer system The motion control has to consist of three key component systems the controller the output system and input sensor system Each system will be further divided into separate subsystems 3 2 1 1 Output System Parameters and Requirements It goes without saying that in order to successfully design and build a prototype for the camera stabilizer careful consideration and research must be made for the type of motor that is to be selected The motor must fall within the parameters of the design that will particularly affect the motor Primarily the specifications about device that are mainly being considered are that the device must be lightweight able to hold a vertical position to within 1 8 perform vertical transient jumps of at least 6 and also last for at least thirty minutes on charge These specifications affect the decision of the motor in many ways The motor cannot be so heavy that it causes the entire design to be too heavy However the motor must be able to generate a high enough torque that cause the camera to move as needed while not consuming too much power as to keep at least thirty minutes of charge All the motors that will be considered for the camera stabilizer will be investigated with regards to how they perform against the requirements stated previously AC vs DC Both AC and DC motors are very useful in their own right however they can exhi
60. actions that will not be reimbursed by Professor Michael Young 100 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Current Expenses Items Price Date Member Where 6 axis Dev 43 96 2 19 14 Tom Mizell sparkfun com Board Soldering Iron 15 13 3 14 14 Tom Mizell Skycraft Soldering Stand 5 25 3 14 14 Tom Mizell Skycraft Wires 3 07 3 14 14 Tom Mizell Skycraft 3X Engineering 40 20 1 20 14 Tom Mizell Amazon com Notebook Battery Pack 4 56 3 12 14 Alex Pennock RadioShack Voltage 11 14 3 12 14 Alex Pennock RadioShack Regulator Battery Clips 2 21 3 12 14 Alex Pennock RadioShack Turning Motor 17 74 2 28 14 Ahmed Salih ebay com GWS Motor 14 99 2 28 14 Ahmed Salih ebay com Breadboard 13 76 3 11 14 Ahmed Salih Wires 2 95 3 11 14 Ahmed Salih Wire Cutter 6 07 3 11 14 Ahmed Salih Multimeter 16 77 3 11 14 Ahmed Salih Total 191 80 Table 19 Current Expenses Mentoring One of the biggest successes found with administration was having the assistance and mentorship of Professor Michael Young He would regularly check in with the group on weekly basis to get the status of where the project stands Professor Young would analysis all the data the senior design group provided him and with that data Professor Young would be able to give appropriate feedback Often times it would proof that Profe
61. adhesives tape screws and various other mounting materials PROS Quick and easy to rig together MH Great for compact apparatus dimensions and last minute bodge jobs CONS m Easy to short out components due to bare leads mu Vibration can wrangle the soldered connections loose 57 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Through Hole Technology THT gt e S Figure 25 Through Hole Technology reprinted with permission Emerged in the 1950s 32 and still used in larger and bulk production products The silicon chip is embedded in a plastic body with long pins stick off the sides and downward with uniform length and pin pitch The pins are placed into a PCB that is properly drilled and designed for THT Most common form is the dual inline package DIP package where the pins are on opposite sides of the plastic body PROS WR Conforms to common breadboard design WR Great for prototyping m Easy to test and probe the pins m Easy to solder for amateurs CONS E Larger footprint than surface mount WR Most newer components do not come in DIP m More expensive than surface mount components Surface Mount Technology SMT Developed in the 1960s for deep space vehicles became popular for manufacturing and industrial purposes in the mid and late 1980s 33 and onward Very similar to THT except the pins are soldered to pads rather than through a drilled hole and soldered PROS
62. adrant 3 Quadrant 4 Forward on off off on Reverse off on on off Coast off off off off Brake off on off on Table 2 Brushless DC Motor Driver Modes of Operation 27 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Using this circuit design several other factors should be considered It is noted that the diodes across each MOSFET helps protect each one from current spikes that are generated by back EMF The diodes are only required when the MOSFETs internal diodes cannot sufficiently dissipate the back EMF current The capacitors are optional as their purpose is to reduce any RF radiation that may be produced by commutator arching Lastly the final design consideration regards MOSFET biasing during unpredictable circuit input such as controller initialization If the MOSFETs on either half bridge is turned on at the same time a short will occur potentially damaging the MOSFETs and rendering the circuit useless The pull down resistors at each input will help alleviate this concern The design team has the option to build a custom BDC motor drive circuit following this circuit topology MOSFET choices would be dependent on the voltage range of the output motor system However there are many predesigned circuit devices available that would accomplish this goal One characteristic of BDC motor control that makes it useful is that the speed is directly proportional to the applied voltage of the motor U
63. as quickly as possible After consideration the design team felt that the best way to receive feedback on the system movement was to obtain acceleration data Based on the initial product concept of being used within a small aircraft turbulent forces must be accounted for These forces are unpredictable resulting in spontaneous accelerations experienced Because these turbulent forces are the most significant influence on camera stability it definitely proves a requirement to incorporate corresponding data into the feedback control With this information numerous system specifications could be determined By using Newton s Second Law the forces acting on the system can be evaluated In addition by integrating the acceleration over a set amount of time the system s external velocity components can be calculated This data can be used to determine the requirement for the opposing motor velocities for compensation Based on the experience of the design team and recommendations from individuals in the industry the design team chose to use the MPU 6050 device The MPU 6050 is a triple axis accelerometer and gyroscopic inertial measurement unit There are several models for different acceleration ranges A device model capable of handling all expected accelerations between 5g was chosen It operates at a maximum of 3 46V and contains a minimal surface mount footprint of 4mm x 4mm x 0 9mm At full power the device operates at 3 8mA This proves to b
64. asted unnecessarily An appropriate means of keeping record of expenditure is also needed to insure that all expense are accounted for and also group members are reimbursed for the costs accordingly Whenever a member of the senior design group is to perches a component for the camera stabilizer the receipt for that transaction must be scanned and sent to one of the folders on a google drive that is dedicated for receipts for transactions The folder on the google drive that is meant for receipts will be organized according for each member of the senior design group and also categorized by when the transaction was made Have the data for the expense properly logged will help to guide senior design team to keep track of the budget and make sure that the 500 budget is not exceeded Finally with the date of the expenditure and the receipts for all the transactions will be presented to Professor Young for him to review Professor Young will then reimburse the senior design group by writing a check for the amount that was spent at that time Once the check has been cashed each member of the senior design group will receive their portion of the check based on how much each member of the group spent out of their out pocket The group will expect to send a constant 99 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih log of the receipts of expenditure roughly every month The senior design group will attempt to have the day that reimbur
65. ater signal energy and the last half of the summed wave will have less signal energy as seen in figure 17 Then the signal is demodulated and amplified The model does not provide the demodulation and amplification is due to initial voltage In a MEMS accelerometer the voltage passed through the differential capacitor is in the millivolt range thus amplification is needed for the final output 33 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih EE e e r e e r x e y e 4 0 Sms 10m 1 2ms Lams Lim e ms 2 2ms d 2 6m Z8ms 3 0ms Figure 18 Output of Balanced Differential Capacitor If the accelerometer is in freefall then the test mass is at rest and the effective capacitance area of both plates C1 and C2 are equal Since there is equal capacitance the impedance is the equal and the differential capacitor is balanced Thus the first half and last half of the square wave have equal signal energy as seen in figure 18 MEMS Gyroscopes Another important factor in determining the motion of an object is radial velocity From classical mechanics radial velocity is the speed at which an object rotates around an observed axis usually measured in radians per second or degrees per second Being able to measure the angular velocity of the frame of the camera stabilizer is important because image blur is highly likely when large radial velocity figures are applied to the body of the camera and image blur is the largest reason for
66. bit different characteristics in terms of the power output torque and controllability that must be looked into All motors have standardized motor dimensions established by the National Electrical Manufactures Association NEMA Based on these dimensions industries that use motors have reported that DC motors have an advantage over AC motors in power out per unit frame as well as the torque output per unit frame Having a better power output will contribute to optimizing the usage of the battery Also having more torque produced per unit frame will also only aide to insuring that the camera stabilizer can perform as required 19 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Power Density Comparisons of Motor Catalog Ratings 500 400 300 200 100 H 180 210 250 280 320 360 400 NEMA FRAME DIAMETER RATED HP MAC BDC Figure 9 Rated Horsepower AC vs DC Motors The camera stabilizer will not be expected to operate at very high speeds Rather this device will be reguired more than often to function at slower speeds Here another important distinction must be made between AC motors and DC motors DC motors exhibit constant flux at very low speeds and because of that DC motors will produce constant torgue AC motors however cannot maintain constant flux at very low speeds and therefore will not be able to produce constant torgue at very low speeds Not having constant torque at very low speeds can only lead to
67. cessing time This is important to reduce lag in the feedback and control system 3 2 1 4 3 Value Binning Lastly another form of data manipulation and control is value binning Value binning is very simple the degree at which values can change is place into possible ranges For the MPU 6050 all data values range from 65 536 to 65 535 but rather a resolution of one unit bit one could lower the resolution so that two four eight bits are represented as one unit 3 2 2 Power There are several ways energy can be harness in order to properly perform any type of function Power can be extracted from either power electronic devices DC power supplies or AC power supply Although both DC and AC power supplies are 43 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih very powerful and capable of providing more than enough power to support the camera stabilizer they are not very practical for what is needed from the specifications Both AC power supplies and DC power supplies are very bulky and very heavy Due to the fact that the design requires a lightweight and portable device these requirements cannot be achieved through the use of large power supplies Another point to emphasis is the cost of AC power supplies and DC power supplies As stated before it is very important to remain within the budget of 500 that was set for building this device Using an AC or DC power supply will immediately cause the cost to
68. controllers the design team began by evaluating the required amount of inputs and outputs in the project design To do this the design team chose to assume the maximum amount of data lines required The design team decided that a maximum of three motors would be used Depending on the control used the maximum amount of output channels required for the motors would be eighteen This is under the assumption that all motors are brushless DC which at most require two controls for each of its three phases With the output amount determined the design team had to realize how many input channels were required The MCU 6050 inertial measurement unit will definitely be used The unit transmits unique data for its accelerometer and gyroscopic sensor If the acceleration and 39 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih rotation is measured on all three axes a maximum of six inputs are required for the inertial measurement unit alone As previously stated the design team will focus on compensation of the tilt and roll motors If quadrature encoders are used each of the motors will require two inputs for position sensing As the pan motor will be manually driven its position feedback is non essential as the other motors The design team can use a single current input to correlate its velocity direction During prototyping the design team can use a brute force method and just test the motor at different values to fin
69. cular camera chosen Also a number of users of the Glidecam HD 1000 have raised concerns with experiencing fatigue when using the Glidecam for an extended period of time 12 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Having to hold the hinge in the manner that is constructed along with supporting the counterweights will most likely cause anyone to become very frustrated and tired In researching the Glidecam HD 1000 it has brought to light one very important decision towards designing the camera stabilizer for the senior design project That decision is that counterweights method will not be introduced into the final design Not only will counterweights cause the system to become very heavy but it may also add unnecessary strain and fatigue to the user as the Glidecam is known to do Also as it has been mentioned by the previously existing models the lack of electrical components towards to stability of the camera is a great concern and does not appear to model what an electrical engineering project should focus on 3 1 2 Proposed Designs 3 1 2 1 Arm Cuff Camera Stabilizer The first HCS proposal design mimicked an arm brace device It was designed to be compact lightweight rugged and safe The HSC base frame housing would use an ergonomic design inspired by cuffed crutches Below is a rough illustration of the original design in figure 5 Figure 5 Arm Cuff Camera Stabilizer Rough Illustration 13
70. d an acceptable speed at which the motor rotates However to prevent component breakdown two limit switches will be used to the pan rotation within approximately 120 Recounting these requirements the system will require thirteen inputs to mechanically function This does not include inputs required for the power monitoring system Overall the mechanical control will need 31 data lines Because of this reason it will be highly probable that the design team will only implement the mechanical control through the microprocessor Either a separate processor will be dedicated to the power monitoring system or it will be performed through analog circuit design Other than having a large amount of IO lines the microcontroller must also be able to meet other specifications The most important factor that also has to be considered is the processors computational performance By maintaining an acceptable performance the control response of the motor output will be maximized This is essential for the rotational compensation required in the gimbal system It has to be power efficient due to the size constraints of the battery Because of the operating voltage range of the motors it is preferential for the microcontroller to be able to provide output voltages of 5v to 7 5v In addition it must Available Components The design team researched several initial components that could be used for the microprocessor Each component was investigated because the
71. de The operation is reversed when the battery is charging One of the biggest advantages of using a lithium ion a battery source for the camera stabilizer would be because these batteries are very well known for the fact that they run on a single charge for a very long period of time compared to other battery alternatives This is due to the fact that lithium ion batteries have very low self discharge rates Lithium lon batteries will lose roughly 2 percent of its charge in a month The primary task of the battery is being able to support enough 45 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih power to last at least 30 minutes This is a task that given the lithium on battery given that the proper selection and measurements are made should be able to achieve Another significant advantage found in using Lithium ion battery is the fact that they are very lightweight in comparison the majority of alternative batteries available in the market Although they may be lightweight lithium ion batteries do not fall short to other batteries with respect to energy density In fact they can store as much as 150 watt hours of energy in 1 kilogram This makes lithium ion batteries superior to other batteries in terms of the energy per unit of gram Unfortunately as good as this battery is it has significant drawbacks that come with it Firstly is that the battery doesn t have a relatively good lifespan lt ages very quickly when
