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MATT – Mobile Automatic Tennis Trainer

1. SPECIFICATION X CHARACTERISTICS NOMINALVOLIAGE Cms CAPCITY DIMENSIONS WEGGA TOTALHEIGHT 114 mm 685ines CONTAINER HEIGHT 65 inches ET ET wom INTERNAL RESISTANCH 25C I 18 APRONE CHARGING VOLTAGE SC 777 MAX DISCHARGE CURRENT 0 STANDBY USE MAX SHORT DURATION DISCHARGE CURRENT 36A 01 RES MAX CHARGING CURRENT Appendix E Launching System Components MATT aaa Appendix 1 Launching Mechanism Components Appendix E 1 1 Motors FIRST CIM Motor M4 R0062 12 Vendor BaneBots Specification Detai Nominal Voltage 12V RPM Peak Eff 4614 Torque PeakEff 317 8 Current Peak Eff 198 Weight Length 4 32 Diameter 26 Shaft Diameter Shaft Length Price 28 00 Shipping Tax 11 85 Quantity 1 Total Pri 39 85 1112 Appendix 1 1 1 Launching Mechanism Motor Calculation Motor Calculations Mass of Tennis kg 0 06 Constant Radius of Tennis Ball m 003 Constant Mass of Wheel kg 985 Radius of Wheel 0 08 Moment of inertia of Tennis Ball kgm 2 0 00 Moment of inertia of Wheel kg m 2 0 00 Top Velocity of Tennis Ball m s 45 00
2. s mm s HE 5 Figure 49 Mobility motor controller low level MATT 60 The MOSFET driver selected is the 1852110 from International Rectifier The basic functionality of these devices can be seen in Appendix 1 The low side MOSFETs are turned on by applying approximately 12V from the 1852110 The high side MOSFETs are turned on by applying approximately 22V from the 1852110 This is accomplished through the use of a bootstrap capacitor circuit integrated internally in the 1852110 The bootstrap capacitor is external connected across Vs and to the 1852110 and was chosen to be It provides 2A of output current in order to quickly hard switch the MOSFET while minimizing the amount of time in the linear region The resistors on the gates of the MOSFET were chosen to limit the amount of current that the 1852110 outputs The calculation for the low side MOSFET is 6 The calculation for the high side MOSFET is 12 The thermal calculations for this device can be seen in Fig 50 This is the input and resulting output when the values of the IRLB3034 N Channel MOSFET is used with the MATLAB code in Appendix G The ambient temperature is set to be a warm summer day temperature of 35 C 95 F Given the results seen in Fig 50 multiple MOSFETs will need to be connected in parallel in order to be able to handle the required current
3. Baten aw Sas PETS OR Tossed iy sena dora fr ON pone ley core mem meone Sms ce Vect ube nauk C BLOCK DESCRIPTIONS see Diagram page 4 gate aaa ee SDE DRNER OTS E ote recta 161 162 Som TC4431 TC4432 1 5A High Speed 30V MOSFET Drivers Features General Description im Loge 2584 Vam Logie 74 1297 STEPPER MOTOR CONTROLLERS NORMALANAVE DRIVE HALEFULL STEP DIRECTION SUITCHMODE LOAD CURRENT REGULA TON PROGRAMMABLE LOAD CURRENT FEW EXTERNAL COMPONENTS RESET INPUT amp HOME OUTPUT ENABLE INPUT DESCRIPTION Tre LIST Stepper Contol IC generates four prase dive br mo chase bipolar four phase sie motors m The be den ih Fal and wane cvs odes end on SIA Stee chest Slo rings A fears of ABSOLUTE MAXIMUM RATINGS gt E55 devices tht reaures dock drecion tnd pve Sires
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5. MATT 136 MATT 137 Title 47 Telecommunication PART 156 RADIO FREQUENCY DEVICES Subpart C Intentional Radiators Radiated Emission Limits Additional Provisions Browse Previous Browse Next 8 15 231 Periodic operation in the band 40 66 40 70 MHz and above 70 MHz The provisions of this section are restricted to periodic operation within the band 40 661 40 70 MHz and above 70 MHz Except as shown in paragraph of this section the intentional radiator is restricted to the transmission of a control signal such as those used with alarm systems door openers remote switches etc Continuous transmissions voice video and the radio control of toys are not permitted Data is permitted to be sent with a control signal The following conditions shall be met to comply with the provisions for this periodic operation 1 A manually operated transmitter shall employ a switch that will automatically deactivate the transmitter within not more than 5 seconds of being released 2 A transmitter activated automatically shall cease transmission within 5 seconds after activation 3 Periodic transmissions at regular predetermined intervals are not permitted However polling supervision transmissions including data to determine system integrity of transmitters used in security or safety applications are allowed if the total duration of transmissions does not exceed more than two seconds per hour for
6. exe 1 ero sor om messes ew esca reso 130 7 4 9 mr SED AIS Uszble machine scraw length 0 max from Wee RS 550PC 7527 aio RS 550VC 7527 iil a Eid ifi A EE AEEA EER Appendix B 2 Gearboxes Physical All Metal 12602 3588 Width Square 1 75 45 Shaft Length 3 00in 76 2 Quantity 2 Total Price 0 00 Repurposed for Harding University Engineering Department Lab MATT 97 198 Appendix B 3 Wheels Arnold 10 inch Nylon Bearing Plastic Wheel Vendor Amazon Specification Details Diameter 10inch Tread Diamond tread Hub Type Offset hub Hub Length 1 5 inch Hub Diameter 0 5 inch Bearing Nylon bearing Maximum Load 8015 Price 10 74 Shipping Tax N A Quantity 2 Total Pri 21 48 3 Inch Pivoting Caster Wheel Vendor Harc University Physical Resources Item Description Non marking Quiet operation provides low starting and rolling resistance Recommended for warehouse and many applications where high capacity and floor protection are required 3 swivel caster 21016 weight limit per wheel
7. amp proved ogie 169 L298 PIN FUNCTIONS refer othe mw see E orm an corte 3 Xu more a dte EI Ma aratna Tom ELECTRICAL CHARACTERISTICS 42 Ves ober sie DTN ve Seep Wate ions Gorter Y ESPECIES PEDI E band een tari Vela MATT 170 470 YZ APPLICATION NOTE THE L297 STEPPER MOTOR CONTROLLER sterea Ungar espe drven win ar L237 cea TRS Contralor for ve L298 ar LOE bias crore steper ring tne contratar a morocorputar hi anc provides a tra cme sowe siage we vut to regulate cur Vth a sutabie power actuator L287 two chase permanent magn
8. B Dates PL Model RWS 374 3 Fecueney Range Node ASK Gre Stepe LC 2 Dare Rare 00 hs Seery Channa Spacing Supp Votage Ho sonst passive desin count Electrical Characters Characteristic Sym Min Type Unit EE swim eta Sensitivity Pref 106 108 110 dBm Cramer Baseboard Data Rate On Tine m Dc characteristic Parameter Condition Min Unit Opening Supply Voltage di Operating m as Supply Voltage e weas ve v panou pem Low O A RWSIA MATT 132 MATT 133 1234 sere com fc tp et tar RWS374 Debe MATT 134 Demo Circuit Ren o 29 tw tp rat BISA Dashes PA HT12D HT12F 2 Series of Decoders Features Selection Table v u o 21002 MATT 135 HT12A HT12E 2 Series of Encoders Applications wer
9. I C UN ms DESCRIFTION TUNEAR CURRENT The i ful molor ar PYM OPERATION UP 10 AGAINST ows ec U STrofeT process BLOCK DIAGRAM P vee package iscisted Ieactramee Package specneaty designes for the nash autores envronment thermal erormaree to exposed de pads Moreover 5 ol The and con drecty when corned ian eter CONNECTION DIAGRAM TOP VIEW resistor enable one eg ofthe age They siso sianal operation is explained in e uh acie cn cage 7 The PWM uo ta lets usto the speed of me molor n ai posse inal cases a Iaw level sine onthe cm wil tum of bom te LS and 15 surtere When PWM nse a hah evel LSK OF XL eee snien me Povar surev iem EPELEN EEEE SH SE SC A OS TROUT ad x MATT 160 PIN FUNCTIONS DESCRIPTION
10. Remote Control Receiver Description The remote control receiver subsystem receives the signal from the remote control transmitter and translates it to the start or stop instruction for the microprocessor Inputs Remote Transmitter Start RF Signal Frequency 315 MHz Range 30 m Modulation ASK Stop RF Signal Frequency 315 MHz Range 30m Modulation ASK Power Source 5 VDC 0 50 Outputs licroprocessor Start Signal SV High Pulse Stop Signal SV High Pulse Sensors Description The sensor subsystem determines the location of the machine relative to the court and the current targeting values This includes both the external sensors and the code to interpret them It then sends this information to the microprocessor main code for calculations Inputs External Information Court Position Analog Coordinates 4 Launching System Horizontal Angle Change 0 5 VDC 0 50 mA Encoder Value Vertical Angle Change 0 5 VDC 0 50 mA Encoder Value Power Source 3 5 VDC 0 50 mA Outputs Microprocessor Main Code Court Position Change 32 bit coordinate values Horizontal Angle 16 bit or 32 bit angle values ATT 20 Vertical Angle 16 bit or 32 bit angle values Microprocessor Main Code Description The microprocessor subsystem receives data for the practice specifications curr
11. pu TUM aac Ec TA MIT Der d ep cde CONTROL denen a i are chopees the non phase 1 ofeach ar erasing he reducer tore eee A common on chip oscliatcr drives te dug Der pubes chopper rats wich eri Uto fidcs and FF2 When e current 1 reaches programmed pesk value the lage scene fe i urt ne ice The peak conet Ses deron he Gourd reise probiers multae into vci by laore T dene by connocing SYNC fine fetta mounts RE codes grounding CSC MATT 166 MOTOR DRIVING PHASE SEQUENCES The 287 meet generates prese sequences Er pore wove are end ha moses The de sequgress and cubus fot fren are shown inal cases saanee on ae OW o HGN ara pd HALF STEP MODE roston indenter tain secuerces ore simpy RESET wre ABCD is seed by a igh level on he incut NORMAL DRIVE MODE Neral dive mode also calle mo phase on dive selected by a low level on the input en
12. 34 Power supply circuit MATT 49 Rp Low Battery LED Fone M 1 o KO tothe usrinerace jx RF Receher kasma Figure 35 Low Battery Indicator The mechanical power needed by the major systems on the machine has been calculated and the power efficiency of the motors was estimated at 70 The maximum electrical power was determined by dividing the mechanical power by a factor of 0 7 Mobility System 210 W 0 7 300 W Launching System 40 W 0 7 57 W Vertical Targeting 20 W 0 7 30 W Horizontal Targeting 5 2 W 0 7 8 W Hopper System 1 5 W 0 7 3 W Other miscellaneous systems microprocessor user interface motor controller sensors etc were estimated to be approximately 45 W ope The total power required for this machine is then 443 W Given that power the total current required is 37 A We can get the current value from the equation 37 Based on this information we will use only one battery for the entire machine 12V 70Ah lead acid battery can supply the necessary power by providing 12 V and 42 A for one hour The maximum discharge current 5 520 A for a period of 5 seconds The current from this battery is a little higher than what the machine needs and it weighs less than 23 0kg More information about t
13. net MATT 102 Get Distance to Net Finds the distance the ball has to travel before it passes the net given machine position and horizontal launching angle cos Figure 61 Trigonometry diagram for the distance to the net calculation Hn Distance from Machine to Net along path of ball Nx Nets X Coordinate Mx Machine s X Coordinate Theta Horizontal Launching Angle int GetNetDistance double Theta int mx return nx mx cos Theta 103 Get Target Distance Finds horizontal distance the ball will travel given machine position and target position igonometry diagram for finding the distance to the target istance from Machine to Target Tx Target X Coordinate Target Y Coordinate Machine X Coordinate Machine Y Coordinate int GetTargetDistance int tx int ty int mx int my return sqrt double ty my ty my tx mx MATT 104 Get Horizontal Angle Find horizontal launching angle given machine position and target position arctan Horizontal Launching Angle Tx Target s X Coordinate Ty Target s Y Coordinate Machine s X Coordinate My Machine ss Y Coordinate Figure 63 Trigonometry diagram for calculating horizontal angle double GetAngle int tx int ty int mx int return atan double ty my tx mx 105 Get Launch Speed Deter
14. tne or Debt P Model TWS BS 6 Frequency Range 315MH2 Modulate ASK Circuit Shape SAW Date Rate kbps Supply Voltage 15 12V Output Power dB Working temperature 20 86C Solder temperature 230 T 10 seconds High sensitivity is designed Application Wireless Data Transmission Wireless Pad Remote Contra e Wireless Toys Carkey Home Automation AMR Automatic Meter Reading Remote Keyless Absolute Maximum Rating Rating Value Unit Power Supply and All Output Pins 034120 Non Operating Case Temperature 20 85 Soldering Temperature 10 seconds 230 THES MATT 127 128 Electrical Characteristic Characteristic Min Type Max Unit sem teas Data Rate 8 Kbps Output Power 32 mw cue 2 ve Assignment GND Data in 1 2 v 4 treat or 129 TTWEBE 130 Demo Circuit ma gagasen WENSHINGS MATT 131 RWS 374 MODULE series Wireless Hi Sensitivity Receiver Module RF ASK Version History Version Date Changes 101 2004 012 2008 2
15. Appendix J Power Components Appendix K Microprocessor MATT 97 98 299 22100 101 108 109 110 111 119 121 122 125 142 144 150 173 MATT 4 Requirements Specification Overview There is a wide range of products currently available on the market to help tennis players improve their skills or to provide an enjoyable practice session One such product is the tennis ball launching machine of which many different types and variations are available each with its own advantages and disadvantages The main problem with such tennis ball machines is the fact that they are stationary With stationary platform the tennis balls are shot to the player from the same location every time decreasing the realism of the practice session In game or match the shots would be hit to the player from a variety of different locations and angles on the tennis court The goal of the Mobile Automatic Tennis Trainer MATT is to provide a competitive alternative to the standard stationary tennis ball machine design MATT will add a new element to the tennis ball machine market by being the first tennis ball machine that moves itself The machine will change its position on the tennis court therefore providing a wider variety of shots to the player MATT will also include
16. V_Reflectivity gt PHOTOTRANSISTOR TCRT5000L Figure 43 Reflectivity sensor circuit Harding University s tennis courts are dark green inside the boundaries of the court and light green outside of the boundaries The lines on the tennis court are white Four measurements were taken of each color of the tennis court The test sensor was placed approximately half an inch above the surface of the tennis court in a box that blocked most of the ambient light The results of the reflectivity sensor testing can be seen in Table 3 From this data it can be observed that there is a distinct contrast between the different surfaces of the court Not all tennis courts are the same and there will be two conditions that will limit the functionality of the sensors First the lines of some tennis courts may be deteriorated to a point where reliable measurements are not available Second the surface of the court and the lines of the court have similar infrared reflectivity values In these circumstances the court either need to be repainted or have a highly reflective tape placed over the lines where MATT will be operating Table 2 Reflectivity sensor measurements 4 38 V 210V 373V 24v ev 4 36V 203V 346V The overall ball launching accuracy of MATT will be affected by its ability to stay parallel to the net In order to achieve this accuracy multiple reflectivity sensors will be positioned in a pre determi
17. Nal cont eaves resin H inte 193s ose Phase A Phase D indet 1 ient usidan poston courier Programma nose on 2 Aleate mode 1 imu on esto count avec Meses MATT 180 sPIC33FJ32MC302 304 dsPIC33F IS4MCXO2K04 AND dsPIC23F 128MCXO2 X04 Communication Modules Packaging Avie SPI fup to lwo modules SPOSOCOFES Fromng O eres simple Suppers ard semping moses ana 121 attesa Dos colision detection anc oben eonsiionag masene UART up to to Inept on aadress getset on UART Wake up on Stat b fom Sleea mode UN 20 tus support 7 encoding and decoding rire Figh Spees Bawd mode Marware Carol wth CTS ane RTS plos and up Loopback Listen Only Messages mozos for diaqnostes ane processing of Remote FFO mede using Paral Save PUPEPSP Suppars Bor feb data Fess per cerc Reauneany Check CRC generar pena us 6 Teo eas dsPIC33FJ32MC302 304 dsPIC33FJGAMCXOZ XO4 AND 3 128 02 04 ds
18. tege npe Er ale LO phase vas around Me suy HO Harte sas ave ouio Vg Hr site tg pp reum IG gate MATT 152 International MATT 153 0 67368 Rectifier HEXFET Power MOSFET POM D V SG Drive iss High EFcercy Syrchoncusecticaton in SMPS ed Uninterruptibie Power Supply nud w High Speed Power Switching Hard Switched and High Frequency Circuits Ib sticon tinea o Pacta Linea Benefits Oplimzed er Logic Level Die 2 Very LawFinggy at 45V Vos Imomwed Gate Avalanche SS Fully Capaotamoo and Avalanohe SOA Enhanced body diode and Capability 585 Absolute Maximum Ratings Sym va a TN W Lies we sacs ie Y vis Toupee Rae EIE ana ae Avalanche Characteristics z Avaancne basil asia gins m Thermal Resistance 1 IRLB3034PbF MATT 154
19. 131545 Scc a sets st se o c Sunasey ar TEES sr ure eig Suds ices Append MATT 88 Requirements Specification Appendices ATT 90 Appendix Customer Needs aad 5 5 2 5 21 5 5 15 5 5 2 5 5 2 5 8 2 15 5 215 15 2 1515 858 18 15 5 12 215 8588 21818181 5 5 4 5 2 5 5 2 5 5 5 2 5 5 5 Need 21512 1215 6212165 5 gt 1 Mobility x Various Launch x 2 Factors 3 Precision Ease of 4 Operation d Long Operation x a em Time Safety x x x 7 Portability x Figure 57 Customer needs metrics matrix The needs listed above in Fig 57 correspond to the seven needs listed in the Customer Needs section The metrics are further described as following 1 The device will not move further than 6 0 0 5 meters from the center line of the court to avoid running away from the court or into another court The launching speed can
20. 69 Price Quanti Mobility Bane Bots MS RS550 12 5750 2 9 40 24 40 Motors Gearbox Bane Bots SM CM330 4 5075 2 N A 1 50 Screws incorrect Gearbox Coast to Coast 345 5035 8 0 26 53 06 5 3 45 Hardware Gearbox CoasttoCoast M3 50 040 1 N A 0 40 Screws M3 50 Hardware Binch Casters Physical 334 2 3054 8722 Resources 10 Drive Amazon 490 323 0002 51074 2 N A 21 48 Wheels 1 16 x1 2 x Speedy Metals 63a 065x5 48 5201 18 1213 54831 1 2 x48 Angle 6063 T52 Aluminum 0 25 x4 x8 Lowe s 80246 51998 1 1 60 21 58 Plywood Repurposed Parts Bane Bots 56450 2 9 40 138 40 Gearboxes Actual Part Cost 104 02 Manufacturing Part 233 02 Cost Actual Shipping Tax 52393 Manufacturing 53333 Cost Shipping Tax Cost Actual Total 127 95 Manufacturing 266 35 Cost Total Cost Repurposed parts are part taken from previous projects and have no effect on actual budget Launching System Budget Table 7 Launching system detailed budget Description ____ Price Quantity Shipping Tax _ Cost Electric Scissor Amazon UPG86025 55632 1 N A 56 32 Jack 6 Lazy Susan Lowe s 71060 5443 1 5114 5 57 Bearing 3 x 8 Semi Lowe s 28878 986 1 9 86 Rigid Aluminum Tubing Bipolar Stepper Trossen M 200 ROB 51495 1 7 99 22 94 Motor Robotics 09238
21. Wage sng ure wan mta yma preten Vp Venga SE 2 Vas erara tom Ue OD Fic f serm eere ww rtcom 155 IRLB3034PbF LS H i Iu Act H E LEAN d Fi z H LE Figs Casctareow Typical v GUN Vago MATT 156 IRLB3034PbF international z 5 i sg Seren deme pum pP ia M H no eimi adis inne stun ve 5 d 1s H i rT 4 157 Intemational IRLB3034PbF Fig 13 Maximum Transient Thema Ingo 4 Fig M Avalanche Currant ve uua 14 18 EE secet armed tyi Tarsier
