Testing Readiness Review March 3, 2014

Transcription

1 Testing Readiness Review March 3, 2014 Ben Azlein, Chris Bennett, Kara Bongiovanni, Eric Brenner, Lea Harris, Austin Kootz, Stephanie Oij, Jason Schelz Customer: Barbara Streiffert, JPL PAB Advisor: Dr. Nabity

2 2 Project Overview Test Readiness Schedule Budget Project Overview Test Readiness Schedule Budget

3 Project Overview Test Readiness Schedule Budget ASEN 4028: TRR 3/3/2014 3

4 References: 3 4 The goal of DARE is to design and build a Child Rover (CR) that is capable of deploying, communicating, and docking with the previously designed TREADS Mother Rover (MR), while also being able to ascend and descend slopes between 30 o and 70 o. These slopes will replicate a sandstone surface found when exploring canyon walls, craters, and caverns on Earth. Project Overview Test Readiness Schedule Budget

5 References: 3, 4 5 Legend Blue = Critical to Project After deploying from the MR and travelling a maximum of 20m across flat ground, the CR will ascend and/or descend a slope of 30 o to 70 o, then return to the MR The CR will travel up to 20m on level terrain The CR will communicate with the MR and the Ground Station (GS) The CR will capture color images The CR will be capable of docking and deploying with the TREADS MR The CR will determine its position relative to the MR to within ±1m and its elevation angle to within ±5 o Project Overview Test Readiness Schedule Budget

6 ASEN 4028: TRR 3/3/ Project Overview Test Readiness Schedule Budget

7 7 Motors Suction Fan Encoders Electronic Battery Fan Electronics Drivetrain Assembly Motor Controllers Fan Battery RoboVero Microcontroller/ FireSTORM Chassis COM Wheels/Cogs Caspa FS Camera Rubber Skirt Project Overview Test Readiness Schedule Budget

8 ASEN 4028: TRR 3/3/ Ground Station CR Approaches Slope CR Descends then Ascends CR Ascends then Descends CR Returns to MR Legend GS to CR MR to CR GS to MR MR CR 20 meters Descending slopes o Rover takes a picture NOTE: Images not to scale.

9 9 Suction Fan Suction fan shall provide 955 Pa pressure differential over a 0.1 m 2 area. Seal design shall maintain an inlet volumetric flow rate of 63 cfm while at required pressure differential. Drivetrain Chassis shall support loads caused by suction fan and motors. Motors shall be able to provide a continuous torque of 4.3 Nm and a burst torque of 5.1 Nm. Wheels shall remain in contact with the surface. Software The software shall allow the user to operate the pressure fan, locomotion, and capture images. The software shall provide meaningful feedback to the user of position, status, images, and history. The software parses information from GS to MR to CR, as well as GS to CR. Status Update Fan assembly tested: ~3000 Pa pressure differential possible Status Update 1. Chassis supports fan load 2. Motors match expected torque at acceptance 3. Planning to complete drivetrain assembly test ~3/7 Status Update 1. Software allows user to command the RoboVero microcontroller and Faulhaber motor controllers 2. Software provides meaningful feedback to the user Project Overview Test Readiness Schedule Budget

10 10 Legend Make Done In-Progress Future Work Procure On-hand On order Future Purchase Project Overview Test Readiness Schedule Budget

11 Project Overview Test Readiness Schedule Budget ASEN 4028: TRR 3/3/

12 12 Acceptance Tests Integration Tests System Test Fan Fan Assembly Final Validation Motors Motor Controller Drivetrain Navigation LEGEND Planned Robovero (Microcontroller) Communication Completed In Process CASPA FS Critical (Camera) FireSTORM (COM) Electronics/ Software Mission Validation Battery Discharge