72. design the design team will use any data line connectors such as RS 232 USB or other serial connectors Instead the design team will be using simple solid copper wire on the 12C lines The design team can cheat away with just copper wire for the data lines since the design team will be keeping the distance from processor to I O component very short thus no fear of excess noise due to cable length Wire Diameter Standards Like most measurements the United States uses a different standard in wire diameter than the rest of the world this is comparable to English units feet gallons pounds etc to the metric system meters liters grams etc There is the American wire gauge AWG Below is table 5 to compare gauge sizes to metric sizes Contrary to usual measurements the smaller the value of gauge the larger the diameter of the wire 54 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih AWG Inches Millimeters 30 0 010 0 255 24 0 201 0 255 20 0 032 0 812 18 0 040 1 024 14 0 064 1 628 10 0 102 2 588 8 0 129 3 264 4 0 204 5 189 0 0 325 8 251 Table 5 AWG vs Inches vs Millimeters 30 Thread Count Depending on the connection sometimes the wire has different needs in flexibility and this is where thread count comes into play Generally the higher the thread count of the wire the more flexible the wire is and vice versa Applications of where a stiff wire is
73. e accordingly Unlike stepper motors servomotors do not require a constant current scheme to operate The control will only send current to a servomotor if it needs to move to a certain position or hold a load This is significant in the sense that unlike stepper motors there will not be a concern about a battery being constantly drained by the 24 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih motor Therefore a servomotor shows that it can have an advantage with regards to being very efficient with power consumption The first issue that may arise when looking at servomotors is the fact that they do not generate the same amount of torque as stepper motors do at low speeds As discussed before the camera stabilizer will be expected to perform at low speeds There are more powerful servomotors however they tend to be very heavy and may very well cause the camera stabilizer to be out of its required specifications for desired weight Another area of concern for servomotors is the fact they require specialized circuit drivers for motor control A tradeoff here occurs between stepper and servomotors One can opt for a more accurate position control with servomotors but the complexity of motor controller will increase greatly over a stepper motor Linear Actuator Linear Actuators are unique in the motor family due to the fact that rather than providing rotary motion they have a linear motion of the rotor Linear actuators
74. e and licensing information Clicking on the media file will lead to this information page Many media files are free to use as long as you follow the terms of the licenses applied to them From the information page to download an individual free image first right click Full resolution or the linked name of the image Next choose to save the image exact option depends on browser A brief overview of some of the licenses that may be applied to media on Wikipedia is visible at Wikipedia Image copyright tags Additional information may be found at Commons Licensing However neither the Wikimedia Foundation nor the authors of material on Wikimedia sites provide legal advice It is the responsibility of the reuser to determine how a license applies to the intended reuse Media file information pages sometimes include contact information for copyright holders If the licensing conditions of a media file are unsuitable for the reuse intended it may be possible to contact the copyright holder of the media file for alternate conditions This will need to be negotiated with the copyright holder directly Figure 25 Through Hole Technology reprinted with permissioOn Woo 58 SparkFun Customer Service cserice sparkfui Mar 18 A to me gt Hello Tom Yes absolutely Thank you for asking Please just be sure to check out the guidelines for doing such a thing You can find these guidelines HERE Please let me know if can be of
75. e essential as power consumption is an extremely important consideration in the electronic circuit design The device contains the added benefit of being incorporated into a breakout board supplied by SparkFun Electronics This makes 72 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih testing and interfacing to the device incredibly easy The MPU 6050 uses an IC bus for data transfer The design team had no previous knowledge of I2C protocols however the design team agreed that it is valuable knowledge that all members should learn The device is capable of running in a 400 kHz fast mode which will be required to obtain better signal processing and therefore smoother and quicker responses in the motor output system As previously mentioned the device also provides gyroscopic data While this is secondary data the gyroscopic information can be extremely useful to evaluate rotational positions of the mechanical system The inertial measurement unit is definitely the most critical feedback sensor It should be capable of producing all the required information regarding the mechanical system s velocity and position But in addition to this proper control of the motors is required Motor velocity and direction will be critical to provide proper compensation Therefore at least one sensor must be used for motor control To minimize the complexity of the control system the design team will use back EMF BEMF readings on the motors
76. e to hang out Flip the PCB over and stick it to a clean and level surface This will ensure that the PCB does not move or jiggle during the printing process Grab the clean solder screen and very carefully align the cut out screen with the proper pads then press down to ensure that the screen has attached to the double sided tape thus why the excess tape was needed The screen should now be aligned with the PCB Now using an alcohol cleaned trowel scoop a small amount of soldering paste onto the solder screen just above the cut out area Using quite a bit of pressure slowly scrape the solder paste over the cut out area of the soldering screen Be sure to keep an even pressure speed of sweep and trowel angle Always work in the same direction top to bottom Once all of the pad locations are filled and level with soldering paste gently lift the soldering screen mask from the work surface and with extreme care as to not smudge the applied solder paste peel the PCB off the bottom side of the soldering screen Now the soldering paste is applied to the pads Be sure to visually inspect all pads for uniform soldering paste thickness Gather the picks tweezers and components to be mounted With a steady hand use the picks and tweezers to place to components onto their desired locations Once happy with the placement of a component lightly press down on the component to ensure that it ll stay on the pad Again a jeweler s monocle is useful
77. ea This would also hold true with the camera stabilizer that is to be presented for the purposes of the senior design project Careful planning with respect to time management as well as proper delegations is needed in order to insure an efficient and well balance work load is assigned to all members in the group Having very good administration will not only insure the project is completed successfully rather it will also help prevent having one member of the group having to have much more work than another Also having good administration is meant to ensure that each member of the group is utilized to their strengths rather than their weakness Most importantly of all the points having good administration on a project will lead to everyone from the group benefiting and learning from the senior design project on the camera stabilizer 7 1 Team Management Of the main requirements for the first part of the senior design project is the submission of the senior design documentation of the project The senior design documentation is required to be a minimum of 90 pages of original content Since there are three members of the group committed to the camera stabilizer project each member of the group is required to produce a minimum of 30 pages of original work that will go towards the documentation Before any member of the group can get started writing anything that would go towards the documentation of the group several meetings needed to be held
78. ed so that the processor automatically outputs computed three dimensional position velocity and acceleration outputs rather than the 6 36 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih axis output of the accelerometers and gyros Unfortunately DMP is easily accessible with the 600 MPU 6050 development board and software which is out of the design team s budget we hope to be able to reverse engineer the DMP system by exploring how the MPU 6050 s DMP registers change with change of input Elsewise we can calculate the same data using the MCU Measuring g Force The team needs to design build calibrate measure record and analyze possible ranges of g force Luckily this will give the team the ability to perform essential design research for the instrumentation system implemented in the HCS The team will test different accelerometers for their accuracy performance and general usage fitness and appropriateness Due to the cost of flying a personal aircraft the design team cannot perform direct acceleration measurements in the actual plane Thus the team needs to be able to simulate similar conditions in a low cost fashion It has been proposed by Professor Michael Young that measuring g force while holding an accelerometer unit on bumpy dirt roads at slow speeds is adequate for simulation of normal turbulence in a passenger plane The team will perform this g force testing in the semester of Senior Design I
79. ensor values 1 g 16384 bit value 1g 16383 bit value Luckily it was pretty easy to convert from bit value to g value x axis to servo counter angle position to a PWM signal Initially testing the prototype involved moving the frame in a roll manner like a plane rolls Luckily first try the needle attached to the servo stayed upright but was very jittery Below are pictures of the first session of the prototype Note the jitter is evident in the middle photo 88 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih SEN Figure 44 Raw Prototype Testing self taken For greater stability in the future the design team will use a rolling average with sampling sizes between 2 and 5 samples Due to time constraints this will be implemented after the spring semester Also the MPU 6050 IMU was located near the servo motor so there was probably feedback being sent through the system due to the torgue jitter 6 2 Acceptance Test Plan The acceptance test plan is the design team s guality documentation Its purpose is to provide a comprehensive set of instructions that should be followed in order to properly gather data regarding the project s robustness The acceptance test plan is used in conjunction with the acceptance test procedure To avoid confusion the acceptance test plan will be referred to as the ATP Members of the design team have extensive experience developing industry ATP documents W
80. es Cables amp Jumpers 53 4 1 4 Component Packages masakan 57 4 1 5 Soldering Melide bulan es ekstasi 59 4 2 Frame EN ASIN IE SEKEN aa 63 ARA Materials ae Na an aad st ae 63 5 DETAILED DESIGN CONTENT sei bian anna kanakkanak 65 5 1 Mechanical System Design ooooooWoWoWoWo WWW WWW Wo W W W 65 Oli Desig 9 eee RR BN BE Bun NN 65 51 2 Design Dit A NAN a 67 5 2 Electrical System Design EE 70 e Ber O A nana 70 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 5221 1 OUTPUT SY SUS IN sitas 70 521 2 INpUt SYSTEM Lena NN NN 72 ad PE Controler AA AN aa 73 5 22 POWER tt tt dd NB 74 5 2 3 Userintertacte nn Dn lia 75 5 3 Explicit Design SUMMAYY 000 iii 75 5 3 1 BIOCK A E EE 75 6 PROJECT QUALITY PLAN oia 81 6 1 Initial Testing Conditions oooooWoWooWoWo WoWoWo WWW Waka 81 6 1 1 Acceleration Conditions AAA 81 6 1 2 Rapid Prototyping cists hie eo coe eee LN SAR KUN 88 6 2 Acceptance Test Plan ii ba 89 6 2 1 Battery Le ea ove pein ada cos ieee ees 90 OLEO ME 90 6 2 1 2 NO LOG as 91 6 2 2 Hardware ErgonomiCS ads 91 6 3 Acceptance Test Procedure aaa 91 6 3 1 Test 1 Handheld Gtabilty AAA 91 6 3 2 Test 2 30 Minute Stair Clmb maaa 92 6 3 3 Test 3 Road Test isa A ane an una Binaan 92 6 3 4 Test4 Plane TOS ius EN A AA BNN 93 6 4 User Manual Development
81. esponse time provides greater motor commutating efficiency While all of these conditions can greatly affect the efficiency of brushless DC motors the design team is primarily interested in the repeatability response time Based on initial considerations it is believed that the voltages and temperature of the system will not reach levels that greatly affect the sensors One of the primary concerns of the design team is the physical implementation of a Hall Effect sensor in a brushless DC motor The design team would either have to find a brushless DC motor that already has a Hall Effect sensor incorporated into it or design its own motor mounting for the sensor While there are some brushless DC motors that contain Hall Effect sensors the cost of the motor is much higher than its non sensored counterpart While building a Hall Effect sensor board and adapter is relatively easy to produce the sensor board sensitivity must be brought into consideration As stated previously the design team would like to mitigate this problem by having a Hall Effect sensor built into the motor and therefore closer to the motor magnet Because of this issue it is highly probable that the design team will not use Hall Effect sensors If brushless DC motors are used back EMF readings will likely be used Optical Encoders Another option to obtain motor data is the use of rotary encoders Rotary encoders are sensor devices that convert the angular position of a shaft o
82. exer logic capable of up to 1 32 step micro stepping and phase enable with capabilities greater than 1 32 step micro stepping In phase enable mode input pins control the direction of current flow through each H bridge allowing PWM speed control of a DC motor or enabling disabling current in a stepper motor Indexer mode allows simple step and direction interfacing for stepper motors The DRV8825 Dual H Bridge Motor Driver is a 16 in device The output current is 1 5A or 500mA depending on the packing options Both options allow for paralleled output current The power supply voltage range is 2 7V to 10 8V It features PWM current regulation The current is controlled by a fixed frequency PWM current regulation current chopping The DRV8332 HT Three Phase PWM Motor Driver is a 44 pin device produced by Texas Instruments The operating supply voltage is up to 50V In addition the continuous current is up to 5A It operates on a PWM frequency up to 500 kHz It features self protection circuits against under voltage over temperature overload and short circuits The device requires two power supplies one at 12V and another up to 50V The device has independent supply and ground pins for each half bridge allowing possible current measurements via shunt resistors The DRV8313 triple 1 2 half bridge driver IC is a 28 pin device produced by Texas Instruments The operating supply voltage range is 8V to 60V lt provides 2 5A maximum current drive
83. fficiency of the motors The g forces involved will also determine how rigid the frame construction needs to be which influences weight of the HCS frame material and dimensions and structure of the frame Objects on Earth experience a near equal pulling force of 9 80665 m s 42 this is referred to as 1 g gravitational unit of acceleration For ease of calculation the design team will use the approximation 9 807 m s as 1 g First and foremost the design team needs to get a rough idea of where g forces will vary for normal use of the HCS The table 13 shows the range of accelerations to develop a general idea of where the design team needs to measure Due to personal experience of one of the design team members in auto racing the comfort and ability to control one s body in very fast cornering is extremely hard to maintain The driver reports the feeling of high speed corner as One s own face being ripped off The Nissan GTR is known in auto racing as a road legal car with the highest cornering acceleration 1 19 g It is advisable to keep the range of measuring g between 3g 81 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Activity g Force g Airplane negative limit load 1 52 Weightlessness 0 00 Standard gravity g 43 1 00 Nissan GTR max cornering 1 19 Airplane positive limit load 3 80 Sustained human blackout range 44 4 00 6 00 Roc
84. from the individual placing the order Fortunately there are quite a few tips and rules available for one to follow so as to insure that the PCB is designed correctly The team will use the Eagle PCB CAD program for layout layering artwork and Gerber file production E Broad frame should be rectangular on a 0 5 grid E Drill size no less than 15mm H Ideal trace size is 10mm and no less than 7mm Power lines require thicker trace sizes Power lines require thicker trace sizes Power symbols are needed VCC 5V etc GND is the symbol for all ground connections LEDs are to have the function on the label status power etc All connecters pins and switches are to be labeled Ground pour is used wherever applicable Color notes are needed for various designs on a PCB A solder mask is needed when adding footprints Footprints require a reference designator Footprints require silkscreen showing size and dimensions of a part Avoid having footprints over pads 29 Other considerations include H Ask the PCB manufacturer the accuracy of the drilling and routing tools Options in solder resist coatings ROHS and leaded solder need different coatings mM Ask the manufacturer about solder pad placement accuracy for various pad sizes 4 1 3 Connectors Cables Cables amp Jumpers Most PCBs do not have all the necessary components needed to operate correctly such as power supply other systems and subsystems that are not physically
85. g com Online Available http www pcmag com article2 0 2817 2417224 00 asp Accessed 27 April 2014 D Swando Interviewee Lead Air Designs Interview 15 February 2014 R Mortimore Interviewee Mechanical Vibration Isolation Interview 6 April 2014 P Nguyen Interviewee Design Feasibility Interview 7 January 2014 L Sotomayor Interviewee Aircraft Vibrations Interview 24 April 2014 Clemson Vehicular Electronics Laboratory Brushed DC Motors Online Available http www cvel clemson edu auto actuators motors dc brushed html Accessed 27 April 2014 Wikipedia org Brushless DC electric motor Wikipedia the free encylopedia 2 April 2014 Online Available http en wikipedia org wiki Brushless_DC_electric_motor Accessed 27 April 2014 Pushek Madaan amp Cypress Semiconductor Brushless DC Motors Part I Construction and Operating Principles EDN EDN Network 11 April 2013 Online Available http www edn com design sensors 4406682 Brushless DC Motors Part I Construction and Operating Principles Accessed 27 April 2014 Technical Documents Documentos Tecnicos Servomotors Online Available http en wikipedia org wiki Brushless DC electric motor Accessed 27 April 2014 14 15 16 17 18 19 20 21 22 23 24 25 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Microchip Brushed DC Motor Fundamentals 2010 On