22. shore ore on he seat rte 502 sulcos can malo perdre arvez ae te VIEN rM or wit raat and pon TWO PHASE BIPOLAR STEPPER MOTOR CONTROL CIRCUIT MATT 163 PIN CONNECTION vou BLOCK DIAGRAM L20771 12070 MATT 1164 PIN FUNCTIONS 2074 L20rD ET RN wis rs redo al ton Wer tma e D Metr stase T Mer srame C drva sana fr ove ae p 2 rows bet a x Wem chaoper ov AM MH wren E E etre can im starsat y ES a MATT 165 PIN FUNCTIONS 12974 12970 pon br adena UU THERMAL DATA mes ee ew CIRCUIT OPERATION TIR LAS ber uoe wh del bite ee
23. 2 5 3 Figure 38 Tennis court with target field partitioned MATT 52 The dials will be turning potentiometers that will vary the input being fed to the microprocessor from OV to SV see circuit board subsection for more details on how this will be done These voltages will be interpreted by the microprocessor using built in logic to follow the patterns set out in Fig 39 Vertical Fuzzy Logic Horizontal Fuzzy Logic Figure 39 Fuzzy Logic Graph for Balance Dials Both charts X axis is the voltage received from the dial and their Y axis is the percentage assigned to each respective block The left chart handles the depth dial splitting the six fields into two blocks the front 1 2 and 3 from Fig 38 and the back 4 5 and 6 from Fig 38 The right chart handles the width dial splitting the six fields into three blocks the left 1 and 4 in Fig 38 the middle 8 2 and 5 in Fig 38 and the right 3 and 6 in Fig 38 get the percentage for each field the percentage for the two blocks that that field falls into will be multiplied together For example the front percentage and the left percentage will be multiplied together to get Field 1 s overall percentage Launching Rate The user has control of how frequently the balls are launched Turning the dial to the left means the shots come less frequently while turning right makes them come more frequently This is a simple analog to
24. 25 C ures spaced 17 gt wer B 7 ae jr TT 1150 Controller Components 151 Data Sheet No 060249 International 15211061 Rectifier u Satana HIGH AND LOW SIDE DRIVER Floating channel designed for operzton Product Summary 241A Eur vus EN EN 130e 1205 4 CMOS SchmitHriggered inputs with pulldown Delay Matching IRS2110 10 max Saad npa tr bo es Description fe Dower MOSFET ard wh ndepencent D gs ind ovaie reiererces output shames Pro nate ngeded coner Log B campata wen ada CMOS or LST TL ou put i933 V ouput aveo cte a aed spit use eget gt The bo east ne an pover MOSFET IGBT nara Ee Typical Connection PETER International Tor Rectifier 1RS2110 1 2 S PbF IRS2113 1 2 8 PbF Functional Block Diagram Lead Definitions Symbol Description lege soul tx igh gle cu im
25. esac see Foues 13 es wo 13849 etna Ty reten Fig 35 Avalanche Tompo 5 MATT 158 81245 Ultra Low VF Schottky Barrier Rectifier Applications Ths device desires for hgh eatery an appears aso designed as bypass diode for slar males Features terme Saca 519501028 gt MOUIS SL GS Low Poner Lass Efeency E Pores als Absolute Maximum Ratings 7 5cies natsa Parameter Value Tis Wee Wasa Peak Reverse v Vaus E v uir DG Beca Vela Than Umama Average Be Pase tone on Race Losi Ve usas Fra vonage t2 2 ie Win DO Reverse Carer at Rataa vc 37 ANM Range sericea Far semiconductor Thermal Characteristics Parameter Vau read pant ang a cas MATT 1159 y VNH3SP30 FULLY INTEGRATED H BRIDGE MOTOR DRIVER CURRENT 0 A
26. Mounted Ball 5913 71 1133 4 54532 Bearings Idler Sprocket McMaster Carr 6663 22 22 22 1 N A 22 22 Motor Sprocket McMaster Carr 6280 331 886 1 5886 Wheel McMaster Carr 6280 332 886 2 N A 17 72 Sprockets ANSI3SChain 6261172 1256 1 N A 1256 SteelRod 3 x Lowe s 44093 5525 1 042 5 67 Diameter S Launchi Tractor Supply 4441143 5699 2 112 51510 Wheels HopperWire ACE Hardware 432425 2899 1 2 32 31 31 Fence 1 4 x2 1 2 x Speedy Metals 61f 25x2 5 48 51742 1 51775 35 17 48 Flat 6061 T6511 Aluminum 1 4 x1 x24 Speedy Metals 61f 25x1 24 5329 1 N A 3 29 Flat 6061 16511 Aluminum 3 16 x12 x Speedy Metals 61 190 12 18 2801 1 N A 28 01 18 Plate 6061 T6 Aluminum 3 0 Printer Components Hopper Rotor HU Engineering 3510 1 N A 53510 Rotor Pinion Engineering 170 1 1 70 Rotor Gear HU Engineering 51615 1 N A 51615 Rotor Shaft Engineering 5385 1 N A 3 85 Repurposed Parts Angular Wonder Motor 7995 1 N A 79 95 Targeting Motor 71 Launching Bane Bots M4 R0062 12 52800 1 5185 53985 Motor Actual Part Cost 289 18 Manufacturing Part 465 78 Cost Actual Shipping Tax 30 74 Manufacturing 42 59 Shipping Tax Cost Actual Total 319 92 Manufacturing 508 37 Cost Total Cost Repurposed parts are part taken from previous projects and have no effe
27. Price 3 34 Quantity 2 Total Price 5722 MATT 99 Appendix Frame and Encasement Frame Materials 1 16 x 1 2 x 1 2 Angle 6063 T52 Aluminum Vendor Speedy Metals Details 0 0625 in B Dimension B 0 5 in Dimension 05 E Length ABin Manufacturing Extruded A d Price 2 01 Shipping Tax 51213 Quantity 18 TotalPrice 54831 Encasement Materials 0 25 x 4 x 8 Premium Underlayment Plywood Vendor Lowe s Price 519 98 Shipping Tax 1 60 Quantity 1 Total Price 521 58 Appendix Interface and Control System MATT 101 Appendix Code Dimensional Standards Figure 60 mensional representation Figure 60 is a visual representation of the dimensions used in the physics calculations With x being the long dimension of the court y the short and z the vertical H varies to be the horizontal path of the ball allowing for 2 dimensional physics calculations instead of 3 dimensional calculations There are only 3 points of interest in the physics calculation the point of launch the net and the point of impact The point of launch and the point of impact both have x 2 and h coordinates The net has a constant x and z an h coordinate and covers all y s within the court For the purposes of the code the points will be named as follows M for point of origin i e machine T for point of impact ie target for net
28. RS 51 Dt MOTOR 381245 ty Qt RI 4432 Figure 52 Launching motor controller The thermal calculations can be seen in Fig 53 in which no additional MOSFETs will need to be connected in parallel with Q1 in order to handle the current The MOSFET is extremely efficient at dissipating heat even at 35 C so the calculations performed for the Mobility Motor Controller will be more than adequate for the Launching Motor Controller Inputs Maximum Drain Current Ambient Operating Temperature 35 C Maximum Junction Temperature 175 C Thermal Resistance from Junction to Case 4 Thermal Resistance from Case to Sink 5 Thermal Resistance from Junction to Ambient 62 User Required Drain Current 4 75 Results Minimum Number of MOSFETs Without Heatsink 0 031849 Minimum Thermal Resistance of Heatsink Required 1945 794441 ility motor MOSFET thermal calculations 163 Vertical Motor Controller The vertical targeting system s maximum electrical power requirement to be supplied to the DC motor is 30 W The motor will be supplied with 12 VDC so the maximum current that will need to be supplied is 2 5 A The electric scissor jack that was ordered will with a manual motor controller There is a button for the lift to raise and another to make it lower The buttons will be replaced with solid state relays that wi
29. and are sensors Postion sensor Iar tat codo hor an fares amillar ard maioral papat care ceded whieh Gods vete T magnete tenes 5 mo ea Genera purpose wbarevar ne ited PRODUCT SUMMARY wm e ma INTEORATED Scream it ORDERING INFORMATION The T ABSOLUTE MAXIMUM RATINGS Fi Y ji x ji cw aa UE emm TCRT5000 TCRT5000L MATT 146 VISHAY Vishay Semiconductors Reflective Optical Sensor wih Transistor Output ABSOLUTE MAXIMUM RATINGS UT OUTPUT DETECTOR 1 1 73 PII ABSOLUTE MAXIMUM RATINGS Fe Ponar Danpaten bintie BASIC CHARACTERISTICS 17 OUTPUT Sec Eni s aa g cen mier put Senai a yar Pare p 147 VISHAY TCRT5000 TCRT5000L Rellecive Optical S
30. and therefore as one design for a subsystem changed another needed to be modified as well Another main factor that contributed our lack of schedule following was the large amount of mechanical components A high percentage of MATT is composed of mechanical subsystems and each system had to be analyzed individually to determine motor and gearing specifications and requirements Many of these mechanical systems became much more involved and complicated than the mechanical engineers previously assumed and therefore each subsystem took a significantly greater amount of time to design than was expected Due to these delays in the design for the mechanical engineers several of the electrical subsystem designs fell behind schedule as well since they were highly dependent on information provided from the mechanical engineers Table 11 shows the main tasks from the Fall 2011 Work Breakdown Structure which were delayed or have not yet been finalized All of the tasks listed have been designed but final iterations have not been completed Therefore though designs have been created the main concern in all areas is the actual part selection and preliminary testing 77 Fall 2011 Delayed Tasks Description Deliverables Duration Engineer s Power Source Power source design Schematics MultiSim 5 Selection and specific models components selected Power Distribution amp Power regulation and Schematics Multisim Regulation de
31. and they will also not need a heat sink Inputs Maximum Drain Current 343 Ambient Operating Temperature 35 C Maximum Junction Temperature 175 C Thermal Resistance from Junction to Case 0 4 Thermal Resistance from Case to Sink 0 5 Thermal Resistance from Junction to Ambient 62 User Required Drain Current 12 5 Results Minimum Number of MOSFETs Without Heatsink 0 220560 Minimum Thermal Resistance of Heatsink Required 280 202677 Figure 50 Calculations for motor controller thermal properties The time it takes the IRLB3034 to turn on given supplied current of 2 was found using following equation 81 Ifthis value is added to the IRS2110 s maximum turn on time of 35ns then the maximum turn on time is 116ns According to the maximum safe operating area figure on the datasheet the drain to source voltage is 12V and the IRLB3034 turn on time takes 1005 then the maximum drain current is approximately 100A The turn on time is significantly less than 100 and the maximum drain current is only 12 5A so the device should have problem switching through the linear region The simulation of this controller can be shown in part in Fig 51 This is only a small part of the controller system but it demonstrates the high current capabilities of the controller Transistor Q4 is MATT 61 being controlled with PWM at 2kHz with 0 to 12V pulses The transistor 01 is b
32. appropriate time then MATT will assume the hopper is empty The encoder wheel for the launching system will be manufactured using the Engineering Department s 3D printer The encoder will be used with Vishay Semiconductors TCST1103 photo gate sensor The two dimensional encoder design can be seen in Fig 46 A resolution of one count per revolution was chosen due to the high rotational speed of the launching wheel igure 46 Launching encoder wheel The microprocessor must accurately know where MATT s vertical and horizontal targeting systems are located Both targeting systems have a limited range of movement so a potentiometer can be used on the pivot points of each system The potentiometer for the vertical targeting system will be attached to the hinge of the adjustment platform The potentiometer for the horizontal targeting system will be attached to the horizontal targeting motor Motor Controllers Mobility Motor Controller The mobility system requires the use of relatively high current motors In order to provide variable speed for the motors at a reasonable cost the motor controllers have been designed specifically forthe mobility system The mobility system will require 150 W of electrical power for each of the two motors The motor will be supplied with 12 VDC so the maximum continuous current that will need to be supplied to each motor is 12 5 A To fulfill these requirements a commonly used motor controller config
33. bearing upon which the launching system will rest Through the middle of the bearing shaft 137 will connect the bottom plate of the launching mechanism directly to the motor The shaft as well mounting bracket will be constructed from steel at the time of final fabrication Vertical Targeting Mechanism The vertical targeting mechanism consists two platforms a hinge and an electric car scissor jack A concept design is shown in Fig 21 The launching mechanism is fixed to the top platform The platforms are hinged together so the electric car scissor jack can lift up the top platform The vertical aiming is then controlled by adjusting the height of the scissor jack This scissor jack design was chosen because of its simplicity and low cost compared to other possible designs The platforms are hinged together at the location shown in Fig 21 so the wheels are closer to where the tennis balls leave the machine Because of that the space in the machine where tennis balls leave is smaller for safety purposes Flexible tube Launching Mechanism Electric Scissor Jack Platform Bottom Platform Figure 21 Vertical targeting mechanism concept design drawing At first a custom scissor jack was designed and analyzed in SolidWorks The purpose for this design was to build using the 3D printer a smaller and lighter scissor jack compared to car sc
34. block diagrams in the following pages The red lines indicate energy moving into out of the system The green lines represent materials moving into or out of the system The black lines represent controls moving into and out of the system A legend is shown below Fig 2 Machine Battery Movement 1270 4247 96 Tennis Balls 1 150 Remote VIA Start Stop Shot Directions Pulse avel O nns 0 50 Vertically Targeting Instructions Distribution Tennis Balls Frequency 1 150 Speed Vertical Angle Control Switch igure 2 Level 0 block diagram of MATT with legend shown below Energy Materials Signals 12 MATT Level 1 The block diagram shown in Fig 3 is a Level 1 block diagram showing all of the major systems present in MATT as well as all the of the inputs and outputs of each major system indicator Machine Movement Tennis Balls Ball Speed 4 45 m s Pulse Targeting Shot Directions Distribution 02 140 Horizontally Frequency 0 50 Vertically Speed Vertical Angle Tennis Balls Control Switch Sensors Court Position Figure 3 Level 1 block diagram of MATT showing all major subsystems Power Source System Level 2 The block diagram shown in Fig 4 shows a Level 2 representation of the individual subsystems of the power source system along w
35. each transmitter There is no limit on the number of individual transmissions provided the total transmission time does not exceed two seconds per hour 4 Intentional radiators which are employed for radio control purposes during emergencies involving fire security and safety of life when activated to signal an alarm may operate during the pendency of the alarm condition 5 Transmission of set up information for security systems may exceed the transmission duration limits in paragraphs a 1 and a 2 of this section provided such transmissions are under the control of a professional installer and do not exceed ten seconds after a manually operated switch is released or a transmitter is activated automatically Such set up information may include data In addition to the provisions of 415 205 the field strength of emissions from intentional radiators operated under this section shall not exceed the following Fundamental Field strength of fundamental Field strength of spurious frequency MHz microvolts meter emissions microvolts meter 40 667 40 70 2 250 25 MATT 138 707130 1 250 125 1301 174 1 250 to 3 750 125 to 375 1747260 13 750 375 2607470 13 750 to 12 500 1375 to 1 250 Above 470 112 500 11250 Linear interpolations 1 The above field strength limits are specified at a distance of 3 meters The tighter limits apply at the band edges 2 Intentional ra
36. estimated The selected wheels are shown Appendix B 3 Brake System The mobility system of MATT will not actually have a separate mechanical system to slow down or stop the machine as required All slowing and stopping of MATT will be controlled using instru from the microprocessor via the motor controller Essentially when the machine needs to slow stop ns even change direction a signal will be sent to reverse the direction of the motors until the desired result occurs Therefore the system is essentially a programmed system and not a separate physical system MATT 28 Mobility Frame and Encasement The frame of the mobility system and outer encasement is crucial for two reasons The structural integrity of MATT is very dependent on the strength and support that is provided in the frame of the mobility system Second the encasement on the outside will prohibit tennis balls from getting under the machine and prohibiting the proper operation of the mobility system wheels The frame must be strong enough to support the weight of the majority of the machine as well as withstand torques applied by the mobility motors and other subsystem components attached to it The mobility frame was designed to create a sturdy base of operation as well as providing place to house the battery and any other bulky stationary parts of the machine The goal was to place as much of the total machine mass as possible in this lower section so that a
37. low center of gravity would increase the overall machine stability possible frame design was assembled in SolidWorks and modeled using finite element methods in SolidWorks to determine stresses due to the expected loads The model was 50 8 cm 20 in wide x 60 96 24 in long x 26 67 10 5 in tall and made from aluminum angle structural members Figure 11 shows the finite element method simulation of the frame with a force applied to the top and a torque applied to each gearbox shaft The analysis showed that all stresses in the frame were well below the yield strength of 6063 aluminum which is 145 MPa The highest stress in the simulation was located on the shaft of the gearbox which is made from steel and is stronger than aluminum After several iterations and modifications to optimize strength and thickness the frame shown in Fig 11 was selected as the design The frame and encasement materials can be found in Appendix 8 4 we Figure 11 Mobility frame finite element analysis MATT 29 Power Requirements Based on the motor specifications provided in Appendix 8 1 power calculations were performed in order to determine total power requirements under the worst case scenario Based on the values provided the torque requirements and the speed requirements Eqn 2 was used to calculate the required power for each motor In Eqn 2 T represents the output torque in Nem represents the angular velocity of the o