86. ge 14 8V Peak at 16 8V Dimensions 2 9 x 0 75 x 2 85 Weight 7 OZ Max charge current 1 3A Max discharge current 2 6A Cut off voltage 12V Table 11 Specifications of the Tenergy Lithium lon 18650 battery 5 2 3 User Interface The final design consideration is the user interface The design will be kept as simple as possible There will be single two position switch to turn the system on and off The user interface will also contain a small joystick to allow the user to control the pan functionality manually and a single battery status indicator light The indicator light will be HSMF C15x a surface mount chip LED device It features a 3 2mm x 2 7mm footprint and contains two LED dies one for red and green During normal operation the LED will be lit green and it will be lit red every 500ms when the battery is near dead The design team will use the COM 09032 Thumb Joystick product It features two embedded potentiometers Only one input will be used as vertical movement of the joystick can be ignored A WRG32F2FBBNN switch will be used for the power switch The device is rated for a maximum of 250V and 16A 5 3 Explicit Design Summary 5 3 1 Block Diagram Because of the two different mechanical design approaches the design team has provided a summary of the differences between the designs The figures 31 and 32 below are block diagrams of the system for Design A and Design B respectively 75 SENIOR DESIGN
87. geable battery 9 oz system was incredibly unrealistic to Must weigh less than 9 oz Weight less than 2 Ibs D house entire stabilizer system Operates at least 30 Nana N A minutes on single charge Power on off switch None N A Green Power ON LED flashes once every three None N A seconds for about 100ms LED flashes red when ZEN N A battery is low Table 1 Specification Modification The design team had found that certain design objectives and specifications generated by the user could not be realistically achieved Therefore after reinvestigating customer requirements the design team provided modifications to the original objectives and specifications Table 1 summarizes the original objectives and specifications compared to the modified objectives and 18 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih specifications that will be used In addition a brief explanation of why the objective or specification was modified is provided 3 2 Electrical System Research 3 2 1 Control With the stabilizers major mechanical system designed the most fundamental design issue is the system s motion control The basic design concept is to initialize a horizontal reference point for the camera staging The motion control is tasked with maintaining this reference point by engaging the mechanical motion system to compensate for positive or negative differentials Closed loop negative feedb
88. h CH D1 opt A AE M EDO D R5 f MME AN e pok 49116k PULSE 0 3V 0 0 00094m 0 00001m 0 4999891 M D Cua RF a v2 AA D NN ue 10k PULSE O 3V 5m 0 00001m 0 00001m 0 499999m 1m 10 tran 0 5ms 0 0 00001 Figure 16 Model of Unbalanced Differential Capacitor Figure 16 is a model of the differential capacitor set up found in accelerometers The positive x axis capacitor plates C2 will have a zero phase square wave passing through it coupled with a resistor while the negative x axis capacitor plates C1 will have a 180 phase square wave passing through it Then the signals are demodulated phase sensitive amplified rectified summed and measured The phase sensitive demodulation filters out the first half of the square wave and last half of the square wave delays the first half and sums the demodulated signals The model only provides the amplification and summing of the output signal tan 225v Did 1 004 uv 1 534 1 4444 e e e e e e e e r e 4 0 8me fen 1 2ms 1 4ms 1 6ms d Z0ms 2 2m 2 4ms 3 gem 2 808 30ms Figure 17 Output of Unbalanced Differential Capacitor Ifthe accelerometer is moving in the negative x axis then the test mass will move toward the negative x axis thus C1 s effective capacitive area will increase while C2 s effective capacitive area will decrease C2 will allow have less impedance while C1 will have greater impedance thus the first half of the summed wave will have gre
89. hanical system only requires 11 inputs Upon further investigation of the device it was noted that it features two independent analog to digital convertor modules and up to four operational amplifiers comparators With this feature the design team will be able to incorporate the power monitoring system including the indicator light output all on the same microprocessor 5 2 2 Power For the final design that will be going towards the electrical system the power component will be supported by a lithium ion battery The research that was completed in chapter three was used as the bases for the decision to go with lithium ion batteries as the power supply that will be used for the camera stabilizer The particular lithium ion battery that has been chosen for the camera stabilizer project is the Tenergy Lithium lon 18650 battery One of the biggest advantages of choosing the Tenergy Lithium lon 18650 battery is the fact that it is a 14 8V battery and it also has a peak of about 16 8V that the Tenergy Lithium lon battery can support All three of the Turnigy brushless DC motors require at least an operating voltage of 11 1V and draw up to a max current of 21 amps The accelerometer requires an operating voltage of 3 46V and draws up to a max current of 3 8 mA The motor drivers require an operating voltage of 5 5V and draw up to a max current of 14mA All nine of the Hall Effect sensors will require an operating voltage of 3 8V and draw a max current of
90. he senior design group have used this exact same type motor for their products This gives assurance to the senior design group that the Turnigy D2826 10 brushless motor is indeed a very good motor to select for the purposes of the camera stabilizer since it has been used so much by others Also the Turnigy D2826 10 brushless motor s power consumption is very efficient This feature helps to insure that the battery is able to maintain a minimum of 30 minutes on a single charge Table 11 shows the respective configurations of the Turnigy D2826 10 brushless motor Product Configuration Table Kv 1400 rpm v Weight 509 Max Current 21 Resistance Omh Max Voltage 11V Power 205W Shaft A 3 17mm Length 30m Diameter 28mm Can Length 14mm Total Length 40mm Table 10 Turnigy D2826 10 Brushless DC Motor Specs Motor Driver Because of the use of brushless DC motors has been decided for motor output the design choices of motor drivers can be drastically decreased It becomes very apparent that the design team reguires a brushless DC motor driver After careful investigation the design team wishes to pursue the use of the A3930 Automotive 3 Phase BLDC Controller and MOSFET Driver The device is used for automotive applications The operating voltage range is between 5 5v to 50v The device is rated for typical output currents of greater than 10A This is essential as 71 SENIOR DESIGN SPRING 2014 TEAM 3
91. hematic for Design B Figure 34 Design B Schematic 79 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 80 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 6 PROJECT QUALITY PLAN 6 1 Initial Testing Conditions The HCS in intended for image mechanical stabilization of a point and shoot sized camera during times of high turbulence in a personal aircraft such as a Cessna Piper or Diamona Before choosing definitive parts such as motors MCU and frame design the conditions of operation of the HCS must be well understood Below is a list of definitive conditions and considerations that are important for further development NH Ease of use for pilot and passengers WR Changes in position and acceleration Cabin dimensions and product maneuverability m Atmospheric conditions 6 1 1 Acceleration Conditions A large consideration for frame design and choosing of motors is the forces involved with light turbulence F m Equation 5 Newton s Second Law of Motion Above is Newton s Second Law every engineer and related scientists should have this formula engrained in their memory For the HCS the design team will need to have a well understood the range of accelerations the device will experience during normal use to minimize the movement of the camera Knowing the range of acceleration will be the largest contributing factor in choosing the size weight pole count thrust range and e
92. here would be sufficient position control the linear actuator would not be able to respond quickly enough to stabile the camera The result from this would show in a poor quality of the video images taken There are however linear actuators that exist in the market that would indeed appear to respond fast enough to be able to stabilize the video image taken by the camera However the issue that will arise is that those linear actuators are very expensive The camera stabilizer is not meant to exceed a budget of roughly 500 and a good high speed linear actuator can price well over 200 dollars If a linear actuator is chosen for camera stabilizer then enough research must be made to find a reasonable priced motor Also great precaution must be taken with that motor as not to damage it in order to keep the project within the budget constraints The last hurdle that must be overcome with choosing a linear actuator for the design of the camera stabilizer is implementation of these motors will require a high level of understanding of operation and troubleshooting This is referring to the fact that there will be a level of complexity added to the motor controller needed for the linear actuator 3 2 1 1 2 Motor Drivers The key component that will drive the control system s design is the output system The output system consists of a single mechanical motion system But in addition to the actual motion system a motor controller will be used All mot
93. high quality images while the user is running on an unbalanced surface The Steadicam is a rather large construct that starts with the user wearing a vest that acts as a harness between the user and the Steadicam as pictured in figure 2 below The harness is then connected to an armature on one end a sled which mounts the camera on another end and also uses counterbalance weights on the bottom of the device There is a gimbal used to connect the harness with the armature and is used as a pivot point keeping the bottom portion of the Steadicam which is slightly heavier upright with the top portion 2 Main Parts of a Steadicam Supportive Vest Camera Sled _ Iso elastic Arm 02001 HowStuffWorks Figure 2 Stedicam Harness and Stabilizer permission requested SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih The added weight of the counterweights and the camera allows for a very high inertial mass that will not allow movement that may be caused by the motion of the user The pivoted gimbal that is attached to the armature gives the user increased stability of photography as well as videography The user has the flexibility to adjust the armature as needed to tailor any type of project For example if there is a need for a low angle shot then the user can have the camera at the bottom of the Steadicam by putting the armature in a vertical position The Steadicam does indeed appear to be quite sturdy and
94. hile a complete ATP document cannot be developed until the design team produces a working prototype investigation can begin in the content that should be found within the document The ATP will be categorized in a way to support a subsystem representation Subsystem categorization will include but not limited to battery frame design motor control Each subsystem category will be further categorized into functionality tests By doing this the ATP can be produced to contain the reguired information regarding all systems Each section will contain a detailed instruction set on how to test a particular functionality The ATP will detail all required parameters specifications to perform the corresponding test Each section will contain expected results of the test being performed The document should be written in a manner that provides the user a very defined understanding of pass failure criteria for each subsystem s complete functionality This is critical as it removes ambiguity of expected results Whenever possible the pass failure criteria should be defined with quantifiable numerical data Table 16 below demonstrates an example of the expected formatting and recorded information from an initial draft revision of an ATP document generated for industry testing 89 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Test Parameter Focus Settling Time Purpose To Determine the camera s average settling time I
95. ign build document and report on a dean approved project The main motivation behind the handheld camera stabilizer HCS originated from Professor Michael Young George Mason University Professor Young approached the Spring 2014 University of Central Florida Electrical and Computer Engineering UCF ECE Senior Design students about a personal need for a handheld lightweight and electromechanical camera stabilizer for personal use while in a passenger plane for greater filming quality Professor Young chose Senior Design Group Three to design and build the camera stabilizer A secondary motivation for this project is due to the Accreditation Board for Engineering and Technology Incorporated ABET approval criteria for the UCF ECE Bachelor s Program to remain viable and accredited in the United States ABET requires that all electrical engineering students must have at least a semester long capstone project The ABET Engineering Criteria 2000 EC2000 Criterion 4 states Students must be prepared for engineering practice through the curriculum culminating in a major design experience based on the knowledge and skills acquired in earlier course work and incorporating engineering standards and multiple realistic constraints which might include the following considerations Economic Environmental Sustainability Manufacturability Health and safety Social Ethical Political 17 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell
96. ign was rejected by Professor Young due to constriction of the pilot s arm Professor Young was concerned that in case of an emergency the pilot would not be able to take their hand out of the cuff and regain control of the airplane in time 3 1 2 2 D Grip Camera Stabilizer The implementation of this idea is a rolling camera along a D shaped frame Below is a rough illustration of this design shown in figure 6 Figure 6 D Grip Camera Stabilizer Rough Illustration 14 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih The D Grip Camera Stabilizer contained two major components the composite channel grip and the movable camera mounting The camera mounting attached to the grip along the vertical section The camera mounting self automated to align itself to the center of the vertical section The camera mounting contained two guide wheels on either side of the vertical section One of the wheels would be directly connected to a drive motor When the wheels rolled along the vertical section the camera mounting moved in the corresponding direction Using an accelerometer within the channel grip the camera mounting would detect position variations of the channel grip The camera mounting moved in the opposite direction to compensate for the grip s vertical position change The camera mounting would try to always return to a zero reference point Limit switches would also be used to prevent the camera mounting from exceeding all
97. ite paper 4763 en Accessed 27 April 2014 Financial Visualizations finviz com Online Available http finviz com help technical analysis moving averages ashx Accessed 27 April 2014 Wikipedia org Alkaline battery Wikipedia the free encylopedia 7 March 2014 Online Available http en wikipedia org wiki Alkaline_battery Accessed 27 April 2014 Wikipedia org Lithium polymer battery Wikipedia the free encylopedia 22 March 2014 Online Available http en wikipedia org wiki Lithium_polymer_battery Accessed 27 April 2014 26 27 28 29 30 31 32 33 34 35 36 37 38 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Chris Gammell A Widlar Poster For The Agers The Amp Hour Electronics Podcast 9 3 2011 Online Available http www theamphour com a widlar poster for the ages Accessed 27 April 2014 Intersil May 2001 Online Available http www intersil com content dam Intersil documents ca14 ca1458 1558 741 741c Im1458 Im741 Im741c pdaf Accessed 27 April 2014 Advanced Circuits Advanced Circuits Online Available http www 4pcb com Accessed 27 April 2014 Enzo 28 Basic PCB Design Rules Upverter Blog 1 August 2013 Online Available http blog upverter com 28 basic pcb design rules Accessed 27 April 2014 Wikipedia org American wire gauge Wikipedia the free encylopedia 14 Ap
98. izer is indeed to only require a one hand grip Also the Fig Rig design appears to be overly simplified What is meant by this statement is that there isn t much room innovation with adding electrical components to add stability to the device The camera stabilizer project for the senior design calls is intended for three student project it would appear almost impossible to delegate enough substantial work between three individuals for a camera stabilizer design that would be based on the Fig Rig One good note to take from the Fig Rig design that would be applicable to the camera stabilizer is how the Fig Rig model gives the user the option to add additional components This something that will be looked into in terms of something along the lines of a manual control for moving the camera in a certain direction will maintaining stability 3 1 1 3 Glidecam HD 1000 The Glidecam HD 1000 is manufactured by a company called Glidecam Glidecam was established in 1992 and has since been a well known brand by both professional film producers as well has camera hobbyist All of the products that are produced by the Glidecam have been reviewed by many as being able to produce very smooth camera shots even when the user is running or go up and 11 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih down stairs 5 Of the many camera stabilizers that have been produced by Glidecam the HD 1000 model is of particular interest for a