38. many of the same features that typical tennis ball machines exhibit MATT will provide a more realistic training experience than a stationary tennis ball machine while having a cost that is competitive with similar products Customer Needs Several tennis players and their coaches were interviewed to determine what features are most desired or needed in a tennis ball machine They all stated that they wanted a tennis ball machine that would behave more like a real opponent A tennis player moves on the court and provides a wide variety of speeds and directions on shots to their opponent The most desired features by these potential customers were variability of shot origin the shot does not come from the same position every time speed angle and height on the tennis ball A large tennis ball capacity a remote control and a high percentage of shots landing within the court boundaries were also stated as customer needs Customer needs determined by the design team were safety ease of use and randomization of shots These needs were translated into seven concise customer need statements shown here The machine itself can move and provide shots from varying locations The machine can vary speed and direction of shots The machine can launch a high percentage of shots over the net and within bounds The machine can be easily operated by either the player or coach The machine can operate for reasonable period of time without damage or resettin
39. operating within the frequency band 40 661 40 70 MHz the bandwidth of the emission shall be confined within the band edges and the frequency tolerance of the carrier shall 40 01 This frequency tolerance shall be maintained for a temperature variation of 1 20 degrees to 50 degrees at normal supply voltage and for variation in the primary supply voltage from 85 to 115 of the rated supply voltage at a temperature of 20 degrees For battery operated equipment the equipment tests shall be performed using a new battery Intentional radiators may operate at a periodic rate exceeding that specified in paragraph a of this section and may be employed for any type of operation including operation prohibited in paragraph a of this section provided the intentional radiator complies with the provisions of paragraphs b through 4 of this section except the field strength table in paragraph b of this section is replaced by the following MATT 139 Fundamental Field strength of fundamental Field strength of spurious emission frequeney MHz microvolts meter microvolts meter 40 661 40 70 1 000 100 70130 500 50 130i 174 500 to 1 500 50 to 150 174i 260 1 500 150 260i 470 1 500 to 5 000 150 to 5007 Above 270 5 000 500 Linear interpolations In addition devices operated under the provisions of this paragraph shall be provided with a means for automatically limiting
40. operation so that the duration of each transmission shall not be greater than one second and the silent period between transmissions shall be at least 30 times the duration of the transmission but in no case less than 10 seconds 54 FR 17714 Apr 25 1989 54 FR 32340 Aug 7 1989 as amended at 68 FR 68546 Dec 9 2003 69 FR 71383 Dec 9 2004 Website Address http ecfr gpoaccess gov cgi t text text idx cecfr amp sid 1f9d125496a86cfbcdb02d9b6a5bc395 amp rgn div8 amp view text amp node 47 1 0 1 1 15 3 240 21 amp idn MATT 140 The Part 15 Restricted Bands Spurious Emissions l m the swiss power sour CR2032 MFR 3V Lithium Battery Technical Data Sheet Specitications MATT 141 renataa batteries Dimensions According 60086 Chemical System Lies Nominal Votage av Rated 225 mAh Standard Discharge Curent Gone Discharge Average Weight 288 Tomporature Range Discharge year Performance ROOM proc cr BWATCN Appendix MATLAB MOSFET Thermal Calculation MATT 143 Program Name MOSFET Thermal Calculations By Trevor Pringle fprintf WiInputs ID str2n
41. system will be given such a command to do this automatically depending on sensor inputs or by a signal provided by the user via the remote control The braking will be performed by the motor controller without having an actual mechanical brake system The entire system will be powered from the power source and controlled via instructions from the microprocessor using motor controllers The mobility system will also have an encasement to prevent tennis balls from causing damage or prohibiting proper operation of the machine by impeding the motion of the wheels Inputs Power Source 12 VDC at 0 25 A Mobility Control Signals Digital From Microprocessor and Motor Controller Movement Speed Two 0 3 3 VDC 0 50 PWM Speed Signal Movement Direction Two 0 3 3 VDC 0 50 mA Direction Bits Outputs lateral Motion Parallel to the net 0 65 1 3 m s Subsystems of Mobility System Drive System Description The drive system of the mobility system will consist of a motor assembly driving the wheels of the machine The motor assembly will have a torque reducing gearing system to reduce the size of the motor required to move the machine under the worst case scenario which would be at a maximum mass of 70 kg The motor assembly will consist of two separate drive motors that can be controlled individually by the motor controllers to adjust the movement direction of the machine if necessary For balan
42. the practice session In game or match the shots would be hit to the player from a variety of different locations and angles on the tennis court The goal of the Mobile Automatic Tennis Trainer MATT is to provide a competitive alternative to the standard stationary tennis ball machine design MATT will add a new element to the tennis ball machine market by being the first tennis ball machine that moves itself The machine will change its position on the tennis court thereby providing a wider variety of shots to the player MATT will also include many of the same features that the typical tennis ball machines exhibit Some of these features include variation of speeds and variation of horizontal and vertical angles All of these features will enable MATT to provide more realistic training experience than a stationary tennis ball machine while having cost that is competitive with similar products System Overview The MATT prototype will provide a more realistic practice experience to tennis players of any skill level with its very own unique mobility feature MATT will be programmed to move itself laterally parallel from the net and remain within 6 0 0 5 meters from the center of the court at all times While moving MATT will launch tennis balls with varying initial speeds between 4 and 45 meters per second MATT will also provide a wide range of different angles for shots The range of horizontal angles will be from 40 to 140
43. together The budget presented here takes into account all major components needed but does not include miscellaneous parts such as fasteners wiring and small amounts of other raw materials needed for the construction and testing of MATT Each subsystem budget will be shown in subsequent pages where it will be broken into much greater detail showing the cost of individual components Table 4 Overview of budget for MATT System Part Cost Shipping Tax Cost Total Cost Mobility System 5104 02 523 93 5127 95 Launching System 289 18 30 74 5319 92 Power Interface and Control System 5235 83 9 16 244 99 Totals 629 03 63 83 692 86 Remainder 337 14 Manufacturing Budget The budget presented in Table 6 takes into account the cost of parts if MATT were to undergo full scale manufacturing at a high volume The costs of components such as those printed on the 3 D printer or repurposed from previous projects were factored in to determine the total expense for each MATT device if it were to be produced for the market Table 5 Ove of manufacturing budget for MATT System Part Cost 5 Cost Mobility System 233 02 33 33 266 35 Launching System 465 78 54259 508 37 Power Interface and Control System 235 83 5916 5244 99 Totals 934 63 85 08 1019 71 Subsystem Budgets Mobility System Budget Table 6 Mobility system detailed budget MATT
44. vary depending on the user input from 4 m s to 45 m s The horizontal angle can vary from 40 to 140 in order to account for movement of the machine while still making accurate shots 4 The vertical angle can vary up to 50 to produce longer distance shots with slower speeds as well as add more variety to the shots 5 The machine can vary its angle from one extreme to the other within 3 0 1 0 seconds 6 machine can consistently hit the player s court without hitting the net at least 90 of the time 7 The controls for the machine are within standing reach of an average player 8 The labels for the controls are readable for an average player 10 12 14 15 16 17 MATT 91 The device can be started remotely from at least 30 meters away The device has enough power to run for at least 1 hour machine can withstand being hit on over 100 returns at an initial speed of 30 meters per second machine can hold at least 150 tennis balls machine can shoot with only one ball left The machine can operate with the maximum capacity of tennis balls The moving parts of the machine are encased The majority of moving parts will not be accessible without modifying the device The device will weigh less than 60 kilograms for portability The machine will resist light rain for a minimum time of 3 minutes Appendix A 2 Tennis Court Dimensions and Test Grid Figure 5
45. with respect to a line parallel to the net and the range of vertical angles will be from 0 to 50 with respect to the horizon MATT will be operational anywhere from 10 0 0 5 to 12 0 0 5 meters from the net and will travel the entire width of the tennis court in less than 20 0 1 0 seconds The maximum time the prototype will take to adjust its aim through the widest range of horizontal or vertical angles is 3 0 1 0 seconds MATT will have adjustable settings which a user can control through a user interface system MATT will be able to hold a minimum of 150 tennis balls which will be launched at a maximum feed rate of one tennis ball per two seconds allowing a continual practice of a minimum of five minutes before needing to reload the hopper with tennis balls MATT 10 Design Concept Figure 1 depicts three dimensional rendering of the general form and shape of MATT major physical components are modeled with simple geometries and assembled here to provide a visual representation of how the finished product will look Overall dimensions will be shown and described in later sections Figure 1 Design concept of MATT depicting all major components and geometries ATT 11 Block Diagrams MATT Level 0 The block diagram shown in Fig 2 is representation of all the materials energy signals inputs and outputs present going into and out of MATT The individual internal subsystems will be outlined in Level 1 and Level 2
46. 25 in in thickness It was assumed that there would MATT 26 be four wheels to support the load and therefore each wheel would carry one fourth of the total load Estimations were made for the radius of the wheel and the mass of the wheel as deemed necessary From the values listed and Eqn 1 the initial torque required for one wheel to be able to roll over an obstructing object was calculated to be approximately 7 6 Nm Therefore if four wheels of the same size and weight were modeled as rolling over some impeding object all at the same time an absolute worst case scenario for the required torque was determined to be approximately 30 4 N m This value was therefore used as an estimation of the most torque that would ever be needed by the mobility system at any given time With such a value known the drive system design could be designed to meet this requirement Drive System The drive system of MATT will be able to move laterally generally remaining parallel to the on the tennis court It will also be able to move both forward and backward in this lateral direction To do this the method selected was a combination of twa identical motors and associated gearing for each Each motor will be controlled individually which would allow for correction if MATT begins to stray off course Having two drive motors would also exhibit the advantage of each motor carrying half of the required load Therefore each of the drive motors would be requi
47. 35 Roller Chain 6261K172 Vendor McMaster Carr Specification Detai Chain Type ANSI 35 Pitch A 0 375 inch Roller Diameter B 0 200 inch Roller Width 0 1875 inch 269155 3 14 ft Shipping Tax N A Quantity 4ft Total Price 1256 Appendix E 1 6 Shaft Steel Rod 3 ft x diameter 44093 Vendor Lowe s Price 5 25 Shipping Tax 0 42 Quantity 1 Total Pri 5 67 MATT 116 Appendix E 1 7 Bearings Mounted Bearings 5913 71 Vendor McMaster Carr Specification De Mounting Style Flange Mount Flange Mount Type Standard Type General Purpose Bearing Style Ball Shaft Diameter 0 5 inch Radial Load Capacity 716 Ibs 5800 Bearing Rating 1 Housing Material Steel Steel Housing Material Stamped Stee Steel Temperature Rang 4 212 Bearing Construction Double Sealed Secure Attaches With Double Set Screw Price 51 Shipping Tax Quantity 4 Total Price 545 32 MATT 217 MATT 118 FE 4 MCMASTER CARR 2 5913071 ES MATT 119 Appendix 2 Angular Targeting Mechanism Components Appendix 2 1 Motor Vender Wonder Motor Item Description The gear motor is measured to be 7 inch long and the motor itself has a diameter of 2 5 inches Drive shaft is 10mm in diameter with 2 flats where flat to flat is 6mm The shaft has a
48. 6280K332 5886 2 N A 17 72 ANSI3SChain 6261 172 31256 1 N A 12 56 1 4 2 1 2 Speedy Metals 611 252 5 48 51742 1 17 75 35 17 48 Flat 6061 T6511 Aluminum 1 4 1 24 Speedy Metals 61425412224 329 1 N A 53 29 Flat 6061 16511 Aluminum 3 16 x12 x18 Speedy Metals 61p 190 12x18 2801 1 N A 28 01 Plate 6061 76 Aluminum Total Part Cost 527 83 Total Shipping Tax Cost 58 37 Total Funds Spent 586 20 Total Expected Budget 692 86 Percent of Budget Spent 84 6 75 Project Plan and Management Organization and Management MATT s design team consists of two mechanical engineering students two electrical engineering students and one computer engineering student With the design tasks complete the next phase of the project will consist of construction implementation and testing While project management responsibilities will be distributed equally among the team members each team member will be in charge of a major subsystem of the device with two other team members supporting him There will be one project manager over the entire project Mark Moore Mechanical Engineer o Markis the project manager and is responsible for organizing the activities and tasks of the build team He will ensure that the required documents presentations constructions and testing will be completed on schedule He will also be the primary engineer responsible for the construction of the mobility sys
49. 8 shows diagram of the dimensions of tennis court and the sections that will be used for testing purposes The percent distributions of shot placements corresponding to the grid is described in the Preliminary Test Plans section MATT 92 CU 6 Center Service Une fp Seges Seine Toues Seine 1 5 Figure 58 diagram of the dimensions of the tennis court and the grid sections labeled 1 through 6 for testing the precision of the machi 93 Appendix Area of Operation of MATT 10 0 0 5 m 12 0 0 5 pr 1 6 0 0 5 1 gt 1 Figure 59 Diagram showing dimensions and location of acceptable area for range of motion Mobility System Components Appendix 1 Motors 5 85550 12 Motors Performance Operating Voltage 6 144V No Load RPM 19300 Stall Torque 486 2 Kt 5 7 mN m A Efficiency 70 Torque Peak Efficiency 62 4 Physical Length 57 Shaft Diameter 3 2mm Price 7 50 Shipping Tax 9 40 Quantity 2 Total Price 24 40 MATT 95 MATT 96 RS 550PC VC MOTOR WEIGHT 2555 APPROX tars 274
50. Bottom Velocity of Tennis Ball m s 45 00 Top Angular Velocity rad s 590 55 563935 rpm Bottom Angular Velocity rad s 59055 5639 35 rpm Total Velocity of Tennis Ball m s 45 00 Total initial Angular Speed of Tennis Ball rad s 000 Kinetic Energy of Tennis Ball J 60 14 Kinetic Energy of Wheels No Load 1 860 63 Kinetic Energy of Wheels Right After Tennis Ball Is Launched 0 LL Assuming Final angular Velocities Are Equal Initial Angular Velocity of Wheels rad s 590 55 Final Angular Velocity of Wheels rad s 569 54 Minimum Time Between Launches s 2 00 Required Acceleration of Wheels After Tennis Ball Is Launched rad s 2 Required Torque N m 003 Required Torque mN m 25 92 Power hp 002 800 48 1050 Using a Factor of Safety of 1 5 Required Torque mN m 38 88 Power hp 003 Angular Velocity rpm 8459 02 Using a Factor of Safety of 2 Required Torque mN m 51 84 Power hp 004 3062 W Angular Velocity rpm 11278 70 MATT 213 Appendix E 1 2 Launching Wheels Arnold 8 in x 1 75 in Plastic Wheel Vendo ractor Supply Maximum load capacity SS Ib Tire type Solid Price 6 99 Shipping Tax 5112 Quantity 2 Total Pri 15 1 Appendix 3 Frame 1 4 A x 2 1 2 6061 T6511 Aluminum Extruded 48 Ve
51. Budgets 69 Mobility System Budget 69 Launching System Budget 270 Power Interface and Control System Budget Purchases 7 Project Plan and Management 275 Organization and Management 15 Fall 2011 Schedule Analysis 2 76 Spring 2012 Work Breakdown Structure 279 Spring 2012 Gantt Chart 83 Spring 2012 Network Diagram Appendices 87 Appendix Requirements Specification Appendices 89 Appendix Customer Needs Metrics Matrix 90 Appendix A 2 Tennis Court Dimensions and Test Grid 91 Appendix Area of Operation of MATT 93 Appendix Mobility System Components 94 Appendix 8 1 Motors 95 Appendix 2 Gearboxes Appendix 8 3 Wheels Appendix 8 4 Frame and Encasement Appendix C Interface and Control System Appendix C 1 Code Appendix D Power Supply Appendix D 1 Battery Selection Appendix E Launching System Components Appendix E 1 Launching Mechanism Components Appendix 2 Angular Targeting Mechanism Components Appendix E 3 Vertical Targeting Mechanism Components Appendix 4 Hopper and Feeder System Appendix Remote Control Components and Regulations Appendix G MATLAB MOSFET Thermal Calculation Appendix Sensors Appendix Motor Controller Components
52. MATT Mobile Automatic Tennis Trainer Interim Detail Design December 7 2011 Michael Gorman Pr MATT MOBILE AUTOMATIC TENNIS TRAINER MATT 1 Table of Contents Requirements Specification Overview Customer Needs Technical Requirements Specification Operational Description Design Deliverables Preliminary Test Plans Implementation Considerations Relevant Codes and Standards System Design Background System Overview Design Concept Block Diagrams MATT Level 0 MATT Level 1 Power Source System Level 2 Control and Interface System Level 2 Launching System Level 2 Mobil System Level 2 Functional Description of Subsystems Detail Design Mobility System Drive System Brake System y Frame and Encasement Power Requirements Design Drawings Launching System Launching MATT 2 Angular Targeting Mechanism 34 Vertical Targeting Mechanism 37 Hopper and Feeder System E Power Source System 48 Interface and Control System 50 User Interface Board 50 Remote Control 52 Sensor Systems 254 Motor Controllers 257 Microprocessor Programming 64 Budget 68 Budget Overview 68 Manufacturing Budget 68 Subsystem