99. k n Rollercoaster Disneyworld 5 00 Top fuel dragster 45 5 30 Airplane ultimate limit load 5 70 Immediate human blackout 46 18 00 Human record for consciousness 46 46 20 Severe injury or death 50 00 70 00 Table 13 g Force Ranges Figure 35 SEN 11028 Breakout Board with MPU 6050 IMU reprinted with permission The team will use the SEN 11028 IMU breakout board figure 35 from Sparkfun com the Arduino Mega 2560 board and IDE and a laptop First a team member will create a program using the Arduino interactive development environment IDE so that the Arduino Mega board can communicate between the MPU 6050 IMU and the laptop s serial output The program will have to access the 12C data register found on the MPU 6050 Second a team member will calibrate the MPU 6050 within the Arduino program so that it reads nearly 1 g when the sensor is held stationary in the X Y and Z directions of the IMU Third the SEN 11028 board will be attached to a prototype stabilizer frame composed of wooden dowels drive down a bumpy dirt or gravel road at low speeds and record the 82 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih acceleration values These acceleration values will be read out to the serial output found in the Arduino IDE Forth the data will be converted to comma separated variable csv data format and formatted in Microsoft Excel as a spreadsheet Lastly the formatted acceleratio
100. ks that can be attested to using NiMH batteries as a power source are the problems with the self discharge rates NiMH batteries are historically known for having very high self discharge rates About 4 of their charge can be lost per day of storage There is a type of NiMH battery known as LSD NiMH this stands for low self discharge NiMH batteries that was introduced around 2005 These batteries give an astonishing rate of about 1 25 on a monthly basis compared to lithium on batteries which would give at best a 4 monthly self discharge rate The one drawback with using the LSD NiMH batteries is that they will have less energy density when compared to both lithium on batteries and regular NiMH batteries 47 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 3 2 2 1 6 Alkaline Alkaline batteries since the early 1900 s have been of the most well known batteries known to the average consumer These batteries take up about 80 of the United States battery market 60 in the United Kingdoms and 47 for the European Union Alkaline batteries are comprised of a zinc negative electrode and a positive electrode made up of manganese dioxide The electrolyte is made up of potassium hydroxide Unlike most other batteries when an alkaline battery discharges only the cathode and anode are consumed meaning that the electrolyte is not part of the reaction The main advantages alkaline batteries have over most other batteries
101. like NiMH batteries is their discharge rates and also they are of the most inexpensive of all battery types that are most commonly used by average consumers However these alkaline batteries due have quite a few number of disadvantages as well Of these disadvantages is their very low energy capacity If the device was a very current device that was being used then the obvious choose from the list of batteries to use would have been the alkaline battery However the camera stabilizer will be considered as a high current drain device Another even more concerning issue with these batteries is the fact that they can leak potassium hydroxide The leaks can be due to a number of reasons that can be attributed to either attempting to recharge disposable alkaline batteries mixing various brands of batteries and other conditions as well When an alkaline battery starts to leak the corrosion will spread and cause oxidation of the electronic components and ultimately damages the circuitry This obviously is something that must be avoided as to not damage the camera stabilizer 3 2 2 2 Battery Monitoring Another important feature and customer specification is the Power ON green LED and the Power LOW red LED intended on letting the user know the current condition of the battery and mode of operation The design team researched two methods of power monitoring using analog comparators or using the HCS s processor for battery monitoring Con
102. line Available http ww1 microchip com downloads en AppNotes 00905B pdf Accessed 2 February 2014 Microchip Sensorless BLDC Control 2008 Online Available http ww1 microchip com downloads en AppNotes 01160b pdf Accessed 27 April 2014 T Instruments Sensorless Trapezoidal Control of BLDC Motors July 2013 Online Available http www ti com lit an sprabq7 sprabq7 pdf Accessed 28 February 2014 Microchip Stepper Motor Fundamentals 2004 Online Available http ww1 microchip com downloads en AppNotes 00907a pdf Accessed 27 March 2014 T Instruments MSP430 Stepper Motor Controller November 2004 Online Available http www ti com lit an slaa223 slaa223 pdf Accessed 6 March 2014 P L Walter Evolution and Comparison of Accelerometer Technologies Online Available http sem org PDF 31 evolution of accel technologies pdf Accessed 27 April 2014 InvenSense MPU 6000 6050 Six Axis Gyro Accelerometer MEMS MotionTracking Devices for Smart Phones Tablets and Wearable Sensors InvenSense Online Available http www invensense com mems gyro mpu6050 html Accessed 27 April 2014 Honeywell Redirecting December 2012 Online Available http www mouser com pdfdocs Selecting Hall Effect for DC Brushless Motors pdf Accessed 27 April 2014 N Instruments Quadrature Encoder Fundamentals National Instruments 9 January 2014 Online Available http www ni com wh
103. lish this goal the design team would like to use composite materials to build the mechanical system However composite material use requires exact dimension specifications If these dimensions are not properly designed the construction using composite materials becomes very problematic If the design team has to produce its own mechanical system then itis highly probable that it will be made out a combination of aluminum and plastic materials This allows for larger acceptable tolerances while producing the mechanical system These materials can easily be produced and modified using available tools such as a battery operated hand drill and Dremel hand tool Initial production will be made using these materials If time permits and first piece production proves successful the design team will incorporate composite materials into the final design With these specifications the mechanical system design can be completed 5 2 Electrical System Design As previously mentioned the design team tried to follow a modular design for the electrical system Doing this will allow concurrent research on the mechanical systems feasibility with the electrical system design Regardless of which mechanical system that will be used all electrical system design can be still be applied The only difference is Design B has one additional system for manual pan functionality Electrical system design was based on the inclusion of this functionality and the design con
104. lithium ion poly is a gel type material made up of a micro porous polymer The electrolyte gel is a catalyst which limits the energy barrier in reaction between the cathode and anode The reduced energy barrier will allow for an increase in the energy density of the battery up to 30 compared with a regular lithium ion battery 25 Also this battery is the most lightweight of all the battery types that will be discussed and can be manufactured in any form to fit any particular design This will aide in insuring that the camera stabilizer be as lightweight as possible and also gives added room in designing the handle of the device that will house the battery along with other components 46 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih The primary drawback to getting the lightweight and flexibility that comes with choosing a lithium ion polymer is the simple fact that it will most likely be the most expensive of all the battery options that will be presented It also shares the same disadvantage of the regular lithium ion battery in terms of the battery being potentially hazardous due to explosions However the lithium ion polymer battery is safer than a regular lithium ion battery due to it being more resistant to overcharge and less prone to electrolyte leakage 3 2 2 1 5 Nickel Metal Hydride NiMH Nickel metal hydride batteries have been historically the most common rechargeable batteries in the market as they have bee
105. lure known as ampacity 31 Though current rating is a more commonly used term than ampacity Below is table 7 with a listing of current ratings for AWG sized wires AWG Max Max Current for Current Power A Transmission A 30 0 860 0 142 24 3 500 0577 20 11 000 1 500 18 16 000 2 300 14 32 000 5 900 10 55 000 15 000 8 73 000 24 000 4 135 000 60 000 0 245 000 150 000 Table 7 Current Rating for Various Wire Gauge The component of the handheld camera stabilizer which has the most concern for an appropriate wire type would have to be the motors The motors are going to 56 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih draw the majority of current and power in the device It is speculated that the maximum current of any necessary motor will be in the range of 20 25 amps thus 16 gauge wire should be the largest diameter the design team uses 4 1 4 Component Packages Due to product needs such as price point operating environment allowable size and fusion of technologies electrical components come in many varieties of packaging Below is a general list of different component packages along with the pros and cons Figure 24 Point To Point Component Technology reprinted with permission One of the oldest used component packaging methods The components are soldered and wired together from node to node and then mounted to a board using
106. lysis In addition thorough material parameters must be incorporated in order to properly eliminate the problematic frequency ranges Lastly without systematic data acquisition the accelerations experienced in flight cannot be properly modeled As a result the controllability and observability of the control system cannot be properly generated To mitigate these feasibility issues the initial design specifications had to be reviewed and modified 8 9 17 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 3 1 4 Objective and Specification Modification Customer Specification Modified Specification Modification Reason Single Hand Held Device None N A Hold vertical position to Objective was Must hold vertical position within 1 4 when no ambiguous and without to within 1 8 with vertical transient jumps are present proper mechanical transient jumps as much isolation response of as least 6 Hold vertical position within stabilizer to 6 is 4 vertical tolerance window unrealistic po poise time MUR Motor response time Quantified a response eliminate all vertical ime movement lt 500ms Must have a standard None N A camera mount Because multiple test Supports the weight of a cameras are unavailable Supports weight of Nikon 1 Nikon 1 camera as well as to test design focus will camera only smaller cameras be on Nikon 1 series only Runs on a single Nara N A rechar
107. m and then operation was possible After discussing this design consideration with pilot and sponsored Professor Michael Young this cuffed crutch handle design was rejected due to restricting the user s reaction time with their hands The user would have to untighten the cuff release the interior grip slide their hand out of the cuff and place the stabilizer down before being able to respond to an emergency Other frame designs will be explored A heavy consideration is a grip design that is similar to a pistol grip quick and easy to grab activation of the HCS would take one motion such as a trigger or button on the grip and it has to feel comfortable and sure gripped for the user This design would also be easy for the user to put down in case of an emergency The user would simply pull the trigger button to deactivate the HCS and place it in a safe place in the cabin This could be done with one motion and become intuitive for the user The less time taken to place the HCS down the more time the pilot has to respond to an immediate emergency Upon review and initial research the design team has to make modifications to the customer specifications The project was proposed to the design team as a camera stabilizer for vertical compensation in a small passenger plan Because of the lack of design experience and project funding the design team may not realistically meet customer specifications such as total weight of the product and the req
108. magnet permanent magnet AC and permanent magnet synchronous motors The various names arise because brushless DC motors do not operate directly off a DC voltage source Because brushless DC do not operate directly off DC sources they are ideal for fixed speed applications but require complex control for variable speed and torque 28 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Usually most brushless DC motors use six step commutation Each step is located in position that is equivalent to sixty electrical degrees The six steps make up 360 electrical degrees or one complete electrical revolution In order to complete a revolution all six steps must be properly sequenced At any given time only two windings in the motor are activated One is driven positively and one is driven negatively This commutation method is usually referred to as a trapezoidal commutation Unlike the brushed DC motor the stator position must be known in order to continue proper seguencing This is performed through sensor and sensor less control Sensor controls has Hall Effect sensors incorporated to provide appropriate feedback The sensor system creates a more complex control system and drives up the cost of brushless DC motors The other control method used is sensorless control 15 16 Although the name would suggest that no feedback is required sensorless control does in fact require position information to drive the motor When the br
109. meras Runs on a single rechargeable battery Must weigh less that 9 oz Operates for at least 30 minutes on a single charge with light to moderate turbulence Power on off switch Green Power On LED flashes once every three seconds for about 100 milliseconds m LED flashes red when the battery is low mM Circuit must be delivered on a double sided printed circuit board PCB with surface mount components mM Project requires complete Production Documentation Schematic Mechanical and Fabrication Drawings Bill of Materials BOM with vendor part numbers and Digikey or Mouser part numbers PCB artwork with Gerber Files Production Test Plan and Procedure User Manual SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 2 3 2 Pilot amp Passenger Use of HCS In many ways aircraft flight is very similar to automobile transportation both driver and pilot must be focused look for dangers up ahead remain free of distraction and passengers are depending their lives on the skill and perception of the pilot driver The HCS will be designed for both the pilot and passengers to easily use and put away in case of emergency maneuvers or choppy turbulence occur For this reason the HCS must be easy to pick up activate and quickly deactivate and put away Originally one initial design resembled a cuffed crutch handle meaning the user slid their arm into the device grabbed the grip tightened the cuff around the forear
110. mi n for Student support firgelli com Photo Permission for Student Hi Im an electrical engineering student at the University of Central Florida was wondering if could have permission to use the attached photo L12 actuator for a paper Thanks Tom L12 actuator bmp 178K x SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Figure 14 Brushed DC Motor Driver with Two Half Bridges reprinted with permission 27 P ei my ed ee ee Se ee men Er AE ee es ia FERETE Da SAE E PA E E A PA P EE PAE A F E li papa pr rl ee ee eee A ee ee Sg e ad sl in med a a E pi TD A PR A el PA Pru CS Rom Lt A ee ee ee PA eee gr men A Ern A A IR A Er ASA ea a o o ab aa P ear a ae Pa ea geng T o e pi da eege ri eme p mb AR ben bi mg ce EH ker CERN ee Dr EECH mmh mr de AA eg Eege era sg ee Schi e NK see er Se ee ep ee a 3 SE ee ere ao parr AP A ra A AA A Y A A A ERE a a Feet AA a A A bk Sa Tp RER EE DE P VR Ten RER El ee le E E EI Ett EE re e De pepe f erei EH ees gn Eegen Pena a a EAR EE NA EE A Je ba Pa e ope rn a il rn Ka bm der a VE TE ITA H ERR kamen Cp Emer TA PANAI berg PM a el epa a aa eet Kr hp geb PE E LEE er E bo bo RR mp alat Pe FR i KSE EA KEE d a E D Ba Beera ba Baam hb A e a geg Dee rw mn ei Gee ag kb ba Em a rr ene A ri E Eat ES CR PI O Tee d ER tree Ft PE Leger kt eer IA rn mein Droa Leg e ro ef ra ze re E A A r m Gm up ep af mm P mr bei
111. microchip com downloads en appnotes 00857a pdf Sensorless Trapezoidal Control of BLDC Motors http www ti com general docs lit getliterature tsp literatureNumber sprabg7 amp file Ty pe pdf MSP430 Stepper Motor Controller http www ti com lit an slaa223 slaa223 pdf Stepper Motor Fundamentals http ww1 microchip com downloads en AppNotes 00907a pdf Sensorless BLDC Control http ww1 microchip com downloads en AppNotes 01160b pdf Sinusoidal Control of PMSM Motors with dsPIC30F DSC http ww1 microchip com downloads en AppNotes 01017A pdf SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Appendix C Works Cited 11 21 BI 4 5 6 7 8 9 10 11 12 13 Accrediation Board for Engineering and Technology EngineeringChange A Study of the Impact of EC2000 Online Available http www abet org engineering change Accessed 27 April 2014 P M Young Single Axis Camera Stabilizer Orlando 2014 Wikipedia org Steadicam Wikipedia the free encylopedia 3 March 2014 Online Available http en wikipedia org wiki Steadicam Accessed 27 April 2014 Manfrotto SYMPLA Version Fig Rig With Universal Mount Fitting to Rods MVA522W Components Manfrotto Online Available http www manfrotto us sympla version fig rig with universal mount fitting to rods Accessed 27 April 2014 Edward Schneckloth Glidecam HD 2000 Review amp Rating PCMag com PCMa
112. mplementation For various distances hold camera steady measure time it takes for camera to focus Conditions Result Comments Tested 3 Approx 3s Focus point was an 8 2 x 11 paper with e Approx 35 paragraph text at 640x480 resolution Focus time felt relatively short when it could focus 4 Approx 4s Camera seems to work better on microscopic rather than macro imaging 2 Approx 3s After approx 3 the image could not focus A Unable to focus SO Settling time data could not be recorded 8 Unable to focus 16 Unable to focus Table 16 Settling Time Testing Example The ATP document will be used every time a quality test is performed This provides uniformity between tests By providing instruction references it guarantees the user performed tests in the exact same way keeping recorded data consistent across all test procedure cycles After all tests are performed the ATP document can be used a reference lookup of all previous test results All expected test procedures will be fully detailed in the ATP document so it may properly support the acceptance test procedure goals While a complete ATP will be a running document until the completion of the project prototype the design team has developed some topics that must be tested for quality purposes The tests are based on initial assumptions and will probably be modified and refined as the design team has a more complete pro