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55. aced on top of the horizontal angle adjustment mechanism It was estimated that at most the mass of the launching mechanism and all of its components would be no greater than 22 68 kg or 50 Ibs It was also estimated that the entire apparatus would fit inside a 50 8 x 50 8 cm x 50 8 cm 20 in 20 in x 20 in box With this information known the mass moment of inertia was calculated as follows Eqn 10 Equation 10 models the system as cylinder where r is the radius of 0 254 m 10 in and m is the mass of the load or 22 68 kg From Eqn 10 the mass moment of inertia was calculated to be 0 732 kg m Then relating the angular acceleration needed for the mass moment of inertia using Eqn 11 torque value was calculated for the horizontal angular adjustment mechanism 11 A torque value of approximately 1 5 was calculated This method of determining torque assumes no friction is present in the system To ensure friction was accounted for an additional factor of safety of 2 was assumed yielding a required 3 0 N m Equation 2 was then used to estimate the power requirements for this system which was approximately 5 2 From the torque and speed requirements a motor was selected a motor was selected that could provide the required torque and speed without any additional gearing components The selected motor can be seen in Appendix E 2 1 The actual design of the angular targeting mechanism will consist of a turntable
56. ack shows to be not fast enough to meet our specifications the gear ratio in the gearbox can be easily changed so our specifications can be met The frame of the vertical targeting mechanism is composed of aluminum plates for the platforms and hinge More information can be found in Appendix E 3 2 A SolidWorks representation of the launching mechanism and targeting system is shown in Fig 26 MATT 40 Figure 26 SolidWorks representation of launching mechanism and targeting system 41 Hopper and Feeder System The hopper and feeder system consists of all of the components that deal with transporting the tennis balls from the hopper to the launching mechanism in a controlled and efficient manner The design of this system can be broken up into smaller components First is the hopper container itself The only design constraint on this part is that it must be able to hold at least 150 tennis balls and do so ina way that does not allow for spillage of the tennis balls while MATT is in operation The next component consists of the hopper rotor mechanism The rotor mechanism is what controls the feeding of the tennis balls for the hopper to the feed tube The rotor will rotate at a rate specified by the microprocessor feeding the balls one at a time into the feed tube The only constraints for the rotor is that it must be able to feed tennis balls at a rate of at most one tennis ball per two seconds and at least minimum rate o
57. aft dimensions 45 The rotor shaft was simulated to determine what loads it would be able to understand A torque of 2 was applied and finite element analysis was performed The results are shown in Fig 31 Based these results it was determined that the shaft wauld suffice for normal operating conditions and the event of a jam the shaft would fail long before the rotor itself This is desired since the construction of the shaft would require much less material Mises 5 21 ar 145 121 se 72 Figure 31 FEA for rotor shaft Hopper The next design of the overall hopper and feeder system was the hopper storage container The only requirement here was that it be able to hold the required number of 150 tennis balls when fully loaded The hopper will also need to be able to maintain the feed of tennis balls to the rotor as long as some still remained Therefore the hopper was designed to meet the minimum volume requirements as well as removing the possibility of tennis balls not automatically moving to the rotor Figure 33 shows the hopper design from an angled view of ease of viewing mechanical components Figure 32 shows the 46 top view of the hopper design The dimensions of the hopper are shown in both figures This design is approximately 50 greater the size of the minimum required volume to store 150 tennis balls Figure 32 Hopp
58. al angles required was calculated based on this operating range and the worst case scenario for shot placement This worst case scenario would be when the machine was as close to the net as allowed as far as possible from the center of the court and placing the shot on the opposite sideline directly behind the net From this information the maximum angle needed was calculated Figure 19 shows the dimensions used to calculate the maximum angle of 50 Worst shot location MATT Figure 19 mensions for horizontal angle calculati A few different design concepts have been considered to provide the mechanical horizontal angle adjustment The main methods have consisted of some sort of lever system or a rotating platform on which the launching system would rest The lever system would implemented with either pneumatic or hydraulic pistons or actuators which would require a large expensive component such as an air compressor or a hydraulic pump Due to the simplicity of the design the rotating platform for the launching system was selected A motor would rotate the platform through the required angular displacement A rough diagram of this system design is shown in Fig 20 Launching Mechanism Rotating Platform Horizontal Adjustment Motor Figure 20 Horizontal angle adjustment design concept drawing In order to determine the motor specifications for this mechanism the r
59. all feeding mechanism and motor assembly for each mechanism The launching mechanism will launch tennis balls at speeds between 4 m s and 45 m s and consists of counter rotating wheels The aiming mechanism will consist of both a vertical adjustment and an angular adjustment to provide for the specified angle ranges The feeding mechanism will keep a steady flow of tennis balls to the launcher depending on the selected setting This system will be powered from the power source and controlled via instructions from the microprocessor and motor controllers based on sensor input information Inputs 12VDC at 0 15 Control Signals Digital from Microprocessor and Motor Controller Horizontal Angle Two 0 5 VDC 0 50 mA Direction Bits Vertical Angle Two 0 5 VDC 0 50 mA Direction Bits Launching Speed 0 5 VDC 0 50 mA PWM Speed Signal Launch Signal 0 5 VDC 0 50 mA PWM Speed Signal Tennis Ball Feed Rate Delivery from hopper and feeder system at a rate less than or equal to 1 tennis ball every 2 seconds Outputs Shot Speed 4 45 m s Shot Direction 0 50 vertical displacement 40 140 angular displacement Shot Feed Rate Less than or equal to 1 tennis ball every 2 seconds Tennis Balls Wide variety of shots to player Subsystems of Launching System launching Mechanism Description The launching mechanism will provide a means of launching the tenni
60. an one remote control can be sending data at the same time or else the transmitted signals may combine with one another to produce an invalid message that the receiver will ignore Transmit Antenna m im ia ise ee mm Ste P Key 0 Stop Figure 40 Remote control transmitter The encoder and decoder are specifically mentioned in the transmitter and receiver datasheets as an example application The mentioned datasheets be found in Appendix RF2 Based on this information it is reasonable to conclude that the given devices will function properly in a configuration similar to the supplied example circuits Figure 41 Remote control receiver The remote control transmitter will have a start and a stop button For future designs the remote control could easily support two more buttons without modifying the current design However 54 the maximum number of buttons could be expanded up to 2 16 if deemed necessary The FCC regulations for this type of operation can be found in section 15 231 of FCC rules and regulations and can be seen in Appendix This section states that the remote control must be a periodic signal instead of continuous signal in order to be appraved for use The remote control will be housed in an enclosure as see
61. azon 86025 5632 1 N A 56 32 Jack Rotary Spark Fun COM 09288 5095 6 53 56 5570 Potentiometer Black Knob Spark Fun 09998 5095 6 5 70 RF Receiver Spark Fun WRL 10533 5495 1 N A 4 95 RF Transmitter Spark Fun WRL 10535 3 95 1 3 95 Signal Encoder _ Jameco 123730 8175 2 N A 3 30 Signal Decoder 123748 165 2 N A 3 50 Dip Switch Jameco 139012 5095 2 N A 5190 74 1 2 4 40 Spacer 108371 5045 4 1 80 MOSFET Driver Digikey IRS2110PBF 5460 4 N A 18 40 ND MOSFETN CH Digikey IRLB3034PBF 5260 10 N A 26 00 ND Schottky Diode SBI245CT ND 5167 10 31670 Motor Driver Digikey 497 3565 LND 51125 1 N A 11 25 0 50 Resistor Digikey PPCSW SOCT 5097 2 N A 5194 Enclosure Digikey SRCAB 2G ND 5728 1 N A 7 28 82032 Digikey SY189 ND 5041 4 N A 1 64 10 00 1 4W 1 Digikey 10 0KXBK ND 50126 5 N A 0 63 Resistor 130k01 AW 1 Digikey 13 0KXBK ND 0126 5 N A 50 63 Resistor Tactile Switch SWA00 ND 5030 2 N A 0 60 Coin Cell Battery Digikey BS 3 ND 5072 4 N A 5288 Holder Schottky Diode Digikey 145822 0413 10 N A 4 13 TPMSCT ND Mounted Ball McMaster Carr 5913 71 1133 4 54532 Bearings Idler Sprocket McMaster Carr 6663k22 2222 1 N A 52222 Motor Sprocket McMaster Carr 6280 331 5886 1 N A 8 86 Wheel Sprockets McMaster Carr _
62. ce and stability there will also be two pivoting caster wheels attached to the base of the machine for support and ease of direction change Inputs Power Source 12 VDC at 0 25 A Mobility Control Signals Movement Speed Two 0 3 3 VDC 0 50 mA PWM Speed Signal gt Movement Direction Two 0 3 3 VDC 0 50 mA Direction Bits Outputs Lateral Motion Parallel to the net 0 65 1 3 m s Braking System Description The braking system will slow and stop the machine automatically on command The braking system will be controlled electronically by reversing or slowing the drive motors via instructions provided by the motor controller Inputs Power Source 12 VDC at 0 25 A Mobility Control Signals Movement Direction Two 0 5 VDC 0 50 Direction Bits Outputs 4 machine can stop itself once in motion 124 Detail Design Mobility System The mobility system is the system that will make MATT a unique product Though there will be nothing revolutionary about the design of the mobility system itself the concept of a moving tennis ball machine is new and innovative The design team has looked through many different patents and resources and has not yet found another tennis ball launching machine that moves to provide variability of shot origin to the player The design of the mobility system was based on three of the explicitly stated te
63. chnical requirements specified The first two are related to the maximum mass that the mobility system must be able to support A specification for portability was stated that the machine will weigh less than 60 kilograms when not loaded with tennis balls It was also stated that the machine must be able to hold a minimum of 150 tennis balls when fully loaded which would amount to a minimum additional load of 8 91 kilograms Therefore the total mass that the mobility system was designed to handle was taken to be 70 kilograms for simplicity The next design criterion that was considered was the specified speed of the machine It was specified MATT would traverse the court in 20 0 1 0 seconds The range of operation of the MATT was also specified as well It was specified that MATT would move laterally while remaining within 6 0 0 5 meters of the center of the court at all times Based on this movement specification it was shown that MATT would need to move a maximum of 13 0 meters in a maximum of 20 0 1 0 seconds for a velocity of 0 65 m s For design purposes the velocity used was actually 1 5 times as much meaning that MATT would traverse the maximum distance of 13 0 meters in 15 seconds yielding movement velocity of 0 87 m s With these design criteria determined the next step was to calculate a value for a worst case scenario torque so motor and drive train system could be designed accordingly To do this a method of estimating fricti
64. complicated to do in a simple digital circuit design so we have chosen to use a microprocessor system microprocessor that was selected is dsPIC33FJ128MC802 made by Microchip Technology Inc The microprocessor has the following features that made it desirable for this project 2110 Pins Up to 40 MIPS 9 ADC Pins 8 16 bit 128 kB Flash Memory MATT 65 16 kB RAM 4 Input Capture Pins 4 Output Compare Pins 1ECAN Module One issue arose in that this microprocessor does not have enough IO pins to handle the information flow The calculated need for information flow is 28 6 from UI 2 from Remote 10 from Sensors 10 from motor controllers To fix this problem we have decided to use two microprocessors with a digital information bus connecting the two This does not cut into our spending budget because we have already received multiple free samples of this microprocessor Also this allows for parallel processing which will help optimize the efficiency of the calculations The master microprocessor will handle the remote and sensor system as well as the mobility motor control The slave will handle the user interface board as well as the launching feeding and targeting motor control The master microprocessor will need to be able to tell the slave microprocessor what state the machine is in running or waiting and the machine s position on the court Figure 56 is the four main program flows for t
65. configured remote control receiver system Test Data Functioning remote control system Test Data Functional programmed microprocessor and remote control receiver interaction on breadboard Accurate PCB design of the control and interface system Accurate PCB design of the remate control transmitter Functioning launching system assembly Test Data Working launching mechanism Test Data T Jan 20 Mi Feb 19 16 T Jan 24 Jan 25 Mi Feb 3 dJanS T Jan 16 T Jan 16 Jan 16 T Jan 227 Jan 28 Mi Feb 5 Jan 22 Jan 28 Feb 6 Feb 15 1 9 Mar 1 9 Jan 27 Hopper System Targeting System Sensor Integration Launching Controller Launching System Operation Mobility System Build Drive System Braking System Sensor Integration Mobility Controller Mobility System Operation Final Design Review Build and test the hopper and feeding mechanism Build and test the horizontal and vertical components of the launching system Mount the sensors to the launching system and calibrate if necessary Interface the motor controller for the launching system to the motors Test the launching system to confirm that it will meet required specifications and modify the system if necessary Assemble and test the mobility system Build and test the drive system Test the braki
66. crasrelerence histo the chats blo Tie rachat provides erp mines the second chat prove the 20 hour raro usualy asd ber af eas 20 over requirement capacy vanes wih and bates AMP Load VS Minutes MATT 175 Series Versus Parallel Installations Batteries arranged sient increased or increased voltage 1o maich your spere equroment Ira ecramely important not to mix Battery types Flooded AGM Parallel installation 10 and stem that and mails a specie This doubles he ower errr ang ofthe battery hte raining te Thus ous in paras vil ue yoa vat syam Series Installation keegan The bananas a mangement e ang em o 25 amp m sot ore ey pese tothe second batarya Installation And Maintenance Esto shout always be ren Bates eae gases ree arg hase and soul norba erpota to spark or omo When saang battery r enportan to voe erher 2 Davee tedoun system o he ater once Tre wi recite unmcceesry rasan Nea su bat
67. ct encasement with any necessary modifications to meet acceptance tests Ensure that the device is able to complete the required specifications and modify the system if necessary Complete testing of system Instructions to the user on how to operate the product inal detailed report of the product s functionality Present product to faculty Public product presentation Functioning system Protective encasement attached to the device Functioning system that meets required specifications Fully functional device Document Document Presentation and demonstration of functioning system Complete functioning system 1 Ivan M Mark Mi Michael P Prosper T Trevor Mar T Mar 20 Mar 4 17 Mar 20 Apr 6 MATT 83 80 sqa ezuer pre sossazid 20 90 2 6 z sterow _ cpm o or 1 6 wow sargen vel os pung somos 6 pueg Spring 2012 Gantt Chart MATT 84 o soupeoy SCA 2307 poasy sseupeay ost onu sas ac
68. ct on actual budget Price of 5 for all 3 D printed components which is not taken from the actual budget 72 Power Interface and Control System Budget Table 8 Electrical component detailed budget Description E Quantity RF Transmitter Spark Fun WRL 10535 5395 1 3 56 7 51 RF Receiver Spark Fun WRL 10533 495 1 N A 5455 Rotary Spark Fun COM 09288 095 6 5570 Potentiometer Black Knob Spark Fun COM 09998 095 6 N A 5 70 SignalEncoder Jameco 123730 175 2 5330 Signal Decoder Jameco 123748 5155 2 53 50 Dip Switch 139012 5095 2 5190 1 2 4 40 Spacer 108371 5045 4 5180 MOSFET Driver IRS2110PBF ND 5460 4 N A 51840 MOSFET N CH IRLB3034PBF 260 10 26 00 ND Schottky Diode SB1245CT ND 5167 10 N A 16 70 Motor Driver 497 3565 1 ND 51125 1 51125 0 50 3W Resistor PPC3W SOCT 097 2 N A 1 94 ND Enclosure SRCAB 2G ND 5708 1 N A 7 28 82032 SY189 ND 5041 4 5164 10 0k0 1 4W 1 100KXBK ND 50126 5 50 63 Resistor 13 0kQ 1 4W 1 130KXBK ND 0126 5 N A 50 63 Resistor Tactile Switch SW400 ND 0 30 2 N A 0 60 Coin Cell Battery BS 3 ND 5072 4 N A 2 88 Holder Schottky Diode 1N5822 0413 10 N A 413 TPMSCT ND 12V Battery Searcy Battery 57995 1 5 60 585 55 Warehouse Prin
69. de wm StMtcraiorance Zodar ana aon A SV suny ens mee Sra comb the cr ope Hon cens s one of Pe key features o he technology the 1287 ver compe 227 is nara used wa an 298 or cer of ese devices make rest ott eos flow USE con wo sem corrclad Dye TTL gc Pc once Gmtorconcectoner Po kwer Yar are broug oto tomes ure 2 For ma gn curent St Swing tis rando araztua povera up t 150 2A per brags Slog foresee css patien ard o alow cene connection i e L237 or sher corral Inch nce pns sr e LEN are unecessary The L2E6N Sead Matin ac pomer package tx sabe en Figure2 The contains two bridge vere four push pu stages each conttolied by two inputa and an enable input External emitter connections are provided for current tenes resistor The L293E hae external connections for four TX stepper motor i
70. diators operating under the provisions of this section shall demonstrate compliance with the limits on the field strength of emissions as shown in the above table based on the average value of the measured emissions As an alternative compliance with the limits in the above table may be based on the use of measurement instrumentation with a CISPR quasi peak detector The specific method of measurement employed shall be specified in the application for equipment authorization If average emission measurements are employed the provisions in 15 35 for averaging pulsed emissions and for limiting peak emissions apply Further compliance with the provisions of 15 205 shall be demonstrated using the measurement instrumentation specified in that section 3 The limits on the field strength of the spurious emissions in the above table are based on the fundamental frequency of the intentional radiator Spurious emissions shall be attenuated to the average or alternatively CISPR quasi peak limits shown in this table or to the general limits shown in 15 209 whichever limit permits a higher field strength The bandwidth of the emission shall be no wider than 0 25 of the center frequency for devices operating above 70 MHz and below 900 MHz For devices operating above 900 MHz the emission shall be no wider than 0 5 of the center frequency Bandwidth is determined at the points 20 dB down from the modulated carrier d For devices