113. n 1 or similar camera series Therefore the gimbal system must be large enough to contain a camera with dimensions of 4 2 x 3 2 x 1 8 for its width height and depth respectively The camera will be mounted within the gimbal system along its width axis The camera will be directly attached to the tilt bracket The tilt bracket consists of an L channel with an oval cutaway for screw mounting and a circular cutaway for motor mounting The camera will attach to the tilt bracket via screw mounting into its base with two adjustable arms on either side The other length of the tilt bracket will contain the screw cutouts for the shaft mounting of the tilt motor In addition to the tilt bracket a roll bracket is required The concept is the same as the tilt bracket albeit a few modifications One arm of the bracket will contain a housing that the base of the title motor will slide through The other arm will contain screw cutouts similar to the tilt bracket to allow shaft mounting of the roll motor Lastly the roll motor will slide through a single bracket that will mount the two axis gimbal system onto the horizontal isolation platform While incorporating dimensions certain considerations must be noted In addition to meeting the minimum dimensions to support the camera the design must also be large enough to provide rotational clearance of each moving bracket Space must also be provided for any type of sensor mounting that is
114. n data will be read into Matlab and analyzed to find average acceleration maximum and minimum acceleration values and determine typical peak acceleration values This test will be performed several times and all calculated values will be compared with different trials to get an idea of acceptable acceleration changes Figure 36 Acceleration Testing Apparatus self taken Knowing the acceptable range of acceleration values is important in deciding on the torque force requirements for the major axis motor Brick Road Testing An important factor in designing the HCS is the amount of force exerted onto the frame and motors due to the camera s mass during turbulent flight In order to understand the forces generated during flight changes in acceleration must be measured due to Newton s Second Law of Motion equation 5 When asked Professor Young suggested that driving slow on a bumpy dirt or brick road would be comparable to medium turbulence experienced in flight The Nikon 1 camera weighs 13 5 oz 47 The design team is aiming for a total lifting weight of less than 24 oz The team drove on bumpy brick roads of Winter Park and Orlando Florida at sub legal speeds recording the acceleration values in the x y and z directions There were a total of six tests all recorded using the test apparatus found in figure 36 Time for the recordings ranged between 1 3 minutes Table 14 gives the values of the six brick road acceleration trials
115. n individual free image first right click Full resolution or the linked name of the image Next choose to save the image exact option depends on browser A brief overview of some of the licenses that may be applied to media on Wikipedia is visible at Wikipedia Image copyright tags Additional information may be found at Commons Licensing However neither the Wikimedia Foundation nor the authors of material on Wikimedia sites provide legal advice It is the responsibility of the reuser to determine how a license applies to the intended reuse Media file information pages sometimes include contact information for copyright holders If the licensing conditions of a media file are unsuitable for the reuse intended it may be possible to contact the copyright holder of the media file for alternate conditions This will need to be negotiated with the copyright holder directly Figure 24 Point To Point Component Technology reprinted with permission 57 Images and other media See also Commons Reusing content outside Wikimedia While in principle Wikipedia s text is subject to the Creative Commons Attribution ShareAlike License and generally the GNU Free Documentation License and can be used free of charge for any purpose so long as licensing terms are met other media including images are sometimes identified as being subject to other licenses Each media file has ts own information page which includes sourc
116. n readily available since 1989 for consumer products In 2010 22 of rechargeable batteries sold in Japan were NiMH Similarly in Switzerland 60 of the sold rechargeable batteries were NiMH NiMH batteries have similar constructs to their predecessor NiCD nickel cadmium cell The cathode is made up of nickel oxyhydroxide NiOOH and a hydrogen absorbing alloy as an anode The electrolyte is made of a potassium hydroxide Of the many advantages found in selecting NiMH batteries as a battery is that they are available in various sizes such as AAA AA C and etc This will lead to an easier design scheme with regards to the handle grip of the camera stabilizer that will house the battery This is also very convenient for the user as if and when they need to replace their battery it would be relatively easy to find a replacement compared to a Lithium on battery Modern NiMH batteries have made huge progress in terms of the energy density they hold The energy density of NiMH can approach 300 watt hour per length which equates to about 1000 Mim of energy That type of energy density is almost of that of the lithium on cells Another thing to consider is of course the cost of these batteries NiMH batteries cost a lot less then lithium ion batters This is very especially important for the user considering that they would not have to worry about overpriced maintenance cost caused by replacing the battery One of the most significant drawbac
117. ne design product used to reduce vertical vibrations The device is titled MIDAS Multi cameras Integrated Digital Acquisition System MIDAS is produced by Track Air a Netherlands based company that works with its US affiliate company Lead Air The device uses several pneumatic systems to provide suspension for vertical stabilization While stabilization is achieved the product s dimensions are 19 x13 x 15 dimensions This is extremely large relative to a handheld device lt requires a considerable amount of design experience to scale down the system MIDAS CAMERA ASSEMBLY Safety retainer Rotation tube e Clamp Optional Applanix IMU ES 5 Drift motor Manual leveling Mount Assembly Pneumatic Suspension Airplane floor plate Camera holding bracket Quick disconnect flange Canon camera Video camera holder Figure 8 MIDAS Camera Assembly Illustration reprinted with permission Upon this investigation the design team believes that vertical stabilization is unfeasible using the originally proposed electromechanical systems In order to isolate vertical vibrations large scale isolation systems are often produced Most camera stabilization systems are heavy and require aircraft mounting Based on isolation techniques used designers must understand aircraft rotor design and vibrational ana
118. nt It s best to cut the lead as close to the PCB board as possible but at the same time not cutting any of the solder joint itself A rule of thumb is to cut the leads at a slight angle to ensure the solder hasn t been clipped After all the components have cooled appropriately a multimeter in the short circuit detection setting can be used to measure connection to applicable components and pads to ensure the soldering was done correctly Last visually inspect the soldered PCB for any component alignment issues proper component direction and no short circuits due to excess solder on ICs A jeweler s monocle is handy for looking at the small soldering points If there happens to be any errors with soldering any of the components then the process can be repeated A device known as a desoldering tool aka solder sucker acts as a vacuum that can be used to remove any solder from the PCB First the soldering iron will provide heat to melt the solder on the board then the desoldering tool will suck the solder in to its tube chamber A second technique of readjusting the soldering of components is to use tweezers and a heat gun to loosen the soldered joint If there are external components that attach to the PCB with wire then the wire needs to be lightly tinned with solder flux added to the pad and then the wire be soldered onto the PCB and washed Fortunately the University of Central Florida s Robotics club offers free soldering lessons
119. nt and Microchip supplies several brushless DC motor drivers After a short investigation the design team narrowed the options DRV8332 HT DRV8313 DRV10866 MCP8063 MCP8024 and MTD6501C The MTS2916A and MTS62C19A dual full bridge motor drivers are 24 pin CMOS devices used for driving two windings of a stepper motor or provide bidirectional control of two independent DC Motors The load voltage supply range is 10V to 40V The outputs can sustain 40V and deliver up to 750mA of continuous current 29 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Current levels are controlled by internal PWM using two logic inputs a current sense resistor and a selectable reference voltage Full half and micro stepping operations are possible Selectable output current limits are 0 33 67 or 100 The DRV8835 dual low voltage half bridge IC is a 12 pin device for control of a single stepper motor or two DC motors Each half bridge has a 1 5A maximum current drive which can also be paralleled for a 3A drive Motor operating range is OV to 11V and the Logic Supply is 2V to 7V The device uses either PWM or Phase Enable interfaces It features a low power sleep mode of 95nA maximum current and is packaged in a 2mm x 3mm space The DRV8834 Dual Bridge Stepper DC Motor Driver is a 24 pin device The output current is 1 5A continuous rating The power supply voltage range is 2 5V to 10 8V It has two control modes the built in ind
120. number of reasons f h S 3 y 3 E E Figure 4 Glidecam HD 1000 permission requested The Glidecam HD 1000 shown above in figure 4 is constructed of a flat sheet metal that is used as the camera mount The plate that acts as a camera mount has a number of holes which allows for a variety of cameras to be used as well as varies potions of the camera based on what type of images need to be taken A pole is run through both the top plat as well as the bottom plat of the Glidecam In the middle of the plate is a hinge which the user will use to primarily carry the Glidecam and move it accordingly The way the Glidecam is used is that at the bottom of the pole are counterweights Once these counterweights are balanced properly they will work with the hinge to remove any disruptive movements or shakes caused by the user while they are filming or taking pictures The Glidecam HD 1000 is known by many indie film makers as the poor man s Steadicam The image quality produced by using these devices is quite remarkable and very comparable to a Steadicam although its price range is far lower than the Steadicam However one of the well known setbacks with selecting the Glidecam HD 1000 for camera stability is that it isn t very user friendly Many of the critics and the reviews for this product have stated that there is a significant learning curve with regards to being able to accurately place the counterweights with respect to the parti
121. o move in the right direction during the polarity changes The brushed motor has lots features that can prove to be very beneficial towards designing the camera stabilizer Of the reasons is cost of the motor Brushed motors are much more relatively cheaper than brushless motors The first brushed motor acquired as research for this project was the RP3091 model that that was worth 2 91 Another important aspect to consider is the controllability of brushed DC motors The motor control schemes of brushed motors are much simpler than that of brushless motors As stated before in the discussion of AC vs DC having to worry about overly complicated control may prove to be time consuming and unnecessary for the scope of performance needed from the camera stabilizer Brushed motors have also been found to have superior performance over brushless motors in more aggressive environments because they do not rely on electronics as much This is very relevant considering the fact that the camera stabilizer will be expected to operate on a plane at high altitudes Despite all the benefits discussed previously careful consideration must also be taken into the cons of theses brushed motors as well Many users have found that more than often the most troublesome part of the Brushed motors is the constant maintenance of the brushes The constant contact between the brushes and the armature causes ware and tare of the components In some instances there have been s
122. o must be able to properly mount the camera on to the frame compartment of camera stabilizer If the camera is not properly mounted the device will not be able to properly stabilizer the camera and will lead to very poor video images A simple screw will be available on the L channel located above the handle grip The screw is a universal 0 25 screw that will fit almost all cameras Once the operator properly places the camera on the screw an added plate is placed above the camera and used as a clamp to properly hold the camera Operation Once the camera is properly mounted on the device and the battery is placed into the handle grip the camera stabilizer will be ready for use The operator can start moving the camera in any direction with any kind for force Immediately the operator will be able to notice that the camera will remain in its original position with little to no disruption to the video images being taken Also the device is very light weight and easy to handle because of this design the operator is free take images in any angel they choose and is not limited to a singular movement The operator is also able to take the camera stabilizer in a moving car and take images while running 94 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 7 Administrative In order to for any good idea to become successful an important element of administration must play a significant role so as to insure the success of that id
123. oint Another hindrance is the physical size of the potentiometer Because of size constraints it will become very problematic to properly mount the potentiometer onto the motor shaft Because of the lack of accuracy size and possibility of slippage it is highly improbable that the design team will use potentiometers for motor feedback 3 2 1 3 Controller 3 2 1 3 1 Microprocessors The last major component of the control system is the microcontroller As previously mentioned a complete motor controller requires the motor driver output feedback input and a controller Because of this a clear distinction should be made The microcontroller will have two main purposes motor control and system control If possible the design team would also like the microcontroller to regulate any required power monitoring Each of these tasked objectives can theoretically be separate electronic circuits However because of cost and physical space constraints the microcontroller will be tasked with as many of the control objectives as possible When choosing a microcontroller the design team will try to find an available product that is capable of handling worst case computation scenarios In other words the product must be able to realistically handle all the project control in reasonable functionality time If tasks are chosen to be mitigated to other components this will only improve the product s performance To begin research into available micro
124. oject is to start as well as when it will be completed 7 3 Budget amp Finances Initially when the group decided to choose the camera stabilizer as the project to pursue for senior design it was clear that the price to put together and build the camera stabilizer was going to be significant The group however was very fortunate in the fact that the camera stabilizer was a project that was pitched to the senior design class by Professor Michel Young of George Mayson University Professor Young was looking for a senior design group to design and build the camera stabilizer for his own use In exchange for the group building the camera stabilizer Professor Young agreed to reimburse any of the cost that would go towards the camera stabilizer project for an amount of up to 500 Having Professor Young sponsor the camera stabilizer proved to be a very beneficial part of choosing this project Having a very reasonable budget mean that senior design group would not have to worry about making compromises on low quality components due to a lack of funds However the senior design group did not lose sight of the fact that there was a strict cap limit of 500 that Professor Young made as a budget constraint for this project This meant that careful consideration of which components of the camera stabilizer took precedents over the other Having this hierarchy of which component was more important than the next would help in insuring that money did not go w
125. orporated into the motor control however with each additional sensor the complexity of the entire control system increases It is important to evaluate the effectiveness of each of the sensor types listed above 37 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Hall Effect Sensors One possible method to determine motor data is to use Hall Effect sensors The Hall Effect sensor is a transducer which varies output voltage based on the corresponding magnetic field For the purpose of motor control the sensors are generally implemented inside the motor housing itself The magnetic sensors determine the amount of current that can applied to the motor coils resulting in rotation When choosing the appropriate Hall Effect sensor several characteristics must be evaluated including the sensors sensitivity repeatability temperature stability and response time 21 The sensitivity of the sensors effect the air gap placement effectively how far the sensors can be placed away from the motor Sensor repeatability is directly related to the sensor s latching time When the magnet in the motor rotates passes the sensor repeatability helps determine how well the sensor changes its input state at the exact same angular position Stability also determines how much the angular position changes but in response to temperature and temperature Lastly the response time corresponds to the time it takes for the sensor to change state Faster r