71. digital converter with the values of 0 V to 3 3 V representing 0 1 to 0 5 Hz Launching Speed or Vertical Angle Since our machine calculates the trajectory necessary to hit a selected target This means that the vertical angle and launching speed are directly related Therefore a user needs to only have control over one of the two factors However some users may wish to control speed while others wish to have control of vertical angle In order to do this we have chosen to have a minimum and maximum dial and switch to decide if they control speed or vertical angle The switch will tell the microprocessor if it should interpret the analog signals on a range of 0 40 and 10 50 for minimum and maximum vertical angle or if it should be interpreted as 10 90mph and 20 100 mph for the minimum and maximum launch speed If the minimum is set to higher than the maximum the microprocessor will assume the lowest possible value for the minimum Remote Control The radio frequency remote control will operate at 315 MHz using ASK modulation The remote control transmitter schematic can be seen in Fig 40 The address byte will be set with a dip switch inside 53 the transmitter enclosure that must correspond with the address byte set by the dip switch on the receiver The remote control receiver schematic can be seen in Fig 41 The address byte ensures that up to 2 256 MATT machines can operate within the same local area However more th
72. e Tem 18 v Peak Wavelength 660 Dominant Wavelength gt Reverse Leakage Current wo Viewing Angle 2012 Spectrum Line 20 NOTE THE DATAS TESTED BY IS TESTER 01 Date 20051019 Page 25 Appendix Microprocessor MICROCHIP MATT 178 dsPIC33FJ32MC302 304 dsPIC33FJ64MCX02 X04 AND dsPIC33FJ128MCX02 X04 High Performance 16 bit Digital Signal Controllers High Performance DSC CPU compte optimized instucion ude estes Lear ests uo to Kee ssuraton Beeren 16 18 muti operatione 218 and 1816 divide operons Upto snis to up Direct Memory Access OMA Kyte dual pored DA bute area CPU code ino Mes pooh eas supp Timers Capture Compsre PWM upto make a Tenth npa fer 1 16 b capte flore seep FIFO on each Output Compare up tu Vetere esie lt Provides cock clad an som functors interrupt Controllers ie niorit sources Up ta tes Savon levels Digital Vo Paihora Slot Up 35 pe Change ter upto 31 pi
73. e entire range of motion The materials selected for this application are shown in Appendix E 4 3 Power Source System The power supply is one of the most important components to this machine It will consist of one 12 VDC 70 Ah lead acid battery This battery can continuously supply 42 for one hour In addition to this the battery has a maximum discharge current of 520 A for a period of 5 seconds which could be used when needed Because there are many subsystems on the machine that need different amounts of power the battery power will be reduced to the correct voltage and current needed by each of these subsystems There will be a low voltage indicator to indicate if the voltage drops at or below 11 5 VOC as illustrated in Figure 34 There will also be a master power switch that will turn the machine on or off which will be independent of the remote The battery unit needs a charger but there will not be a supplied charger The user has to supply a personal charger Figure 35 does not show systems that will be directly attached to the battery which are mainly all the motor controllers Low Battery LED 3306 Power Switch RI ro the microprocessor Tote d is T D i Es BEEN DLL ui R3 tothe RF Receher wo ves
74. ea of concern here is with the launching system The launching system has been designed but has not been finalized due uncertainties in part selection and design analysis The main concern here is the be customized on site An electric scissor modification of the vertical targeting mechanism which jack was selected for the main vertical targeting component but in order for the part to work as desired modifications to the gearing may be necessary The next major concern was in regard to the design of the horizontal angular targeting mechanism The angular targeting mechanism design has been completed but not finalized since some custom manufacturing will be necessary MATT 78 The last major schedule deviation was related to the hopper and feeder system design hopper and rotor system has been designed and a large portion of the components have been manufactured on site via the 3 D printer The rotor the rotor shaft the rotor gear and the motor pinion have all been printed on the 3 D printer The feeder system has not yet been completed since it is highly dependent on the geometry of the launching system Once components are chosen for the entire launching system the entire feeder system design can be finalized Though the design of MATT had fallen somewhat behind schedule in the previous weeks the design team has made great strides toward meeting all deadlines and following the schedule in the last weeks of the semester T
75. eing raised 10V above its drain voltage in order to function as a high side switch The current going through the motor resistance is 11 5A and the voltage drop across Q1 is shown to be 16 635 mV This shows that the on state resistance of the motor controller drops an almost negligible amount of voltage Verba woman luv HN H pum MES SRLBSO34PEF 2252 Ein E Lr Figure 51 H Bridge Simulation Launching Motor Controller The launching motor will need to spin in only one direction The direction of current travel will never need to be reversed so the motor controller and the wheels will not need braking functionality The motor controller will then essentially consist of a high current N Channel MOSFET used as low side switch The microprocessor will control this motor by sending 2kHz PWM signal that will vary the amount of power being allowed to flow through the motor The maximum continuous current that will be drawn by the launching motor is 4 754 The MOSFET driver will be Microchip s TC4432 as seen in Fig 52 which has an output current rating of 1 5A The gate resistor R1 has been chosen so that the maximum output current of the TC4432 cannot exceed its 15Alimitwhere 12 8 PWM IN V Battery
76. elated to what difficulty setting the user chooses e Precision Atleast 90 of the tennis balls launched will go over the net and land within the tennis court boundaries with the constraint that wind speeds are no greater than 5 meters per second The tennis court will be divided into a grid of six sections for testing purposes as seen in Appendix 2 Safety The majority of moving parts of the machine will be in an encasement to protect against User injury Moving parts such as the launch mechanism and the ball feeder may not be completely enclosed and warnings about such hazards will be posted on the machine All electrical components will be properly covered and insulated to prevent electrocution Durability The machine will be constructed to withstand tennis ball strikes without damage The encasement will protect tennis balls from getting under the machine and prohibiting proper operation The machine will also resist light rain for at least 3 minutes Ease of Use Machine controls will be readable and accessible to but not limited to a standing user Operational instructions will be labeled clearly on the machine The machine can be started and stopped remotely from up to 30 meters away Operational Time The machine will operate continuously for at least 60 minutes with the constraint that constant supply of tennis balls is provided The maximum storage capacity of the machine will be a minimum of 150 tennis ball
77. elocity 0 785 rad s 7 5 rpm a power requirement of 0 23 W was calculated Adding an additional factor of safety the design team specified that power requirement of 1 5 W would be used for selection of drive components The only required component from this system that will need to be purchased is the motor With both low torque and low speed requirements an inexpensive motor has been selected to power the rotor The motor that was selected is shown in Appendix E 4 1 The rest of the drive components for the rotor system have been constructed and analyzed on SolidWorks and will be printed the 3 0 printer where applicable Based on the selected motor which could provide a maximum torque of 0 24 N m 3 1 gearing ratio was designed The minimum pinion size of 15 teeth was chosen and designed to fit directly on the shaft of the selected motor To achieve the desired gear ratio a 45 tooth gear was designed as well Both gears can be seen in Fig 29 Figure 29 Hopper rotor pinion left and gear right Both gears are 15 mm thick Finite element analysis was performed on each gear to verify they would be able to withstand the loads under normal operating conditions The results for the gear analysis indicated that under the normal operating conditions with torques below 1 neither gear would fail The next component designed was the rotor shaft whi dimensions labeled is shown in Fig 30 Figure 30 Rotor sh
78. endix Hopper and Feeder System Appendix 4 1 Motor Bipolar Stepper Motor M 200 ROB 09238 Vendor Trossen Robotics Detent Torque 120 Price 14 95 Shipping Tax Quantity 1 Total Price 22 93 MATT 1122 1123 ww 3 rows DE wwionow _ wona MATT 124 Appendix E 4 2 Hopper Material Garden Zone 24 x 25 Welded Cage Wire Fence 432425 Vendor ACE Hardware Item Description 4 x25 feet 1X2 mesh openings e 14 gauge galvanized wire Heavy gauge utility mesh 25 foot rolls Price 528 99 Shipping Tax 5232 Quantity 1 Total Price 3131 Appendix E4 3 Feed Tube Imperial 3 x 8 Semi Rigid Aluminum Duct Vendor Lowe s Item Description Flexible Semi Rigid Aluminum 8foot in length Price 5986 Shipping Tax Quantity 1 Total Price _ 9 86 TT 1125 Appendix Remote Control Components and FCC Regulations 126 TWS BS MODULE series Wireless Hi Power Transmitter Module RF ASK Version History Version Date Changes ZI 01 2002 m su 05 2008 20 210 7 Eaton
79. ensor with Vishay Semiconductors Transistor Output BASIC CHARACTERISTICS Tare 25 G unless EU E emm ENTE 1 MATT 148 5000 TCRTSOOOL Vishay Semiconductors Reflective Optical Sensor with Transistor Output Spe 14 i3 E i4 PACKAGE DIMENSIONS n vi ees TERTSO00 ae Taaa o a Daae rbe ET MATT 149 TCST1103 TCST1202 TCST1300 VISHAY meer Vishay Semiconductors Transmissive Optical Sensor with Phototransistor Output m mensions Lx Wx Hin mm 11963 108 tot is ma ROHS estos ji oor ouput ourer under sast c 0 5 Deviate boca teer mer wave 60 rm ood Poj es lated rarest APPLICATIONS leu usenet ener wich Shen toce vape Ig Tress pas amose meote POS ta apata vicis tne aede PRODUCT SUMMARY em B ve a ORDERING INFORMATION Creer L3 LIII I ILI ABSOLUTE MAXIMUM RATINGS 1
80. ent machine conditions and remote control signals The microprocessor then processes the information making the decisions and calculations necessary to set up the next shot and keep the machine from leaving the court It translates this information into signals to send to the appropriate systems Inputs 4 Remote Receiver Start Signal SV High Pulse Stop Signal SV High Pulse User Interface Target Distribution Two 0 5 VDC 0 50 mA Signals Launching Speed Range Two 0 5 VDC 0 50 mA Signals Height Range One 0 5 VDC 0 50 mA Signal o Firing Rate One 0 5 VDC 0 50 Signal 4 Sensors Current Court Position 32 bit coordinate values Current Horizontal Angle 16 bit or 32 bit angle values o Current Vertical Angle 16 bit or 32 bit angle values _ Power Source 3 5 VDC 0 50 mA e Launching System Control Signals Horizontal Angle Two 0 5 VDC 0 50 mA Direction Bits Vertical Angle Two 0 5 VDC 0 50 mA Direction Bits Launching Speed 0 5 VDC 0 50 mA PWM Speed Signal Launch Signal 0 5 VDC 0 50 mA PWM Speed Signal Mobility Control Signals Movement Speed Two 0 3 3 VDC 0 50 mA PWM Speed Signals Movement Direction Two 0 3 3 VDC 0 50 mA Direction Bits 21 launching System Description The launching system will consist of a launching mechanism an aiming mechanism a tennis b
81. equired speeds accelerations and torques of the system needed to be determined Two different specifications affected the design here The first was the requirement that the machine have a horizontal angular displacement totaling 100 The second was the specification that MATT s horizontal angle adjustment be able rotate through the widest range of angles in 3 0 1 0 seconds This means that MATT would be able to rotate through 100 in as few as 2 seconds starting from a stopped position To calculate the torque MATT 36 requirements and therefore select a motor the highest required angular acceleration needed to be calculated To calculate an initial angular velocity Eqn 9 Eqn 9 was used where The minimum required angular acceleration required was calculated to be 0 873 rad s However if this acceleration were applied for the whole two seconds the angular targeting mechanism would speed past its desired angle To account for this the mechanism will need to apply acceleration and therefore a torque and then apply an acceleration and stop the rotation at the desired angle all in the given time requirements Using only equations of motion for rotating bodies an estimated value for the required acceleration to slow and stop the machine as desired was recalculated to be approximately 2 1 rad s The next step was to determine the mass moment of inertia of the launching mechanism that will be pl
82. er top view 147 Figure 33 Hopper design showing location of rotor The hopper will be constructed out of a material that is able to withstand tennis ball strikes There is no need for any excessively strong material however because the hopper will not be bearing much load Therefore the hopper will be constructed out of welded wire mesh which can be seen in Appendix E 4 2 The wire mesh will be bent to the desired shape and then supported with aluminum angle iron structural members where needed The wire mesh may also be used to cover other portions of the frame of MATT where necessary Feed Tube The feed tube will be the means of transporting the tennis balls from the hopper rotor to the launching mechanism The ball will rotate through the hopper rotor fall into the feed tube and then move to the launching mechanism only under the influence of gravity The feed tube will be constructed out of flexible plastic tubing The tubing will be connected to the back of the launching system and will move with the launching wheels as they rotate through the total range of horizontal angles Therefore the tube must be able to flex from side to side without causing extra loading upon the horizontal targeting mechanism The flexible tube will be made from a semi rigid aluminum vent which will have enough structure for smooth rolling of the tennis ball but will have enough flexibility connect to the launching mechanism and provide for th
83. ery amis t Addon vo oar ho trae and comers wit a The shout be eso Eve severa Faure wi rest por oncom and irre Ducem Be erc ties mors amc to bo draun run When nailing a now battery sr t remova any plasie banery protectora before Maintenance A Exide marine terion exce AGM cape Po ovate con be checked regulary You sous che eer eel every mon Wher dorm a battery ft the wir check and ifm warar er fly sore in lace When preparing Ihe ater wer atrage recharge batery charge MATT 176 E 72 UT1871 81 M1 5 0mm ROUND LED LAMP Absolute Maximum Ratings 25 Parameter Symbol Unit Power Dissipation Reverse Voltage 4 v DC Forward Current 30 ma Reverse Leakage Current 100 Peak Curent Duty ims Pulse Width Operating Temperature Range 2510 85 Storage Temperature Tag Lead Soldering Temp from bods for 5 seconds 260 Electrical and Optical Characteristics Parameter Symbol Condition Min Typ Mex Unit Luminous Intensity w ma 429 750 med Forward Voltag
84. et meters pase uneo overt mor av phase mau of the deve are avaiable e regular L297 ons specia version calec ADVANTAGES aver combinston a nanan te cence enue metra m poner derien ve res purpose ry tew componens are equrez asemby cos ard the varden on re micro pac ques degee osea any siage Figure 1 In thin configuration an 1297 stepper molor controller ans L298 dual driver combina form a compiats micrenroeseser to binlar stopper motor interfaco MATT 171 APPLICATION NOTE For bipslar molore nth winding cares up to 2A the 287 shoul bese wits for winding curente 1293 vil alo be ure Fighe cures win catre tr unpoar mobis a daingin such as De sugong ha boc caram Ire item Dpgicaters of 1287 be ound carnage poston daly poston pace ce roan yer prs ced cuo vs dat se paper tape opal characte rennes eco vaes na L297 ema
85. f one tennis ball per ten seconds Obviously the rotor must be able to withstand the load of many tennis balls on top of it as it spins as well as operating consistently without jamming Lastly the feed tube will transport the tennis from the rotor to the actual launching mechanism The ball will move through the tube and into the launching wheels only under the influence of gravity Rotor The first component designed from this subsystem was the rotor The general shape and function of the rotor was borrowed from the Prince tennis ball machine that was donated to the design team The part was designed specifically with the use of the 3 D printer for manufacturing in mind do this it had to be ensured that the part was no greater than 20 32 cm 8 in wide The rotor was designed under this constraint yielding a four tennis ball holding rotor To verify that the part could be manufactured in the 3 D printer finite element methods were used to test the part of failure under loading The hopper rotor dimensions can be seen in Fig 27 The mass of the 250 tennis balls was applied as a force of 145 7 N on top of the rotor to provide a greater load than the required minimum of 150 tennis balls An initial value of 10 for torque was applied the rotor Intuitively such torque is extremely high for the operating conditions but in order to determine if the part would fail under any circumstances this higher value was used as a baseline The load
86. for sections 1 and 3 25 for section 2 15 for section 5 and 10 for sections 4 and 6 The margin of error will be 3 for all sections The maximum number of tennis balls that can be placed in the hopper will be counted The machine will be operated while tennis balls are allowed to strike the machine to test its durability Using a pitching machine 100 tennis balls will be launched at the machine with initial speed of 30 meters per second measured by radar gun This test will be performed only on the front section of the machine 4 The machine will be weighed on a simple scale The machine will be visually inspected to determine if all moving parts are properly encased or noted with proper warnings electrical components will be inspected in a similar matter to determine if they are properly covered and insulated 4 The machine will be sprinkled with water for a period of 3 minutes Implementation Considerations Service The user will be able to transport the machine to the tennis court by rolling it The user will power up the machine and turn it on either locally or remotely The machine will then move sideways along the opposite backside relative to the player of the tennis court launching tennis balls to the player All movement of the machine will be lateral moving no more than 6 0 0 5 meters from the center line of the court and remaining anywhere from 10 0 0 5 meters to 12 0 0 5 meters from the net w
87. g machine is safe The machine is portable NOW awn Each of these needs was broken down into sub categories that were related to the actual technical specifications The needs metrics matrix shown in Appendix A 1 shows these relationships 5 Technical Requirements Specification Mobility The machine will be programmed to move itself laterally and remain within 6 0 0 5 meters from the center of the court at all times This range of lateral movement will cover the entire width of the doubles lines on the tennis court The machine will be able to operate anywhere from 10 0 0 5 meters to 12 0 0 5 meters from the net with the motion of the machine intended to be parallel with the net This range of motion can be seen in Appendix Diversity The machine will launch tennis balls at an initial speed between 4 and 45 meters per second It will launch tennis balls at vertical angles between 0 and 50 and horizontal angles with a range from 40 to 140 The horizontal angles will be measured from a line parallel to the net where rotating counter clockwise yields positive angles The maximum time the machine takes to adjust its aim through the widest range of horizontal or vertical angles is 3 0 1 0 seconds The machine will travel the entire width of the court in less than 20 0 1 0 seconds Randomization of shots will be provided within user set limits meaning that the amount of randomization will be r
88. he 2 microprocessors With flow a being on the master microprocessor and flows c d on the slave Master Program master microprocessor will stay in a busy waiting state waiting for the signal from the remote telling it to start It will proceed to move to the right until it reaches the right most edge of the base line for calibration purposes Then it will send the signal to the slave microprocessor to switch to running state and begin sending the stored court position to the slave During each timer interrupt it will determine what fine adjustments need to be made to remain on the baseline and set the movement for the machine Using the encoders it will determine how far it has moved and adjust the stored court position accordingly Upon receiving the brake signal it will stop the machine movement switch the slave into waiting state and reset the program to the busy waiting state Slave Program The slave microprocessor will continuously interpret the user interface into stored data until it receives the signal to switch to the running state Upon switching to the running state the launching and feeding motors are set to start running During the periods between timer interrupt the main code will determine the point to be targeted after the next launch The timer interrupt checks to see if a ball has been fired If one has a flag is set to tell the main code to send the next target Then the timer interrupt gets the stored court position fr
89. he spring work breakdown structure will not need to be modified to account for these delays as they should all be completed before the end of the semester Based on how the fall semester has panned out some adjustments will be made accordingly to ensure that the construction and testing of MATT proceeds according to plan The main adjustment will be that the mechanical engineers will attempt to complete all major system constructions as early as possible to allow for maximum integration and testing time MATT 79 Structure lanned Spring 2011 Schedule Breakdown Structure Spring 2012 Work Brea Table 11 Task ID Task Name Deliverables Duration Engineer s Project Management Ensure that the Budget Statements __ Jan 9 M project teamison schedule Apr 29 schedule and meets budget constraints Documentation Records of all Design reports da 9 documents tests schematics flow charts 29 design work etc Component Build Complete assembly of Subsystems are b 9 IMMIPT subsystems designed Mar 1 Power System Implementation and Working subsystem Jan 9 testing of the power _ that provides the Feb 24 subsystems correct voltage and current values Power Source Test the power Functioning Power danS P capabilities of the Source that meets 19 power source exceeds necessary power ratings Low Voltage Indicator Build the low voltage Working p
90. her currents than what the horizontal motor will need but the high current rating also means the motor controller has relatively low losses The drain to source resistance of each leg is approximately 45m0 This means the power losses while travelling in onedirectioncanbefoundby 067 02045 404 Hopper Rotor Motor Controller The hopper rotor motor that sends balls from the hopper to the launching mechanism will be a stepper motor The use of the L297 chip from STMicroelectronics controls the more difficult functions of controlling the signals to stepper motor This will be coupled with STMicroeclectronics L298N chip to drive the stepper motor controller Appendix gives a brief overview of the features of this setup The chopper circuit will be determined after testing the characteristics of hopper rotor motor The microprocessor controls the hopper motor controller by first enabling the L297 chip by setting the ENABLE pin high Then the microprocessor can select whether to use the stepper motor half full mode by setting pin 19 appropriately The direction will always be the same so pin 17 will be tied to the desired accordingly To move the stepper motor the microprocessor then only has to send a clock signal to pin 18 at the desired frequency of rotation Figure 55 Hopper Rotor Motor Controller Microprocessor Programming The on board logic necessary do the ball trajectory calculations too
91. his battery can be found in Appendix 0 1 MATT 50 Interface and Control System Most of the cheaper machines available on the open market have manually controlled targeting This means that the user has to set the speeds and angles on their own Sometimes even running the machine multiple times till he she gets the settings right However these are also stationary machines adding the complexity of a moving machine base requires real time adjustments to speed horizontal angle and vertical angle To accomplish this we have chosen to include an electronically controlled targeting system with an onboard logic and control system This system will also handle controlling the movement of the machine itself and interpreting implementing the user s instructions We have decided to implement this in the following subsystems User Interface Board Remote control Sensors Systems Motor Controllers Microprocessor Programming User Interface Board In order to meet the requirement of matching the machine to the user s skill level we have chosen to give the user indi factors Launching Distribution Launching Rate and Launching Speed or Vertical Angle Figure 36 is a LabVIEW simulation of the User interface The Physical Appearance is what the user will actually see with the labeling made clearer The Electrical Signal section is the electronic value of the dials The Digital Dials is what these values will interpreted a
92. hown in Fig 7 Electrical Power 12V 0 25A Electrical Motor Control 0 33 V PWM x2 O or 33 V signal x2 0 65 13 m s Brake Control 0 3 3 PWM x2 Movement Control SS 0 0r 3 3 Vignal x2 0 3 3 V PWM x2 0 or 3 3 V signal x2 7 Level 2 block diagram for mobility system and its subsystems 17 Functional Description of Subsystems Power Source Description The power supply will consist of one 12 VDC 70Ah lead acid battery The power will then be reduced to the correct voltage and current needed by each of the other systems on the machine There will be a low voltage indicator to indicate if the voltage drops below a certain level There will also be a master power switch that will turn the machine on or off which will be independent of the remote Inputs Power 12 VDC 0 42A from battery Outputs Control and Interface System 3 5 VDC 300 mA launching System 12 VDC 0 15 A System 12 VDC 0 25 A Subsystems of Power Source Low Voltage Indicator Description The low voltage indicator is a circuit that will light an LED once the voltage of the battery drops at or below 11 5 VDC Power Source Electrical power greater than 11 5 VDC 0 10 Light 75 mcd when voltage drops at or below 11 5 Power Splitter Description The power splitter will distribute the required am
93. i pira efe 38v ESV nib coe arain cnigurston on preva eer ploy sek on at VO On chip Flash and SRAM Fash program memory pte 128 Kbytes Date SRAM 16 Ken Boot Secure and General Securty for program Fash MATT 179 dsPIC33FJ32MC302 304 dsPIC33FJ64MCXOZ XO4 dsPIC33FJ128MCX02X04 System Management resonator Fr negated Phase Locked Loop PLL Power Management Onchp2sv vatage regulator ide and Doze maces win tost wakeup Analog to Digital Converters ADCS 1 1 Mops or 1228 500 conversion ao and four samples 10 bit ADC Us tonne chonnes retener ot ur umen sont Audio Digita to Analog Converter DAC Comparator Module Tuo analog comparators wih contguraton CMOS Flash Technology Low power eges Fas tte 235v 210 operating volage Motor Control Peripherals dependet or Coripemenry mods 2 or conl Trager T conversions Te tours 1220 H Tor Cage tnea lon wr Cor duty 1 dee me aut Eege aienea
94. issor jacks This design is shown in Fig 22 MATT 38 Top plate Support Lifting Members Threaded Support Screw Figure 22 Custom scissor jack design in SolidWorks The custom scissor jack had a threaded support with an additional sleeve section for reinforcement purposes as seen in Fig 23 Figure 24 shows the teeth on the lifting members The teeth prevent the scissor jack from moving sideways Threaded sleeve Figure 23 Threaded support with additional sleeve Figure 24 Teeth on lifting members to prevent side motion MATT 39 Simulations were performed in SolidWorks which showed that the design was strong enough for its purposes Although its volume was approximately 30 cubic inches meaning it would cost approximately 150 dollars to have it printed A more viable option was then found an electric car scissor jack shown in Fig 25 which is nearly three times less expensive Gearbox Figure 25 Electric car scissor jack The electric car scissor jack is composed of a motor and a gearbox connected to a regular car scissor jack Because the electric car scissor jack can support maximum load of 2200 Ibs no stress strength calculations were performed More information can be found in Appendix E 3 1 information was found on how fast the scissor jack can go up or down besides watching videos of similar product on the internet Although if the electric car scissor j
95. ith all of its power outputs to the various subsystems Electrical Power 12V 0 25 Electrical Power 12V ower Input 0 15 Electrical Power Figure 4 Level 2 block diagram of power source system showing individual subsystems 14 Control and Interface System Level 2 The block diagram provided in Fig 5 is the Level 2 representation of the control and interface system and its signal inputs and outputs as well as its power requirements Electrical Power 3 5V Movement 0 300 mA Control 03V PWM Signals 00r3 3 V Bits 2x Practice raci Launching Analog PWM Signals Oor3 3V Bits 4 Court Position Figure 5 Level 2 block diagram of the control and interface system with its individual subsystem 15 Launching System Level 2 The Level 2 block diagram shown in Fig 6 shows the launching system and its individual subsystems with respect to its inputs and outputs as well Ball Feed Rate Tennis Ball 1 150 Tennis Ball 1 150 Electrical Power 12V 0 15A Tennis Balls 09 509 Vertical Launching Control Signal Figure 6 Level 2 block diagram of launching system and its individual subsystems Mobility System Level 2 The Level 2 block diagram for the mobility system and its corresponding inputs outputs and subsystems is s
96. ith the motion of the machine intended to be parallel with the net Maintenance The unit will not be serviceable by customer and must be sent in to manufacturer for repairs and maintenance Manufacturability The machine will be manufactured mainly of pre fabricated purchased parts for most internal mechanical and electric components Any custom molded parts that will be needed will be produced via manufacturing options such as the 3 D printer or the CNC machine The frame of the machine will be constructed to custom fit the design using standard fastening methods such as glue screws bolts and MATT 8 some cases possibly welding The entire design should able to be manufactured with the equipment at Harding University except for the ordering of specific parts Relevant Codes and Standards The rules and regulations of tennis can be found at www ITFTenn s com 9 System Design Background There is a wide range of products currently available on the market to help tennis players improve their skills or to provide an enjoyable practice session One such product is the tennis ball launching machine of which many different types and variations are available each with its own advantages and disadvantages The main problem with such tennis ball machines is the fact that they are stationary With stationary platform the tennis balls are shot to the player from the same location every time decreasing the realism of
97. ks and will be in charge of testing the components of the device they construct according to the specifications outlined Each team member will also be expected to be familiar with all other systems on the machine keeping mind the total integration of all these systems in the final product at all phases in the build process It is also important to note that though each major subsystem has a primary engineer and two secondary support engineers the work done on each subsystem is not limited to these three team members MATT 76 Fall 2011 Schedule Analysis Throughout the course of the semester the work breakdown structure and project plans were not followed precisely in many areas As the semester progressed the tasks and assignments for each of the individual subsystems and designs remained essentially the same however the time frame in which each task was completed or not completed for that matter varied significantly from our original estimates Upon discussion with the team it seems the general consensus as to why this occurred was a result of several factors As general rule the amount of time that was allotted to many of the tasks was not enough to complete the designs thoroughly This was due to the highly iterative process that was needed for many of the designs and the different dependencies of the various subsystems The requirements and needs of many of our subsystem designs were much more intertwined then previously assumed
98. ll be controlled by the microprocessor Horizontal Motor Controller The horizontal targeting system s maximum electrical power requirement to be supplied to the DC motor is 5 2 W The motor will be supplied with 12 VDC so the maximum current that will need to supplied is 0 67 A The horizontal targeting system will require bidirectional movement so the horizontal motor controller will use an H Bridge configuration of motor controller The motor controller is an H Bridge motor controller chip that is rated at a maximum of 30A The microprocessor will send 2kHz PWM signal to the PWM pin and the rotational direction will be selected by INA and INB INA and INB are logic signal inputs that inform the motor controller how to operate More information about this functionality can be found in Appendix 1 If INA is enabled then the motor will rotate clockwise Likewise if INB is enabled then the motor will rotate counter clockwise If both INA and INB are disabled then the brake will resist the motor s rotation The motor controller design can be seen in Fig 54 STMicroelectronics VNH3SP30 E has several onboard fault detection systems sv V PWMiNBINA bet bee A AA sph Figure 54 Horizontal targeting system motor controller The motor controller chip can handle far hig
99. lution of the encoder is then the circumference of the wheel divided by the desired accuracy We will assume that the necessary accuracy is 0 2 in this yields the following result 50 CPRBCounts per Revolution The standard length of the tennis court is 10 97 m 432 in So using this information the total length of the court according to the encoder will 2160 The microprocessor will then record maximum of 5433 sensor that will be used to read the encoder wheel will be Vishay Semiconductors TCST1103 Additional information about the sensor be found in Appendix Figure 45 Mobility motor encoder wheel ATT 57 Launching Sensors The top launching wheel will have an encoder attached to it from which the microprocessor will be able to measure the rotational speed of the wheels This will allow the microprocessor to know how to adjust the speed of the motor to achieve desired ball exit velocity The launching system will also have a sensor to indicate when ball has successfully been launched This will be incorporated in the form of a photo interrupt circuit consisting of an infrared emitter and an infrared detector The ball exit sensor replaces the need for a feeder sensor as it supplies the rate at which balls are exiting the machine which is approximately equal to the rate at which the is being supplied by the feeder If the ball exit sensor does not register a ball exit at the
100. m design report Not Included Tennis balls Tennis court Tennis racquet Preliminary Test Plans e Aradar gun will be used to test tennis ball launch speed The difference between the widest angled launch paths will be measured using a measuring tape and trigonometry The time to switch between the widest range of launch angles will be timed with stopwatch to determine if it is less than 3 0 1 0 seconds The time it takes the machine to traverse the entire width of the court will be measured with a stopwatch to determine if itis less than 20 0 1 0 seconds Arandomly selected group of five tennis players will be asked to set up the machine turn it on and start it while being timed with a stopwatch to determine if it takes the user less than 10 0 0 5 minutes to have the machine set up and operational The selected group will be surveyed MATT 7 about the ease of use and convenience of controls to determine if at least 90 find them satisfactory e The remote will be tested at increasing distances to determine if its maximum range is greater than 30 meters machine will operate for set period of time while someone records the number of shots in bounds and the total number of shots machine will operate for a set period of time and the overall distribution of the shots will be measured using the grid shown in Appendix A 2 The percent distribution of the ball placement will be 20
101. mass moment of inertia and angular velocity of a wheel respectively Subscripts and f stand for before and after the tennis ball is launched respectively The acceleration a to bring the angular velocity back up within the minimum time interval between shots dt was found to be Eqn 6 Finally the required torque and power P for the launching mechanism found to be Eqn 7 Eqn 8 An Excel spreadsheet was created to easily find motor specifications based on the radius and mass of the launching wheel and initial velocity of the tennis ball The excel spread sheet can be found in Appendix E 1 1 1 The calculations were performed with 7 62cm radius wheel with a mass of 0 85kg and with the highest initial velocity of the tennis ball 45m s A factor of safety of 2 was used in the calculation The motor specifications are shown in Table 2 Table 2 Motor specifications calculated for launching system Required Torque mN m 52 Power W 31 Angular Velocity RPM 11300 Although when buying bearings to support the shaft for the launching wheels the viable option to buy 5800 maximum RPM bearing since the one above it 9500 maximum RPM was too expensive for the budget Using no factor of safety the angular velocity of the launching wheels to launch tennis balls at 45 m s is 5640 RPM To compensate the factor of safety a motor was selected with torque m