126. orporating a spring suspension system into the handle This design is inspired by the EasyGimbal KickStarter project The product is designed for GoPro3 cameras but the design can be applied for the design project as well A concept drawing of the EasyGimbal is provided in figure 29 below Figure 29 Easy Gimbal Mechanics permission pending The design goal is to maintain an extremely simple mechanical design By evaluating this the design team can reduce the time required for mechanical adjustments Instead more time can be used for electrical design and control tuning Upon initial data collection from the inertial measurement unit the design team has found that one of the most challenging aspects of the project will be tuning the system to provide the necessary compensation within an acceptable response time To minimize the amount of time spent on the mechanical systems the design team will try to purchase commercial mechanical components when available Regarding the gimbal system many commercially available products are specific to a particular brand of motor As a result this may limit design choices for the team If this proves to be a hindrance the design team will have to produce custom built mechanical systems As a proof of concept for the mechanical design 68 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih the team began with the design of the gimbal system The system must be capable of supporting a Niko
127. ors require a controller In its simplest form a motor controller is used to turn on and off the motor However their use can become more complex to include direction control speed and torque regulation and overload protection Motor controllers become an essential component for precise closed loop precision control Design of motor controllers varies significantly based on the type of motor used There are two main criteria when designing the motor controller the type of controlled motor compared to its ease of computational control While there are many types of motors the three prominent design choices and therefore motor controller designs are DC brushed DC brushless and DC stepper motors In actuality a complete motor controller includes the signal processor drive circuits and feedback sensors Because of the design requirements of the project the processor and feedback sensors will be discussed in detail separately Brushed DC Motor Driver The first motor driver design to be considered is for brushed direct current BDC motors Brushed motors are one of the easiest to control as their soeed and torque are proportional to the applied voltage and current However because of the heavy rotor design brushed motors require more inertial starting and stopping power In addition heat is generated on the windings and is difficult to dissipate One advantage of BDC motors is that the commutation of windings is performed 26 SENIOR DESIG
128. ou arent connected to him on Facebook See More https s3 amazonaws com ksr assets 000 850 154315c08d40bdd259a5c56c579680817a2491 large jpg 1377170415 s3 amazonaws com Figure 30 Two Axis BLDC Gimbal Stabilizer permission pending oooWooWoo 69 Attempted to contact by phone No email provided http cs dx com FAQ Phone SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Figure 33 SEN 11028 Breakout Board with MPU 6050 IMU reprinted with permission 82 SparkFun Customer Service cserice sparkfui Mar 18 a to me Hello Tom Yes absolutely Thank you for asking Please just be sure to check out the guidelines for doing such a thing You can find these guidelines HERE Please let me know if can be of further assistance Have a great day Best Regards Taylor Iversen Customer Service Representative SparkFun Electronics mew sparkfun com x 303 945 2984 x609 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Appendix B Datasheets Selecting Hall Effect for DC Brushless Motors http www mouser com pdfdocs Selecting Hall Effect for DC Brushless Motors pdf Quadrature Encoder Fundamentals http www ni com white paper 4763 en Motor Control and Drive https www microchip com pagehandler en us technology motorcontrol Brushed DC Motor Fundamentals http ww1 microchip com downloads en AppNotes 00905B pdf Brushless DC Motor Control Made Easy http ww1
129. owable vertical positions on the grip As a result camera stabilization could be achieved 3 1 2 3 Gyro Based Servo Camera Stabilizer The Gyro Based Servo Stabilizer GSS was a hand held device designed to stabilize the vertical position of a camera Below is a rough illustration of this design in figure 7 EM A gt Ep on Ke la pa S Ir EA ABLA ne Sec se Dai gt v Figure 7 Gyro Based Servo Stabilizer Rough Illustration Gyro based servo stabilizer would be a light weight composite frame designed in a football goal post shape The gyro based servo stabilizer had servo motors that travel along the upper sides of the frames Both motors could be connected using a beam containing the camera mounting The gyro based servo stabilizer had two gyroscopic sensors located on each top end of the device Two slider arms connected between the gyro sensors and the camera mount The lower end of the 15 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih gyro based servo stabilizer served as the grip It housed a rechargeable battery and microcontroller Right above the grip the device contained an indicator light for power and low battery statuses The gyro based servo stabilizer had a microcontroller used to initialize the appropriate reference angles for the slider arms used to balance the device The gyroscopic sensor measured the angular rate of the rotation for the slider arms When changes in the slider arms
130. p 2 The operation of a rolling filter is very simple it takes the current value and calculates the average from n amount of previous samples 1 2 5 10 20 samples for a given causal signal Every time the amount of samples in the rolling filter are increased the output loses signal quality versus the raw output As seen from figure 20 signal characteristics are mostly maintained for sampling sizes between 2 and 5 samples from 10 to ever increasing sampling sizes the filtered data becomes flattened or dampened Thus there is a bit of an art to selecting an appropriate sampling size so as to lose the major swings or noise in the signal but to also maintain or keep the characteristics to be studied or used As a side not rolling averages is a reliable tool and a common practice found in future stock price estimation acausal rolling filter and as a business trend following indicator 23 This aspect seems relevant to the HCS research because 42 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih of the bounded nature of a random output such as item pricing and acceleration measurements 5 No Sampling Raw Data 2 Samples 5 Samples 3 No Sampling Raw Data 2 Samples 5 Samples 25 25 25 25 25 25 2
131. paper Figure 8 MIDAS Camera Assembly Illustration reprinted with permission Info Contact Email Wati TP Alenander Peanoch 20 syra com 318 PU t how aga My rara zt Aranda Peaneck Tm an electrical erepneenng student at the Unearety of Central Even am soring on a des Marian repent of Camera tela RIOS A ROSA om IAN AO Le e an me Porn you ens ara MIDAS rut is The mage at located at the wt prowded below Thank you tor yaw support SEO Tak tt Cat OSE PS DCI Te ETE ndak Secere hearde Permock Under adusie Rede UCF Beciscai Eaerwereeg 49 PU 14 rentes aga e Go tor 4 Alexander Bra os morti are made e Kenamaan Arh P Sart bore zm pore SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Figure 9 Rated Horsepower AC vs DC Motors ne Woman 20 IEEE Open Access In August 2010 the IEEE Board of Directors approved a five point Statement on Open Access and Public Access to engage the organization in the continuing public dialogue on open access scholarly publishing The first active step authorized in the pobey statement is the extension to all IEEE journals of an option for authors to select open access for their accepted articles Figure 12 Stepper Motor Teeth Diagram oo Waka 24 Images and other media See also Commons Reusing content outside Wikimedia While in principle Wikipedia s text is subject to the Creative Commons Attribution ShareAlike License and generally the GNU Free Doc
132. pecifications There will be 4 to 5 trails for test Based on the results of first three tests data will be compared to the desired specifications If any the specifications are not meet a review of the specific area as well as all the sub systems that are directly tied into that area will be made Once cause of the error is determined and all the appropriate actions have been taken to correct issue the final test can be taken 92 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 6 3 4 Test 4 Plane Test This will be the final test taken and will only be performed once all the specifications desired have been meet during the previous three tests The camera stabilizer will be used during a flight on a plane Different video images will be taken in various angels The camera stabilizer will be tested to see how it may respond to sudden movements caused by a number of factors i e sudden movement of the plane caused by the pilot or turbulence etc Once again the video images taken by this camera will be compared to that of images taken without the camera being stabilized as well as the video images from the previous tests Observations will be made to see if the cameras position stays within the desired limits Also the flight test will be at least 30 minutes long to test the performance of the battery once more This particular test will only have one trial due to cost Ideally at this point of the testing all meas
133. pensive IMUs use either I2C or SPI digital communication formats due to their availability to share multiple master and slave devices on just two wires This will greatly simplify the printed circuit board PCB design and decrease the number of pins needed in the MCU MPU 6050 by InvenSense The camera stabilizer will need to have quick and accurate access to the IMU output thus it seems logical to go with a digital IMU package The MPU 6050 offers programmable three axis acceleration three axis radial velocity as well as thermal information thus this package is referred to as a six axis IMU Gyro Full Scale Gyro Sensitivity Accel Full Scale Accel Range E EE Range 9 Sensitivity degrees second LSB g 250 131 2 16384 500 65 5 4 8192 1000 32 8 8 4096 2000 16 4 16 2048 Table 3 MPU 6050 Characteristics 20 The MPU 6050 uses I2C digital output logic voltage supply of 1 8 5 or the master MCU VDD level operating voltage range of 2 375 2 46 DCV and has a small package size of 4x4x0 9 mm We chose the MPU 6050 due to its low cost 12C digital output speed range of accelerations available are within range of a plane s designed acceleration load roughly 3 89 small footprint and the device is very well documented The IMU 6050 is found in many handheld devices such as smartphones and tablets and incorporates an inner logic called Digital Motion Processing DMP The DMP logic is us
134. plemented 65 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih The important factor for this design to work is to find a linear actuator that can work against 3lb of force or go above the undesired torque of the major axis arm caused by the camera and mounting For now the major axis arm will be less than a foot from the arm joint thus the maximum torque applied will be less than 3 ft lb or torque thus proper positioning of where the linear actuator will join the major axis arm will be important Another consideration is that the average force applied will most likely be in the range of 1lb or 1ft lb thus we would want to find a nice balance between the linear actuator joining placement and the most efficient force for the linear actuator to conserve battery life Lastly another consideration for the linear actuator is the speed and stroke length The need the speed of the linear actuator to be fast enough to match or overcome the speed at which the camera mount is moving Also the need for a long enough stoke length to lift lower the camera mount by 6 Thus altogether this problem of choosing an appropriate linear actuator involves speed stroke length maximum force and most efficient force range A Canadian company by the name of Firgelli produces such a linear actuator the L12 The following table table 8 describes the qualities of the L12 linear actuator Gearing Option 50 100 21
135. plore major axis arm lengths freely calculate that mean and max min torque applied torque with respect to prospected arm length and then find appropriate motors Acceleration g o Acceleration o o x axis 50 Time seconds z axis Acceleration g 100 Acceleration g o q N mb y axis 50 Time seconds Magnitude 100 o 50 Time seconds 100 0 50 100 Time seconds Figure 37 Trial 1 Brick Road Acceleration Testing 84 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih x axis y axis Acceleration o Acceleration g mb o 0 50 100 0 50 100 Time seconds Time seconds z axis Magnitude Acceleration q 25 o a Acceleration g mb N LA 50 100 50 100 Time seconds Time seconds o o Figure 38 Trial 2 Brick Road Acceleration Testing In the first and second trials you can see moments in the graph when the car is stopped possibly at a stop sign rather than a traffic light as indicated by the stable spots then followed by acceleration in the y axis start around 42 and 50 seconds respectively x axis y axis Acceleration g ul o sl Acceleration g ah o 0 50 100 0 50 100 Time seconds Time seconds z axis Magnitude 25 81 3 E E E 8 9 By w w o o q 1 d 0 50 100 0 50 100 Time seconds Time seconds Figure 39 Trial 3 Brick Road Acceleration Testing 85 SENIOR
136. produce the camera device to more than double the intended budget Batteries on the other hand are a very practical alternative They are very lightweight allowing for easy portability and not causing the camera stabilizer to be overweight Also most commercial batteries on the market are very reasonability priced Most batteries however do have one very distinct draw back that can make them inferior to AC and DC power supplies That simply is the power output This being the very purpose for their use means that careful consideration must be taken in choosing which battery will be used The ideal battery used for camera stabilizer would be optimized with respect to the lifetime of the battery power output and cost One very important distinction that must be made about choosing the battery is knowing to go with either a rechargeable battery or a non rechargeable battery Both options come with their advantages and disadvantages that will need to be weight in order to make a sound decision on what would be best for the camera stabilizer 3 2 2 1 Batteries 3 2 2 1 1 Non Rechargeable Non rechargeable batteries are well known to have a much longer shelf life than that of the rechargeable batteries Meaning that two comparable batteries are used for the same application the non rechargeable battery will be able to provide power to the application for a longer period of time than that of rechargeable battery This type of battery would appear to
137. r axle into useable analog or digital signals Two main types of encoders are produced absolute and relative encoders The outputs of absolute encoders establish the current shaft position making them ideal for angle data Relative encoders provide shaft motion information This data can be further manipulated into information for speed and position Absolute encoders continuously generate digital signals indicate their current position which can be obtained even when power is turned off Relative encoders only pulse when the shaft is turned In order for the sensor to work 38 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih properly an initial time must be set All future pulses are then counted against the elapsing time 22 Potentiometer One of the simplest data methods that could be implemented are potentiometers They can be incorporated into the turning shaft of the system As the system rotates the potentiometer also rotates The design team can use the variable voltage output to determine the current potentiometer position Because the rotation of the sensor will be directly related to the system s rotation the motor s position can be inferred The control of the sensor would be extremely simplistic However one of the major drawbacks of potentiometers is the potential for slippage Once the sensor s shaft has slipped it becomes incredibly difficult to tune the output control as the motor has lost its reference p
138. re cost effective and ultimately becomes an unmeasurable learning experience as well Unfortunately the drawbacks to making a printed circuit board is that firstly it isn t safe to handle the various hazardous solutions needed to etch a PCB Also the printed circuit design may sometimes leave out ink in locations that will lead to a poor PCB Contract PCB Manufacturing The alternative option to making one s one printed circuit board is having a manufacturer produce one and later ship it to a desired location There is a price that comes with but that price may not be the biggest concern with ordering PCB For instance a website sells PCBs for as low as 33 28 The real concern with ordering a printed circuit board is having to wait for it to arrive This means that one must ensure the design is accurate as to not waist time having to wait for another PCB to arrive Also the board must be handled with care as to not damage the soldering pads or crack a layer 52 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih An adequate time cushion must be given for the electrical system production prior to the deadline of the presentation of the project as to not be jeopardized by waiting for a PCB board and costing undue penalties to the grading of the project 4 1 2 Layout 8 Rules of Thumb It goes without saying that in order to have a manufacturer provide the printed circuit board they will require a design of the board
139. required A figure of a gimbal system and horizontal isolation platform the design team wishes to model the mechanical system around is shown below figure 30 Figure 30 Two Axis BLDC Gimbal Stabilizer permission pending In addition to the gimbal system the design team must also produce a design for the vertical handle grip Unlike the gimbal system that can probably be purchased it is very likely that the handle grip will be originally designed and produced by the team Luckily the handle design can be very simplistic Essentially a cylindrical rod the biggest design constraints is the diameter size lt must be large enough to 69 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih house the power supply and motor but within a size small enough that the user can ergonomically hold in their hand The design team settled on an absolute maximum diameter of 2 After measuring the width of several individuals hands the design team settled on a rod length of 6in Concerning materials used the design team needs materials that are lightweight yet durable The Nikon1 camera weighs 11 40z without a battery One of the design objectives of the project is to be lightweight Based on research of available products consumer devices claim to be lightweight with a system weight range of 2lbs to 6lbs Therefore the design team s goal is to keep the entire system including the camera system at a maximum of 2lbs To accomp