102. mines the speed the ball has to travel to hit selected target at selected vertical angle ignoring net and drag oy cos sin 1 1 1 2 1 2 ET sim B 20 BC 0 0 d 28 2 Geos 280 2 A 22 Gun jos azo 2 0005 0 cos MATT 106 Figure 64 Ballistics trajectory of the ball Vertical Angle Ht Distance to Selected Target V Launch Speed g Acceleration of Gravity Initial Launch height double GetLaunchSpeed double Phi int Ht double V Ht sart 2 double g 2 sart double Ht sin Phi 20 cos Phi sqrt cos Phi return V Check if Ball Clears Net Checks to see if Ball will clear the net with given target vertical launch angle and launch speed compensates for drag by assuming net is foot taller than standard 8 4 cos sin Z a 2i m lymm e 21 m lymm d sin 0 2 28 MATT 107 70 pe Figure 65 Ballistic trajectory for clear net check Phi Vertical Launching Angle g Acceleration of Gravity bool clearsNet double Phi int Hn double V int Zt 20 Hn tan Phi 5 g Hn Hn V V cos Phi cos Phi if ZF gt Zn return true 108 Appendix D Power Supply Appendix D 1 Battery Selection MATT 109
103. motors and gearboxes can be found in Appendices 8 1 and 8 2 respectively Figure 10 shows one motor and gearbox assembly for the mobility system 27 ity motor and gearbox Since the mobility system has two drive motors there will also be two drive wheels connected to the motors Unless a greater torque increase is needed and therefore more gearing the drive wheels be mounted directly on the shaft of the gearbox Based on the original assumption of wheel radius size and the related speed a 25 4 cm 10 in diameter wheel will be used for each of the drive wheels support the machine and still allow for frequent direction changes two pivoting caster wheels will be used on the mobility system as well help determine the size of pivoting caster wheels to use Eqn 1 was used to calculate the torque on wheels of various diameter The results can be seen in Table 1 Table 1 Relationship of diameter to required torque Wheel Diameter cm Torque Per Wheel Nm 508 2 0654 1016 5 101 1524 60293 2032 6 8442 254 7 5757 30 48 82442 can be seen as the diameter decreases the required torque does as well Therefore the selection of a smaller pivoting caster wheel would be beneficial and therefore 7 62 cm in pivoting caster will be used With this selection along with the 25 4 cm 10 in drive wheel the required torque of the system is actually lower than previously
104. n common use permenent magnet en vocale reluctance unipolar oes 2 574 MATT 172 1173 Appendix J Power Components 174 Ps Akami 0 1 785 Series Fixed Output 1 5 Amp SIP DC DC Converters Murata Power Solutions asc fed any SP pode heOX Fen reum vay be eon ie TASR setae ve cor melaa eating po TE GUT args ouput Pin ates as tatanen an hgh leerer epo dom Te OB TES et acy Testa nar scat pets HS rel Tro namra otoit vatages ent ccr Str aeren a aa aT p Tuner alee p Den vce Bagn 2 1 me rot i Wave eis ey i eorr rica hae SA EE Calculate The AMP Hour Capacity Battery You Need In order fo determine proper ame ating you need for tost amet up tho 12 vot you have by 2 hia m you ave youu boats bay Then
105. n in Fig 42 The enclosure has two buttons that will have momentary tactile switches mounted on a printed circuit board below them The printed circuit board will also have the encoder and RF transmitter components mounted on it remote control will be powered with one to four CR2032 lithium coin cell batteries The number of batteries required will be increased in order to achieve the desired range of at least 30 meters Figure 42 Remote control enclosure Sensor Systems Court Positioning Sensors MATT will be able to estimate its position on the court by monitoring the baseline of the tennis court and intersecting sidelines with respect to its own position as it travels laterally along the baseline of the tennis court The Rules of Tennis 2011 state that all lines of the court shall be of the same color clearly contrasting with the color of the surface An infrared reflectivity sensor was selected in order to be able to differentiate the lines of the court from the surface based on this information The sensor that will be used is Vishay Semiconductors TCRTSOOOL The appropriate datasheets for this sensor be found in Appendix The reflectivity sensor is composed of an infrared emitter and phototransistor that has a filter to block visible light The test circuit seen in Fig 43 was used to test the sensor on the Harding University tennis courts The measured voltage will decrease as reflectivity increases ATT 55
106. nally the launching system is powered from the power source and controlled via instructions from the microprocessor and motor controllers based sensor input information Launching Mechanism The launching mechanism consists of two launching wheels a motor an idler sprocket chain and sprockets for the launching wheels and motor The launching wheels are driven by the motor by means of a single chain and sprockets on each wheel allowing them to rotate with the same angular velocity The idler sprocket makes the wheels to counter rotate The launching mechanism concept design is shown in Fig 15 Sprocket Launching Chain gt Motor lt Idler sprocket Figure 15 Launching mechanism concept design This design was chosen because of its simplicity of one single chain and for having one adjustment point for tensioning the idler sprocket The launching wheels are U shaped for two reasons First it increases the area of contact between the wheels and the tennis ball this way increasing friction The higher friction helps prevent the tennis balls from slipping Second it prevents the tennis balls from slipping sideways out of the wheels due to the shape of the wheel The positioning of the launching wheels that makes the tennis balls to go just over the net with the smallest vertical angle is defined to be the default position as shown in Fig 16 The smallest angle calculated when the machine is a
107. ndor Speedy Metals Item Description Material Aluminum Grade 6061 Shape Flat Weight 2 96 Ibs Price 51742 Shipping Tax 512 75 Quantity 1 Total Pri 53017 MATT 14 1 4 A x 1 B 6061 T6511 Aluminum Extruded 24 Vendor Speedy Metals Item Description Material Aluminum Grade 6061 Shape Flat Weight 0 44 Ibs 2 5 Shipping Tax 50 Quantity 1 Total Price 525 Appendix E 1 4 Sprockets Idler Sprocket with Bearing 6663 22 McMaster Carr Details ANSI3S 0 375 inch 19 Bore Diameter 0 5 inch Outer Diameter 2 47 inch Width B 0 375 inch Price 522 Shipping Tax Quantity 1 Total Price 52222 L MATT 115 Fi Bore Sprockets 6280K332 Wheel Sprockets Vendor McMaster Carr IB Specification Details B Chain Type ANSI 35 Pitch 0 375 inch T Teeth Bore Diameter 0 5 inch A Outer Diameter 1 5 inch Width B 0 75 inch Hub Diameter 1 0625 inch Price 8 86 Shipping Tax N A Quantity 2 Total Price 1 Finished Bore Sprockets 6280331 Motor Sprocket Vendor McMaster Carr ML C Be i Detai B ANSI3S 0 375 inch T Teeth 11 Bore Diameter 0 375 inch A Outer Diameter A 1 5 inch Width 0 75 inch 1 Hub Diameter C 10625 inch Price Shipping Tax N A Quantity 1 Total Price _ 5886 Appendix 5 Chain ANSI
108. ned arrangement The base of MATT will have fifteen total sensors They will be positioned as can be seen in Fig 44 The sensors will be placed one inch apart from one another along either side of MATT The distance was experimentally chosen as the minimum distance without a significant amount of cross contamination The control system will use the values of the sensors to actively have the mobility system adjusting its movement in order to ensure that the baseline stays within the middle most sensors The sensor positioned in the center of the two rows of sensors will be used as a target point for where MATT should decelerate to when the double s sideline is sensed Figure 44 Reflectivity sensor configuration Matt will require an encoder to be attached to each of the mobility motors in order to have an accurate position at any given time The encoders will be manufactured using the Engineering Department s 3D printer The encoders will be designed to attach to the shaft of the gearbox directly linking the mobility motors the mobility wheels two dimensional version of the encoder design can be seen in Fig 45 where the black represents printed material An appropriate value for the resolution of the encoder wheel can be found with the use of a few calculations Based on the information from the mobility system the circumference of the mobility wheel is 25 4 cm 10 in and the maximum rotational speed will be 65 2 RPM The necessary reso
109. ng method and provide alternative braking methods if necessary Mount the sensors to the mobility system and calibrate if necessary Interface the motor controller for the mobility system to the motors Test the mobility system to confirm that it will meet required specifications and modify the system if necessary Present the final design to the faculty Hopper that can hold required tennis balls and a functioning feeding mechanism Test Data Working horizontal and vertical components of the launching system Test Data Functioning launching system sensors Test Data Functioning control of launching system motors Test Data Functioning launching system Test Data Functioning mobility system Test Data Working drive system Test Data Working braking method Test Data Functioning mobility sensors Test Data Functioning control of mobility system motors Test Data Functioning mobility system Test Data presentation demonstration of Tans TM Jan 28 Jan 16 Feb 3 Jan 28 Feb 3 Feb 3 PT Feb 21 Feb 21 IMP Mar 1 Feb 3 Feb 12 Febi3 Feb 24 Mar 1 System Integration Encasement System Testing Acceptance Tests Complete User s Manual Product Readiness Report Product Readiness Review Engineering Showcase Integrate the subsystems together Constru
110. o 0 3 3 0 50 mA Direction Bits Subsystems of Interface and Control System User Interface Description The user interface will provide a method for the entry of user instructions and will allow the user to determine the effective skill level of the machine The interface will be easy to understand and use as well as providing user control over the following factors target distribution speed range height range and launching rate Input User Commands Instructions for operation __ Power Source 3 5 VDC 0 50 mA Outputs icroprocessor Target Distribution Two 0 5 VDC 0 50 Signals Launching Speed Range Two 0 5 VDC 0 50 mA Signals Height Range One 0 5 50 mA Signal Firing Rate One 0 5 0 50 mA Signal Remote Control Transmitter Description The remote control transmitter is a remote that the player can carry with them to signal MATT once they are ready for it to start launching the tennis balls The remote will also be used to signal MATT to stop launching if the machine needs to be turned off quickly Inputs 4 User Commands Instructions for operation Power Source 3 12 VDC 0 50 mA 19 Outputs 4 Remote Receiver Start RF Signal Frequency 315 MHz Range 30 m Modulation ASK RF Signal Frequency 315 MHz Range 30 m Modulation ASK Power Source 3 12 VDC 0 50
111. om the master processor Then the timer interrupt calculates the settings necessary to launch the ball to that target Once these settings are calculated the motor control signals are sent to the respective motors The position of the targeting system will be determined and the motors set to adjust them towards the calculated target 66 Upon receiving the signal to switch back to waiting state the slave processor will stop the launching and feeder motors and set the targeting motors back to a stable state Then the program will be reset to the user interface interpreting loop w ev ov sv iv ev MATT 67 Figure 56 MATT program flow Save baie Cc m Fram AS 8 rgered 8 Motors n Y x X d I m 5 motors to esting 1 q esr sivo mia 2 PEL z sers ion settore raner 5 Leser z ptem js Waiting sane MATT 68 Budget Budget Overview A budget overview is provided for the construction of MATT and can be seen in Table 5 The expected cost of each major system is shown here The mobility and launching system were individually computed while all electrical components were tallied
112. on Microprocessor and Remote Control Receiver Integration PCB Design of Control and Interface System Design of Remote Control Transmitter Launching System Launching Mechanism on a breadboard Program the Microprocessor to interact with the user interface Assemble and test the motor controllers on a breadboard Program the Microprocessor to interact with the motor controllers Assemble and test the sensor systems breadboard Program the Microprocessor to interact with the sensor systems Assemble and test the remote control transmitter system on perfboard Assemble the test remote control receiver system on perfboard Test the remote control transmit and receive systems Program the Microprocessor to interact with receiver of the remote control Design the PCB for the control and interface system Design the PCB for the Remote Control Transmitter System and populate the PCB Assemble and test the launching system Build and test the launching mechanism Functional programmed microprocessor and user interface interaction ona breadboard Functioning contral of motors Test Data Functional programmed microprocessor and motor controller interaction breadboard Functioning sensor system Test Data Functional programmed microprocessor and sensor interaction ona breadboard Properly configured remote control transmitter system Test Data Properly
113. on in the mechanical components or a statically determinant model had to be used It was determined that a worst case scenario would be a case when the wheel was impeded by a small object such as a pebble and thus requiring a much larger torque than would be required for normal operation to overcome such an object This scenario allows for a torque estimation using only the geometry of the wheel and the load applied due to the mass of the machine Figure 8 shows the model Used to estimate the required torque for the mobility system wheel based on the design criteria previously stated 125 of geometry used in worst case scenario torque estim model Figure 8 Figure 9 shows the free body diagram of the model used to estimate the torque required by the mobility system CQ Figure 9 Free body diagram of torque estimation model From the geometry shown in Fig 8 and the forces shown in Fig 9 a relationship for torque could be derived once some values were known and some assumptions were made Summing the forces in the x direction and y direction and calculating the moments about point Eqn 1 was derived 4 8 Eqn 1 The following are the definitions of the variables used 70 1 9 81 0127 5 000635 025 Equation 1 calculates the torque required for a single wheel carrying one fourth of the total specified load to roll over an object of 0 635 0
114. ount of voltage and current to all the various subsystems of the machine Inputs 4 Power Source 12 VDC from battery at 0 42 Outputs Control and Interface System 5 VDC 300 mA 4 Launching System 12 VDC 0 15 Mobility System 12 VDC 0 25 A Interface and Control System Description The interface and control system receives information from the user via the user interface the remote control and all other external sensors The microprocessor will process the information to determine the targeting controls movement instructions launching signals and parameters and then distribute the necessary information and instructions to all of the various subsystems Inputs User Commands Instructions for operation Power Source Electrical power at 3 5 VDC 300mA External Information o Court Position Analog Coordinates Launching System Horizontal Angle Change 0 5 VDC 0 50 mA Encoder Signal o Vertical Angle Change 0 5 VDC 0 50 mA Encoder Signal Outputs Launching System Control Signals Horizontal Angle Two 0 5 VDC 0 50 mA Direction Bits Vertical Angle Two 0 5 VDC 0 50 mA Direction Bits Launching Speed 0 5 VDC 0 50 mA PWM Speed Signal Feeder Speed 0 5 VDC 0 50 mA PWM Speed Signal Mobility Control Signals o Movement Speed Two 0 3 3 VDC 0 50 mA PWM Speed Signal Movement Direction Tw
115. red to be able to apply at least 15 2 N m under the worst conditions When searching for motors with output torques anywhere near this value it was quickly determined that such a motor would be cost prohibitive The only plausible option was to design a smaller less expensive motor to work with a torque increasing gear or sprocket set After comparing many motor specifications and torque reduction scenarios it was determined that an increase of 1 64 was required at a minimum in order to decrease the cost of the motor needed However with this increase in torque came the additional cost of the mechanical components to gear it properly Also with the increase in torque cames a decrease in speed by the same factor Therefore if a high torque is required for the mobility system a high speed at a low torque must be put into the gearing system Based on our initial estimate of wheel radius and court traversal time an output speed of approximately 100 rpm was needed Therefore input speed of approximately 6400 rpm would be needed to increase the input torque by a factor of 64 Due to the availability of two identical 64 1 speed reduction gearboxes 1 64 torque increase this method was selected for the mobility system With these gearboxes selected two identical motors that can supply at least 0 2375 a factor of 64 less than 15 2 N m and operate at high speeds of greater than 6400 rpm were selected as well information about the selected
116. rototype of Jan 20 indication system the low voltage Jan 25 breadboard and test indication system the precision of the system Power Distribution 8 Assemble the power _ Working prototype of Jan 20 Regulation regulation regulation system and Jan 30 components ona distribution methods breadboard and test power distribution methods at maximum power ratings Power Switch Test the power switch Suitable primary power Jan 31 at the system s switch for the overall Feb 4 maximum power system ratings PCB Design of Power Design the PCBfor Accurate PCB designof 5 System the power system power system Feb 14 components PCB Build of Power Populate the power Functioning PCB of Feb 17 P System system PCB and test power system Feb 24 the subsystems components Test Data Control and Interface Implementation and Working controland Jan 8 Build testing ofthe control interface subsystems Feb 15 andinterface subsystems User Interface Assemble and Functioning user dam S9 Components connect the user interface system ona 17 interface components breadboard Microprocessor and User Interface Integration Motor Controllers Microprocessor and Motor Controller Integration Sensor Systems Microprocessor and Sensor System Integration Remote Contral Transmitter Remote Control Receiver Remote Contral Operati
117. s The machine will have a maximum ball MATT 6 feed rate of not more than one tennis ball per 2 seconds With this ball capacity and feed rate the machine will be able continuously launch tennis balls for approximately 5 minutes before it must be refilled Also the machine will still operate with as few as one tennis ball in the hopper e Portability The machine will weigh less than 60 kilograms excluding tennis balls and can be set up and operational within 10 0 0 5 minutes The machine will roll easily without being turned on for ease of transport Operational Description The user will set up the tennis ball machine by first activating its power source which could be a battery extension cord gasoline engine or some other suitable power source The user will turn on the machine and will input the desired settings Then the device will idle on one side of the tennis court while the user goes to the other side Upon receiving the signal to start the machine will move if desired and launch tennis balls to the user s side of the court The movement will be entirely lateral moving no more than 6 0 0 5 meters from the center line of the court and remaining anywhere from 10 0 0 5 meters to 12 0 0 5 meters from the net with the motion of the machine generally parallel with the net Design Deliverables Moving tennis ball launching machine User manual e Testing and capabilities specification report Final syste
118. s ball from MATT at variable speeds The launching mechanism will most likely consist of counter rotating wheels attached to a single chain and a single motor allowing both of the wheels to rotate at the same speed With the wheels rotating at the same speed variable ball spins will not be possible Input 4 Power Source 12VDC at 0 15 A Launching Control Signals Digital from Microprocessor and Motor Controller Launching Speed 0 5 VDC at 0 50 mA o Launch Signal 0 5 VDC at 0 50 Outputs Tennis Balls Launched at speeds ranging from 4 m s to 45 m s Targeting System Description The targeting system will control the aiming of the tennis ball launching mechanism This system will consist of two major components the horizontal angle adjustment mechanism and the vertical angle adjustment mechanism The horizontal angle adjustment will provide horizontal angles from 40 to 140 and the vertical angle adjustment will provide vertical angles from 0 50 Both of these aiming mechanisms will be powered by their own motor assembly Inputs Power Source 12VDC at 0 5 e Launching Control Signals Digital from Microprocessor and Motor Controller 22 Horizontal Angle Position 0 5 VDC at 0 50 mA Vertical Angle Position 0 5 VDC at 0 50 Outputs Tennis Balls Launched at speeds ranging from 4 m s to 45 m s Curren
119. s in the microprocessor Figure 37 shows the circuit representation of the user interface board jual control of the follo Figure 36 LabVIEW layout of user interface system 151 sv E Keyi A Sich Koy n 10 LSVA Miri fois ps B Koy f sho perd Ground Figure 37 MultisIM diagram of UI Board Launching Distribution The launching distribution describes the variety of the targetable locations This field is controlled by the first two dials from the left in Fig 36 To the user the controls will be similar to the balance dials on a car stereo Turn the depth dial left and the balls land closer to the net turn it right and they land further from the net Turning the width dial left and the machine will tend to launch towards the machine s left the player s right more while turning it right the machine will tend to launch towards the machine s right the player s left more However instead of an entire court of targetable positions we have decided to split the court into six fields and specifically target an arbitrary point within each field Figure 38 shows the fields that we have decided to split the court into The points will be near the back middle of each field so that drag will pull the balls forward within the field Landing point variance will be present due to air resistance and physical limitation of the machine 1
120. s were applied and the results can be seen in Fig 28 The same model used to estimate the torque requirements in the horizontal targeting mechanism was used to provide a more realistic estimate of the torque required for the rotor to operate properly The torque calculated was 0 029 N m A factor of safety of 10 was used yielding a torque of 0 29 Nem 42 Figure 27 Hopper rotor dimensions vanos Figure 28 Finite element analysis of hopper rotor under extreme operating conditions MATT 48 material used in this simulation was the material as the 3 D printer uses ABS plastic This material has a yield strength of 33 MPa When compared to the results of the finite element analysis shown in Fig 28 it can be seen that the maximum stress under this loading is well below the yield strength Therefore this design will be used for the hopper rotor part with minor modifications to allow for the assembly of motor and gearing components The next step in the design of this subsystem was to determine the required power requirements for this system Based on the specifications for minimum and maximum tennis ball feed rate the required angular velocity of the rotor was calculated For the maximum feed rate the rotor will need to rotate at 7 5 rpm and for the minimum feed rate the rotor will need to rotate at only 1 5 rpm Based on the previously estimated torque value of 0 29 Nm and the maximum angular v
121. sign of distribution models Nov 9 for various subsystems Launching Launching mechanism Schematics SolidWorks OcLi3 Mechanism method and models datasheets Oct 25 controller and feeding mechanism major components selected Targeting System Design of both Schematics SolidWorks Oct 13 horizontal and models datasheets Oct 30 vertical aiming mechanisms major components selected Hopper Design Design of hopper size SolidWorks models Oct 25 and shape to work miscellaneous diagrams 2 with overall design and feeder mechanism Feeder Mechanism Design of mechanism SolidWorks models Nov 2 to feed tennis balls diagrams and Nov 11 from hopper to schematics launcher 1 Ivan M Mark Prosper T Trevor The first area of concern as seen in Table 11 was the with the power source system of MATT Due to mechanical engineering delays and therefore a lack of specific information in regards to motors and power consumptions the power source was previously delayed Since such delays a power source was selected and purchased that should be able to provide the necessary power to all the subsystems The selection was made based on worst case scenario power calculations With the power source chosen the design of the power distribution and regulation system has also been completed The rest of the delays have been largely related to mechanical systems as well The second ar
122. t Conditions Horizontal Angle Change 0 5 VDC 0 50 mA Encoder Signal Vertical Angle Change 0 5 0 50 mA Encoder Signal Hopper and Feeder System Description The hopper will store at least 150 tennis balls in the machine when loaded to capacity The hopper will be designed to prevent the tennis balls from spilling out during motion of the machine The feeder will supply a steady flow of tennis balls to the launching mechanism as long as there are still tennis balls in the hopper The feed rate will be adjustable and determined by the microprocessor and motor controller based on movement launching and user inputs Inputs Power Source 12VDC at 0 15 A Tennis Ball Feed Rate Microprocessor and Motor Controller Signals Delivery from hopper and feeder system at a rate less than or equal to 1 tennis ball every 2 seconds Tennis Balls Launched at speeds ranging from 4 m s to 45 m s Shot Feed Rate Less than or equal to 1 tennis ball every 2 seconds 23 Mobility System Description The mobility system will consist of a motor assembly that will power wheels and therefore allow the lateral movement of the device generally parallel to the net The machine will be able to traverse the court in a maximum of 20 seconds The machine will have a braking system which will be able to slow or stop the machine when command to do so is provided by the microprocessor The
123. t the center of the court furthest away from the net launching the tennis ball straight at maximum speed The default position was found to be where the top wheel is MATT 32 shifted 8 counter clockwise from bottom wheel and the distance between the wheels is approximately Wheel Figure 16 Default position of the wheels in launching mechanism The motor accelerates the launching wheels until a desired angular velocity to launch the tennis ball is reached Right after the ball is launched the wheels slow down since some of its kinetic energy is lost to launch the tennis ball The required motor was specified to have a torque large enough to bring the angular velocity back up within the minimum time interval between shots 2 seconds Figure 17 shows the linear and angular velocities of the wheels and tennis ball Although because the tennis ball has a small mass in reality almost no kinetic energy from the wheels is lost to launch it so the motor is assumed to hold the speed constant V ueR igure 17 Free body diagram of wheels and tennis The kinetic energy of the tennis ball and the kinetic energy of the wheels before and after the tennis ball is launched are shown next Eqn 3 MATT 138 Eqn 4 oy og us Eqn 5 where m arand the mass and velocity of the tennis ball respectively and w are the
124. ted Circuit 4pcb com 33 00 1 533 00 Board Actual Part Cost 235 83 Manufacturing Part Cost 235 83 Actual Shipping Tax Cost 9 16 Manufacturing Shipping Tax Cost 916 Actual Total Cost 6244 99 Manufacturing Total 244 99 Cost 73 Purchases Table 10 below gives a detailed summary of the components that have actually been purchased for the construction of MATT Any materials parts that are salvaged from other previous projects will be recorded in the Manufacturing Budget accordingly Table 9 Summary of all purchased components for MATT Quantity Shipping Tax Total Cost Mobility Motors 5 85550 12 5750 2 9 40 2440 B Gearbox Screws Bane Bots SM CM3304 5075 2 N A 1 50 Incorrect Gearbox Screws CoasttoCoast 3 45 035 8 0 26 3 06 45 Hardware Gearbox Screws Coast to Coast 3 50 040 1 N A 0 40 M3 50 Hardware 3 Pivoting Caster Physical 334 2 054 5722 Wheels Resources 1 16 x1 2 x Speedy Metals 63a 065x 5 48 5201 18 51213 48 31 1 2 x 48 Angle 6063 52 Aluminum 6 Lazy Susan Lowe s 71060 443 1 134 557 Bearing 3 x8 SemkRigid Lowe s 28878 5986 1 N A 9 86 Aluminum Tubing Bipolar Stepper Trossen M 200 ROB 51495 1 57 99 22 93 Motor Robotics 09238 10 Drive Wheels Amazon 490 323 0002 51074 2 N A 21 48 12 V Battery Searcy Battery 7995 1 5 60 85 55 Warehouse Electric Scissor Am
125. tem frame and encasement and the hopper and feeder system He will be a secondary engineer for the both the launching system build and the power source build Michael Gorman Computer Engineer o Michael is the primary engineer responsible for the construction of the microprocessor the programming and the user interface of MATT He will also be a secondary engineer for both the mobility system and the control and sensor systems Michelli Mechanical Engineer Ivan is the primary engineer responsible for the construction of the tennis ball launching system including the targeting mechanism He will also be a secondary engineer for both the mobility system and the control and sensor systems Prosper Majyambere Electrical Engineer Prosper is the primary engineer responsible for the construction of the power source for and all power distribution for the entire machine He will also be a secondary engineer for both the microprocessor and interface system and the launching system Trevor Pringle Electrical Engineer Trevor is the primary engineer responsible for the construction of the control and sensor systems on MATT This system will consist of the all motor controls positioning and data input sensors and the remote control He will also be a secondary engineer for both the microprocessor and interface system and the power source system Each team member will ultimately be responsible for the assigned tas
126. threaded end that is to fita tightening nut Rated voltage of this gear motor is 13 5 VDC and maximum speed is 50 RPM Rated output load is 60 watts and output torque at 50 RPM is 11 5 N m 8 5 ft lb Mounting is based on 6 screw mounting Price 79 95 Shipping Tax N A Quantity 1 Total Price 0 00 Repurposed for Harding University Engineering Department Lab Potentiometer 2 with Switch and Knob Reversible 12VD PM Gear Motor PWM Controller Appendix E 2 2 Bearing Waxman Stainless Steel 6 inch Lazy Susan Bearing Vendor Lowe s Item Description ich square plate e 0 25 inch ball bearings 300 Ibs maximum load 12 25 inch turntable diameter Price Shipping Tax Quantity 1 Total Price 557 MATT 120 121 Appendix E 3 Vertical Targeting Mechanism Components Appendix E 3 1 Electric Car Scissor Jack UPG 86025 12V Automotive Tire Jack Vendor Amazon Item Description Plugs into 12V DC power source Dimensions 16x 5x 6 8 in Weight 9 Ibs Maximum load 2200 Ibs Draws maximum of 10 amp current Price 35632 Shipping Tax 50 Quantity 1 Total Price 556 32 Appendix E 3 2 Frame 3 16 6061 T6 Aluminum Plate 12 x 18 Plate Vendor Speedy Metals Item Description Material Aluminum Grade 6061 Shape Plate Weight 4 1 Ibs Price 28 01 Shipping Tax 55 Quantity 1 Total Pri 33 01 App
127. tm tects Sov id sunbed sie Sort in d and NEU MATT 167 MOTOR DRIVING PHASE SEQUENCES WAVE DRIVE MODE avs drive mace also called one selected by a level on the input Wien even aae ELECTRICAL CHARACTERISTICS Bock aram Tee 9V otherwise pe pem tox ve Sero on m sv pm retos vote Y MATT 168 OT L298 DUAL FULL BRIDGE DRIVER OPERATING SUPPLY VOLTAGE UP 46 5 TOTAL be CURRENT UP TOSA T LOW SATURATION VOLTAGE 1 OVERTENSERATURE PROTECTION I LOGICAL O INPUT VOLTAGE UP To 1 5 V HIGH NOISE IMMUNITY DESCRIPTION Ts 208 an tren draitina 19 ana pasagos ign vago tigh eurent aul ul semo standerd TTL anv lnc such we lye DC en Tac enata re mote is he dese depende cfi put saras Tre rites one war anasto ach braga ara cenmaced and cone Sandro con o wad reco BLOCK DIAGRAM K e Anasdan
128. uch greater than the required torque and with a RPM close to 6000 Because of the high torque motor it rotates somewhat close to no load RPM The no load RPM for the chosen motor was found to be 5310 The torque at stall was found to be 2425mN m approximately 50 times greater than the required torque using a factor of safety of 2 The current at stall and at no load was found to be 133 0 A and 2 7 A respectively More information be found in Appendix E 1 1 The rest of the components can also be found in Appendix E 1 Angular Targeting Mechanism The horizontal angle range was specified to be between 40 and 140 measured from a line parallel to the net on the tennis court and rotating counter clockwise The widest horizontal angle range of similar products on the market was a total of 50 with the range being from 65 115 The wider horizontal angle range for MATT was needed because unlike other tennis ball launching machines MATT will move laterally on the court It is because of this motion that MATT will need a much larger range of horizontal angles to provide a comparable set of shot angles from varying launch positions The operating range of the machine was determined mainly based upon the horizontal angles required The determined operating range can be seen in Fig 18 f 100505m Figure 18 Operating range of MATT in regards to the tennis court The widest range of horizont
129. um input Maximum Drain Current s Tamb str2num input Ambient Operating Temperature s Tjmax str2num input Maximum Junction Temperature s Rthetajc str2num input Thermal Resistance from Junction to Case Rthetacs str2num input Thermal Resistance from Case to Sink Rthetaja str2num input Thermal Resistance from Junction to Aubien 1D Desired t str2num input User Required Drain Current s PDmax Tjmax 25 Rthetajc RDSon max PDmax ID 2 PDmax without heatsink Tjmax Tamb Rthetaja without heatsink sqrt PDmax without heatsink RDSon max PD Desired ID Desired 2 RDSon max format short fprint nResults fprintf Minimum Number of MOSFETs Without Heatsink f n PD_Desired PDmax_without_heatsink Rthetasa Tjmax Tamb PD Desired Rthetajc Rthetacs fprintf Minimum Thermal Resistance of Heatsink Required f n Rthetasa Appendix H Sensors MATT 145 VISHAY TCRTS000 TCRTSO00L v Vishay Semiconductors Reflective Optical Sensor with Transistor Output FEATURES Pesan i eto Desertos 68 Operating angearthin gt 20 avene ROHS core undor est p oaint miockong tar erster m T as acecrdares o WEEE DESCRIPTION APPLICATIONS TCHTSDO
130. uration known as an H Bridge configuration will be used for each motor The high level view of the motor controller can be seen in Fig 47 The device will accept pulse width modulation henceforth referred to as PWM as a way MATT 58 to vary the power being supplied to the device input PWM_F will be a PWM signal from the microprocessor to control the power supplied to front motor in relation to the net of the court while the input B will control the power supplied to back motor The logic input from the microprocessor to the motor controller can be seen in Table 4 This enables the microprocessor to use only four pins for the entire motor controller The schematic for this logic can be seen in Fig 48 us 50 E a ss lt m LEFT lt zx e em Pr 56 RIGHT moror Mobility Motor Controller Mobility Motor Controller Logic Figure 47 Mobility motor controller Table 3 Mobility Motor Controller Logi vet ww 30080883 THIGH EINENAN Input ze XE C UE m Figure 48 Mobility motor controller logic
131. utput shaft in rad s and P represents the power in W Eqn 2 Using Eqn 2 and 15 2 Ncm for torque and 6 82 rad s 65 2 rpm for the angular velocity approximately 105 W of power is needed to run each motor under the worst conditions Therefore the mobility system which will be the system that requires the most power will need at least 210 W of power supplied to it to ensure proper operation Design Drawings Figures 12 13 and 14 show the design of the mobility frame with placement of motors wheels and battery The overall dimensions of the mobility system are labeled in the figures 5080 056 Figure 12 Top view of mobility system frame and major drive components MATT 30 Figure 13 Side view of mobility system and frame Figure 14 Angled view of mobility system frame and placement of major components MATT 31 Launching System The launching system consists of three subsystems launching mechanism targeting system and the hopper and feeder system The launching mechanism controls the initial velocity of the tennis balls which is between 4 and 45 m s The targeting system controls the angular and vertical displacement of the launching mechanism for shot aiming purposes The targeting system is then divided into angular and vertical targeting mechanisms The hopper and feeder system controls the rate in which the tennis balls fall from the hopper into the launching mechanism Fi

MATT – Mobile Automatic Tennis Trainer

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MATT &ndash; Mobile Automatic Tennis Trainer

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MATT – Mobile Automatic Tennis Trainer