140. ril 2014 Online Available http en wikipedia org wiki American wire gauge Accessed 27 April 2014 IEEE Standards Association IEEE SA National Electrical Safety Code NESC 2014 Online Available Ref http standards ieee org about nesc Accessed 27 April 2014 Wikipedia org Through hole Technology Wikipedia the free encylopedia 26 January 2014 Online Available http en wikipedia org wiki Through hole_technology Accessed 27 April 2014 Wikipedia org Surface mount Technology Wikipedia the free encylopedia 22 April 2014 Online Available http en wikipedia org wiki Surface mount_technology Accessed 27 April 2014 B Patel Interviewee Wave Soldering Discussion Interview 8 April 2014 ElementAluminum Pros and Cons of aluminum Online Available http elementaluminum tripod com id8 html Accessed 27 April 2014 J W Winco Inc J W Winco Engineering Tips Pros and Cons of Aluminum 2011 Online Available http www jwwinco com engineeringtips prosconsaluminum html Accessed 27 April 2014 Lee Agur Carbon Fiber vs Aluminum vs Steel vs Titanium gt gt Love Bicycling Love Bicycling 10 December 2013 Online Available http www ilovebicycling com carbon fiber vs aluminum vs steel vs titanium Accessed 27 April 2014 Acrylonitrile ButadieneStyrene ABS ides com 2014 Online Available http www ides com pm 3_ABS asp Accessed 27 April 2014
141. rom Boeing mechanical engineer for Lockheed Martin and lead design engineer for Lead Air a company that specializes in aerial survey systems Each individual provided extremely enlightening information regarding camera stabilization performance and methods that are currently being practiced The general methodology uses a dampening isolation system This comes in various forms pneumatic suspension rubber shock material or springs One of the simplest methods for vertical stabilization within an aircraft system is to design an isolated mounting platform In order to do this the random vibration frequency of the aircraft must be determined The frequency is dependent on the aircraft s rotor RPM and the amount of blades it contains Once the frequencies are obtained acceleration data is acquired for a typical flight The data must go through signal processing to obtain the acceleration spectral density ASD which is an applied use of the power spectral density function By using a combination of low and high pass filtering the vibrations can be isolated Corresponding springs or rubber shocks are placed between platforms to dampen vibrations The stiffer 16 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih the shocks the higher the frequency that is mitigated This method is extremely dependent and therefore sensitive to the specific aircraft and isolator material parameters 6 7 The figure below illustrates o
142. s must be 805 or 603 imperial Non ROHS Restriction of Hazardous Substances Directive components and construction when possible Compact dimensions Multiple PCBs for measuring equipment locations Durable and stiff Leaded solder pads Fiberglass construction Ideal for solder paste and convection oven SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 3 RESEARCH amp INVESTIGATION 3 1 Mechanical System Research Probably the most fundamental and challenging component of the project design is the mechanical system The project was originally introduced to the design team as a vertical camera stabilization system The specifications provided by the customer generated numerous questions and technical complications When initially proposed the design team realized that a lot of mechanical research would be required as the design team had little mechanical design experience To gain a better understanding of the project design requirements the design team first researched currently existing products 3 1 1 Existing Products 8 Designs 3 1 1 1 Steadicam The Steadicam invented in 1975 3 by a cameraman of the name of Garrett Brown is a camera stabilizer mount used to isolate the camera from any movement by the user lt s definitely one of the well known devices used for camera stability by camera enthusiasts due to the fact that it can take
143. sement occurs to be as properly aligned as possible with any credit card payment cycles that the group members may use This will help in preventing any of the group members from accruing any interest on their credit cards The reason that there such an emphasis on this point is because Professor Young will not reimburse any interest that may accrue on any of the member s credit cards A table has been provided in table 18 to give a clear representation of what expenses that are to be expected when construction is to begin of the prototype for the camera stabilizer lt is very important to note that the data provided in table 18 is only meant as very rough estimation and is not meant to be comprehensive of all expenses This is simply due to the fact that at this stage of the project all that can be done is a forecasting of the expenses based on research of subsystems and other comparable products and past projects Expected Budget Items Cost Motors 120 Sensors 120 PCP Production 60 Battery 50 Hardware Frame 150 Total 500 Table 18 Expected Budget Table 19 is another table that provides the current expense that have already accrued at this point Having this particular table may prove to be very beneficial in terms of providing comparison between what has already been spend and what was expected to be spent Also it is important to note that the data in table 19 includes expense towards certain trans
144. siderations for the analog battery monitoring system include power consumption complexity of design component sensitivity and voltage reference isolation If the analog battery monitoring system is implemented then the LM741C comparator will be used in respect of Bob Widlar inventor of the LM741 op amp analog IC pioneer and all around crazy guy 26 Below is a rough sketch of the intended analog power monitoring system 48 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Vopte Figure 23 Analog Battery Monitoring System As seen in figure 23 above the analog battery monitoring system has many analog components the LM741C comparator a voltage regulator optocoupler for voltage isolation NPN bipolar junction transistor a green LED a red LED the battery and many jelly bean parts resistors and capacitors This system will add more space to the PCB and more than likely will draw a lot of power to properly function Another downside to this design is that the voltage regulator and reference resistor Rret will need to be precision parts Any unbalance in the voltage reference section may cause the LM741C s output to drop from high to low due to its typical input voltage offset of 2mV 27 Other design details include the need for a blinking red LED when the battery s power is low Professor Young requested that the blinking rate of the red LED to 100ms 100ms on 100ms off etc thus Rrep and Creo will ha
145. sing a PWM signal an average voltage is obtained in the motor The winding acts as a low pass filter generating a stable current in the motor The relation between the supply voltage duty cycle and average motor voltage is shown in equation 1 below Vaverage D Vsuppty Eguation 1 BDC Motor Average Voltage Because of the relationship the freguency of the PWM signal becomes an important consideration Low freguencies cause noisy motors and sluggish responses Extremely high frequencies diminish the system s efficiency due to switching losses Based on information researched good modulation occurs with input waveforms in a freguency range of 4 kHz to 20 kHz Following this rule of thumb a PWM signal must be generated One option is to use a microcontroller and toggle its output pin accordingly However with the components currently available it is usually easier to select a microcontroller that contains dedicated PWM modules Brushless DC Motor Driver Another viable motor driver design is for brushless DC motors As the name suggests brushless DC motors do not contain the brushes and commutator found within a brushed DC motor As a result brushless DC motors are usually faster more efficient and more reliable than their brushed counterparts In addition heat is much easier to remove and maintain Because less inertia is required it is easier to start and stop the motor Brushless DC motors are also referred to as brushless permanent
146. ssor Young s comments and suggestions on a particular topic would lead the senior design group to producing an idea that would later prove to be very beneficial towards the camera stabilizer project Professor Young was careful with how he would support and advice the senior design group Professor Young is very aware that this project is meant to be a learning experience for the senior design group and as such would not want to give away 101 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih key information that would otherwise oversimplify designing and building the camera stabilizer Also another of the very beneficial reasons of having Professor Young as a mentor for the group is how he would push the members of the group to insure that all milestones are meet in a very timely fashion Professor Young s involvement in the group at certain times throughout the course of the project would almost resemble that of him being an employer and the members of the senior design group being his employees Having this type of relationship between Professor Young and the members of the senior design group helped to push to senior design members an avoiding a lot of problems The biggest of the problems would have to be procrastination Often time s college students would end up leaving behind any type of major project to the very last minute before it must be submitted for grading This more than likely would lead to having an overall poor
147. stored To limit this affect the battery needs to be around 40 charged and in a very cold environment This is an unpractical scenario to expect a user to perform in order to optimize the battery lifetime Another inconvenient that may arise from choosing lithium ion batteries is the fact that they do not come in standard cell sizes unlike traditional alkaline batteries that come in AA AAA etc 24 The lithium ion battery is designed to fit a specific device when it is manufactured This leads into the fact that lithium ion batteries are more expensive than the alternative batteries that would be considered for the camera stabilizer A final point to bring up is unfortunately a safety concern due to the fact that Lithium ions are not as durable as other forms of batteries A Lithium ion batteries may be unsound and will need a power circuit to keep it safe The power circuit limits peak voltage when charge and limits the voltage drop from getting too low during discharge There have been report of lithium ions being very and can even explode if not used properly If indeed a lithium ion battery is choose careful consideration into that specific batteries history must be made in order to prevent any serious problems that may arise from the battery 3 2 2 1 4 Lithium lon Polymer This class of battery was released around 1997 and they differ from a typical lithium ion battery due to the material of the used as the separator The electrolyte in a
148. t feel comfortable while using a filming device they become distracted with holding the camera correctly rather than focusing on the subject that is being filmed Another point for good ergonomics is that it creates an emotional attachment for the user an undefinable quality The team will ask photographers and videographers focusing on sports and nature image capturing to use the HCS for 10 to 30 minutes Then a team member will ask the user for opinions input criticism and the short falls of using the HCS Afterwards the team will adjust the components or systems under severe criticism and find new users to give the HCS a try 6 3 Acceptance Test Procedure The camera stabilizer is to be tested in multiple ways in order to determine if it can meet the desired specifications There will be four unique tests handheld stability 30 minute stair climb road test and a flight test The number of trials for each of these tests will vary The main criteria s that will be measured throughout the tests are the stability of the video images taken by the camera stabilizer accuracy of how close or far is the camera from the desired 1 8 position and the battery life of the device All the measurement data will be logged and used for future analysis as well as a reference if it is discovered that modifications must be made to any part of the design 6 3 1 Test 1 Handheld Stability The first test of the camera stabilizer is meant to measure the
149. t from most of the camera stabilizers that have been researched for this project The model of the Fig Rig camera stabilizer can best be described as the steering wheel of an automobile As pictured in figure 3 within the circular frame of the Fig Rig model is a cross bar on which a camera can be mounted onto The frame of the Fig Rig can also mount additional accessories to the camera such as a remote controller lights monitors and microphones The way the Fig Rig is able to stabilize the camera mount is through its non conventional frame As someone is filming or taking pictures their muscles and tendons will absorb all the disturbances caused by the users movement and the Fig Rig will only receive fluid motion from the user This allows for one to take video images from various angles while in motion 10 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Figure 3 Fig Rig Camera Stabilizer permission requested Lots of camera hobbyist tend to prefer the Fig Rig over other devices such as the Steadicam due to it being more user friendly and yet still giving a professional feel to its use Itis also very easy to set up and use unlike the Steadicam which requires the user to be harnessed on to the device Also the price of the Fig Rig is lower than that of the Steadicam One problem that comes with basing the camera stabilizer of the Fig Rig design would be that the Fig Rig is a two hand grip while the camera stabil
150. tatements made by users of sparks generated in the motor caused by these brushes that leads to the motor catching fire and damaging the motor all together Other cons to consider are that the internal rotor construction in most brushed motors do not allow for proper heat dissipation Also the torque production is limited at high speeds which can be attributed to mechanical limitations of the brushes The multiple issues attributed to the brushes are most alarming when the motor is expected to operate at very high speeds The camera stabilizer will not be expected to run at very high speeds and therefore the maintenance issues with the brushes are not expected to arise with what is needed from this application Brushless Motors Brushless motors are comprised of permanent magnet on the rotors three phase driving coils on the stator and Hall Effect sensors 11 Current passes through one phase of the driving coil at a time which will cause the rotor to turn The Hall Effect sensor determines the position of the rotor and sends those signals to a motor driver that will determine which phase of the stator coils to pass current through The outcome of this operation is a three phase synchronous motor 12 Two brushless motors where acquired in the beginning stages of the research in order to learn more about their operations One was the GWS 3000kV Inrunner brushless motor and the other was the Turnigy D2826 10 1400kV Outrunner brushless motor 21
151. technical knowledge to full operate However this user manual will be used as a reference and to add clarity It is with high hopes of the senior design group that the operator of the camera stabilizer is able to use the device to its full potential and is able to generate a high quality of photo images and videography 93 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih E Camera Stabilizer WR 14 8V Tenergy Lithium lon 18650 Battery E Star bit head screws E Star bit screwdriver Mounting plate When the operator is about to put together the camera stabilizer for operation the main things they will mostly be consider with are the battery and mounting the camera With regards to the battery at the very bottom of the handle grip will be a compartment that can easily be opened and closed The operator will open the door of the compartment and then be able to insert the 14 8V Tenergy Lithium lon 18650 battery After which the operator will close the door of the handle grip compartment The operator can then observe the light emitted diode LED indicator to see the status of the battery Table 17 below will show the operator how to interpret what the LED indicator is displaying LED indicator Solid Red Light The battery is fully charged Blinking Red Light The battery is low and needs charging No Light at all The battery has no charge at all Table 17 LED Indicator Status The operator als
152. tent has been written to reflect as such If the functionality is not used any components required for the subsystem will be eliminated from the final design 5 2 1 Control System 5 2 1 1 Output System Motors For the electrical system the first major consideration of the design team is which motors will be used The design team reviewed several types of motor outputs including brushed DC motors stepper motors brushless DC motors micro servomotors and linear actuators The design team decided that for the output system three brushless motors will be used The Turnigy D2826 10 1400kv brushless motor will be used to support the stabilization required in the maximum tilt roll and pan directions 40 The Turnigy D2826 10 1400kv brushless motor 70 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih has been found to be cost efficient while still being able to generate the torque needed to support the weight of about 16 oz This simply means that that selecting the Turnigy D2826 10 motor will help keep the expense below the budget of five hundred dollars The fact that the Turnigy can support a weight of up to 16 oz will prove to be useful in the sense that the Nikon one camera is about 12 ounces The 4 oz buffer means that there is flexibility in choosing from a range of batteries that can weigh up to 4 oz Also lots of the camera hobbyist that have produced similar projects to the camera stabilizer that s being built by t
153. through a specialized on board arithmetic logic unit ALU and sent out of the gyroscope module to be used for information processing Inertial Measurement Units Luckily due to the similar technologies and micromachining techniques needed to produce MEMS based accelerometers and gyroscopes many manufacturers provide packages that provide both acceleration and radial velocity output Such packages are called inertial measurement units IMU Popular and low cost manufacturers of IMUs include Analog Devices and InvenSense Analog VS Digital IMU There are two methods of using the output of the IMU to the microcontroller MCU m Using an analog output IMU and using an analog to digital ADC converter on the MCU mu Using a digital IMU and find an MCU that can accompany the same digital format Analog IMU PROS Easy to start reading information from the ADC ports of the IMU Cheap Small package footprint CONS Will have a slower sampling rate as compared to digital IMUs Power hungry Lower resolution of data compared to digital IMU Slow sampling rate 35 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Digital IMU PROS Will communicate with any devices that share the same digital format Again cheap Higher resolution of data compared to analog IMUs Power efficient compared to analog IMUs Small package footprint CONS Having to learn to use the MCU to access the IMU s data and functions Most inex
154. tion techniques is key for a success manufacturing process The research into the PCB board will focus on the various options of attaining a PCB board as well as the layout rules Appropriate connecters and cables for the PCB boards must also be considered Also of the most important concerns with the PCB boards will be the soldering methods and techniques that will be needed to put everything together 4 1 1 PCB Options DIY PCB One interesting method of attaining a PCB board can simply be to physically make one An individual by the name of Collin Cunningham has a very informative YouTube video on a step by step process into etching a circuit board Initially a PBC layout program such as Eagle can be used to design most kind of circuits and produce the necessary Gerber files The circuit design is then printed on to an overhead transparency sheet A bare copper board is then washed with isopropyl alcohol to rid of any hand oils manufacturing grime and dust A clean copper board is key to proper circuit stencil transfer From now onwards any handling with the copper board should be done with gloves to avoid surface contamination Next a photosensitive development film is gently placed on top of 51 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih the bare copper board note beware of bubbles and folds in the development film and placed in a calm and warm water bath deionized water is favorable for ten minutes
155. totype available 6 2 1 Battery Life One of the more important specifications of the HCS is that the battery must last 30 minutes or longer Below are the methods to employ to determine a passable battery life 6 2 1 1 Load In order to determine the battery life of the HCS the team will perform a series of simple real world test to determine if the battery is suitable for the HCS application 90 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Load Test 1 The team will walk up and down flights of stairs with the HCS powered on till stability is lost or the unit dies The footage caught using the HCS will be reviewed to ensure that at no point stability and filming quality was reasonably lost The team will record the time taken till shut down Load Test 2 The team will drive on bumpy dirt or brick roads with the HCS powered on till stability is lost or the unit dies Again the footage caught using the HCS will be reviewed to ensure that at no point stability and filming quality was reasonably lost The team will record the time taken till shut down 6 2 1 2 No Load The team will place the HCS in a vice grip turn the unit on and allow it to operate without any disturbances till the unit dies The team will record the time taken till shut down 6 2 2 Hardware Ergonomics In any form of filming photo or video a steady and confident sense of grip is important for the user If the user does no
156. uired maximum 6 vertical translation These changes in the specifications and requirements have been discussed and approved by Professor Young The exact feasibility process that led to this decision will be fully discussed within the Research amp Investigation section of the report The design team will try to maintain as many of the customer specifications as possible Compared to the specifications the design team s main focus will be to eliminate optical jitter introduced by human interaction rather than jitter introduced as a result of vehicle turbulence and vertical translation SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 2 3 3 Microcontroller The controller will have the following qualities m Integrated Inter Integrated Circuit I2C serial communication WR Minimum output control for three motors HR Pulse Width Modulation PWM output WR C C programmable WR Available development board MH Integrated PID Proportion Integration Derivative controller if needed E Surface mount package with 0 5 mm pin pitch 2 3 4 Motors The motor design will have the following qualities E Small Approx 2 diameter or less E Low power consumption Max voltage lt 15 V low current draw m Fast yet smooth operation E High holding torque gt 2 Nm E High torque force to weight ratio 2 3 5 Motor Drivers The motor drivers will have the following qualities E Input voltage PWM MH Output amplified var
157. umentation License and can be used free of charge for any purpose so long as licensing terms are met other media including images are sometimes identified as being subject to other licenses Each media file has its own information page which includes source and licensing information Clicking on the media file will lead to this information page Many media files are free to use as long as you follow the terms of the licenses applied to them From the information page to download an individual free image first right click Full resolution or the linked name of the image Next choose to save the image exact option depends on browser A brief overview of some of the licenses that may be applied to media on Wikipedia is visible at Wikipedia Image copyright tags Additional information may be found at Commons Licensing However neither the Wikimedia Foundation nor the authors of material on Wikimedia sites provide legal advice It is the responsibility of the reuser to determine how a license applies to the intended reuse Media file information pages sometimes include contact information for copyright holders If the licensing conditions of a media file are unsuitable for the reuse intended it may be possible to contact the copyright holder of the media file for alternate conditions This will need to be negotiated with the copyright holder directly Figure 13 Miniature Linear Actuator permission requested ea 25 Photo Per
158. uracy in keeping the camera within 1 8 of its desired position Stepper motors do not require an encoder for position feedback This results in having an inexpensive motor Being able to meet the position accuracy requirements while maintaining simple control is very good advantage The stepper motor have anywhere from 50 to 100 poles between the rotor and the stator This high pole count leads to a generation of high torque for stepper motors at low speeds At high speeds this leads to a significant loss of torque however this can be overlooked since the camera stabilizer will not be operating at very high speeds Thus far the stepper motor has shown it is reliable in the sense that it can give high accuracy position control and generate a lot of torque while remaining relatively low cost and not adding complexity to the control Though despite these advantages stepper motors have important drawbacks that must be addressed In order to achieve the position accuracy that stepper motors are well known to have they much have a constant current open loop scheme Due to the high pole counts of the stepper motor there will be a high volume of current exchange through the windings This leads to a great deal of power being drawn from the battery Since the design of the power system requires a battery that lasts for at least 30 minutes unless a strong enough battery is used the stepper motor may not be an optimal motor to use 23 SENIOR DES
159. urements meet the desired specifications If however after the flight test is conducted and an error is detected then adjustments will be made and all the previous tests would have to be repeated once more before attempting the flight test again 6 4 User Manual Development In addition to the design of the project the design team must also provide a deliverable document to the customer User manuals come in a variety of formats Sections that are typically found in user manuals are a cover page contents page usage guide for system s main functionality a troubleshooting section frequently asked questions and contact details for further assistance For the user manual development the design team will focus on component functionality and troubleshooting The user manual will be written in as simple language as possible and use many figures and pictures However it will be assumed that the reader is familiar with current technology topics The user manual will not be fully developed until a working prototype is available Below is an excerpt of the current user manual in initial revision Its purpose is to provide an understanding of the terminology that will be used in addition to the level of knowledge that is required 6 4 1 Initial Manual Excerpt The purposes of this user manual is meant to be a guide for the operator of the camera stabilizer Although the camera stabilizer is meant to be a very simple design and will not require too much
160. ushless DC motor rotates each winding will generate back EMF that opposes the supplied voltage Using this information is key to effective torque and speed control DC Stepper Motor Driver The last motor driver design consideration is the stepper motor driver Advantages of stepper motors include the brushless design that decreases maintenance set speed regardless of load open loop positioning excellent response and good holding torque However stepper motors are generally noisy and require holding torque even at rest This causes a much higher power consumption and is not efficient for battery powered applications Due to the design criteria a bipolar stepper motor would be required The basic circuit used to drive a bipolar stepper motor is two half bridge circuits In total eight control lines are sent to the driver circuit However most available components use internal inverting circuits to compensate If a predesigned full bridge circuit driver is used only four control inputs are used similar to the brushed DC motor design 17 18 Available Driver Devices If brushed DC or stepper motors are used the design team has several components options available Microchip and Texas Instrument both contain viable components Microchip supplies two full bridge drivers the MTS2916A and the MTS62C19A Texas Instruments supplies the DRV8834 DRV8833 and DRV8835 There are several options also available for brushless DC motor use Texas Instrume
161. ve to be finely tuned to allow the red LED to have the required current for easy visibility yet also blink at the required rate The analog solution may be a bit overkill and unnecessary for the design team s application The above solution seems proper for higher powered circuits for larger motor use or power monitoring systems where digital ICs cannot deal with large changes in voltage or current More than likely the HCS will be controlled by the dsPIC33EP128GM306 microprocessor referred to as GM306 by Microchip Inc The GM306 is a 64 pin microprocessor intended but not limited to brushless motor control Fortunately the design team will more than likely not use all the analog I O pins nor the available op amps and comparators that are featured in the package Also the clock speed on the GM306 is 70 MIPS so there is not worrying that the added function of battery monitoring will slow down performance of the GM306 Implementation would be simple pull a resistor between the battery and power isolation device to the ground attach an analog in pin from the GM306 to the positive terminal on the resistor and adjust the parameters of the GM306 to flip in a red LED when the voltage in the pull down resistor reaches below a minimum All of the parameters depend upon the final chosen components This will more than likely be one of the last stages of development 49 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih 50 S
162. very good at isolating movements from multiple axis Also it has been used in the film industry from quite a while which shows that that experts in photography and videography have found ita very good device for camera stability With regards to basing the Steadicam as a reference for the camera stabilizer intended for the senior design project it would seem that unfortunately the Steadicam is not an ideal choice Of the reasons that the Steadicam may not be the best choice to use as a design reference is simply because the device is a large and very heavy construct As stated previously the camera stabilizer based on the specifications would need to be light weight and also is meant to be a handheld device Also the central idea behind the Steadicam is using weight balances that take advantage the inertia of the device and gravity It can easily be argued that this is quite an effective method that can be used to isolating any kind of movement The only concern here is that the camera stabilizer is intended to be a project for an electrical engineering student which would mean that the design would ideally use electronic movements via an electric motor to stabilizer the camera The Steadicam may be a more lucrative project for perhaps a mechanical engineering project 3 1 1 2 Fig Rig The Fig Rig camera stabilizer was invented by an English film director by the name of Mike Figgis 4 At first glance this particular device is quite differen
163. wo batteries to use for the camera stabilizer will be the devices power requirements If it is determined that there will be a high drain generated by the camera stabilizer then it would be more optimal to use a non rechargeable battery Another thing to consider other than whether the battery is chargeable or non rechargeable is the type of battery There are quite a few batteries to choose from however only batteries that may seem applicable to the camera stabilizer will be considered 3 2 2 1 3 Lithium lon Lithium ion batteries are of the most well known rechargeable batteries in the market The overwhelming majority of consumer electronics as well as an emerging electrical car market have turned to these batteries as their source for power generation A typical lithium ion battery has a cathode positive electrode and an anode negative electrode The cathode is made of a metal oxide and the anode is made of carbon or graphite A lithium ion battery also has an electrolyte transport medium that is needed for the lithium ion to flow freely The electrolyte is made of an organic solvent and also has layer called the separator used to prevent a short circuit within the battery The electrical current is able to reach the batteries due to the conductive surfaces like aluminum and copper Lithium ions are stored in the anode and when battery is discharged Lithium ion passes through use the electrolyte to pass the separator and reach the catho
164. y listed can be performed 3 2 1 2 Input System 3 2 1 2 1 IMU Polysilicon micromachined MEMS microelectromechanical system analog and digital accelerometers have been in production were invented in 1999 19 and have been highly desirable for the industry for their reliability survival to high g conditions in excess of 10 000 g favorable range of operation temperatures linear acceleration to output voltage behavior and low cost of production The automobile and aircraft industries were first to implement large volume use of polysilicon micromachined MEMS accelerometers Figure 15 Accelerometer Structure reprinted with permission The theory behind MEMES accelerometers is pretty simple There is a rigid structure known as the test mass with known inertial properties The test mass is suspended by a springs of equal and controlled spring constant Attached to the test mass are whiskers that branch out in a perpendicular fashion and are accompanied with carefully aligned external whiskers attached to a common base The base whiskers and test mass whiskers form capacitive plates When the test mass moves in one direction the effective capacitive area will increase in the direction of acceleration while the effective capacitive area will decrease in the direction away from the acceleration This changing of capacitance is called a differential capacitor 32 SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Sali
165. ying DC current m Efficiency gt 95 E Impedance matching mM Fast transfer time H Possible heat sink WR Surface mount package 2 3 6 Sensors The sensors will have the following gualities m Read acceleration figures past 3 8 g and quickly m Read radial velocity figures accurately and quickly m Reliable range of accuracy WR DC serial communication protocol WR Sleep low power mode E Small footprint and surface mount component 2 3 7 Power Supply amp Monitoring The power supply and monitoring will have the following characteristics E Haptics Green Power On LED Red Low Power LED HR ON OFF button on handle WR Compact and lightweight rechargeable battery with separate and external recharger E Low voltage lt 15 DCV m Power monitoring hardware must have IC serial communication if needed SENIOR DESIGN SPRING 2014 TEAM 3 Mizell Pennock Salih Low thermal waste output Built for shock and bumpy conditions 2 3 8 Frame Design The frame will have the following qualities Single handheld device Automatic tilt and roll rotational gimbal system Manual pan system Standard camera mounting Lightweight System 2lb Comfortable sturdy and balanced grip Battery and PCB housing Rigid construction Compact when not in use 2 3 9 PCB The printed circuit board PCB will have the following characteristics Double sided Surface mount components only Passive and low power component

Senior Design I Report - University of Central Florida

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