13 13 Expected Actual Impact Expected Actual Impact Expected Actual Impact Expected Actual Impact 1400 Pa Verifies Results fan design Validates Match supplier design specifications concept Passed Results Fan can maintain 955 Pa on prototype base Verifies the motors can be controlled Results and provide necessary torque Can receive signals and return digital output Passed Results Verifies board is functional and ready Determine for programming battery discharge and profile integration In progress Verifies sufficient power for mission duration LEGEND Planned Completed In Process

14 14 LEGEND Planned Completed In Process

15 15 Results Expected Actual Impact Purpose Equipment Method Expected Results Impact Fan can maintain 955 Pa on actual base ~3000 Pa Test Overview Verifies fan/seal design Validates Ensure design drivetrain concept assembly can deliver expected torque without deforming Motors, motor controllers, power supply, torque gauge, Static torque measurements Continuous torque of 4.1 Nm and burst torque of 5.3 Nm Verifies meet drivetrain requirement LEGEND Planned Completed In Process

16 16 gsmain GS computer Port Communication MR computer Port Communication mrmain User Legend Software Hardware Firmware Encoder1 Encoder2 Camera Motorcontroller1 Motorcontroller2 Fan CR robomain RoboVero MR computer Port Communication CR FireSTORM COM Firestorm Library RoboVero RoboVero Library Project Overview Test Readiness Schedule Budget

17 Legend Software Hardware Firmware ASEN 4028: TRR 3/3/

18 18 Test Overview Purpose Equipment Method Expected Results Impact Command fan and receive fan status Fan, Power Conditioning Circuit, RoboVero, FireSTORM, GS Ensuring code output corresponds to physical state of fan Fan turns on and off, fan status is accurately provided upon request Fan can be controlled and system is ready for next level integration Legend Software Hardware Firmware

19 Legend Software Hardware Firmware ASEN 4028: TRR 3/3/

20 20 Purpose Equipment Method Expected Results Impact Purpose Test Overview Equipment Obtain Distance Traveled Encoder, GS, RoboVero Method Manually roll wheels over Expected measured distance Results Distanced traveled and software output matched Impact within ± 1 m CR is capable of meeting navigation requirement Test Overview Capturing images upon user command GS, RoboVero, FireSTORM, Caspa FS Command camera and validate image on GS Camera captures and communicates image to GS Camera can capture and communicate images for science Legend Software Hardware Firmware

21 Legend Software Hardware Firmware ASEN 4028: TRR 3/3/

22 22 Purpose Equipment Method Expected Results Impact Test Overview Command and Status update of Motors GS, FireSTORM, RoboVero, Faulhaber, Motors Send command or status check Motors rotate intended linear distance, status is clearly received by GS CR is capable of traveling Legend Software Hardware Firmware

23 Legend Software Hardware Firmware ASEN 4028: TRR 3/3/

24 24 Software Environment Configuration Communication with GS to FireSTORM Wi-Fi Communication GS to FireSTORM Command_motor Read_motor Command_camera Command_fan Read_fan Read_encoders Wi-Fi Communication GS to MR to FireSTORM System Integration Test Legend Done In-Progress Future Work Project Overview Test Readiness Schedule Budget

25 25 LEGEND Planned Completed In Process

26 26 Purpose Purpose Equipment Equipment Method Method Expected Results Expected Results Impact Impact Test Overview Test Overview Ensure GS can communicate Ensure with CR navigation is within required accuracy RoboVero, FireSTORM, GS RoboVero, Encoders, FireSTORM, Place CR up GS to 20m away from GS and send commands Compare software results with physical Exact distance at which CR can maintain communication Position known within ±1 m and ± Validate 5 o communication objective Verify navigation meets requirements LEGEND Planned Completed In Process

27 27 Purpose Validate CR is able to complete simulated mission To investigate the capability of the complete rover system Assure all systems are compatible with each other All requirements validated except R.5.4, R.11, R.16 Test surface is not large enough to meet range requirements R.11 and R.16 R.5.4 will be met in communication component testing Expected Results Performance map of capabilities to compare to objectives Project Overview Test Readiness Schedule Budget

28 28 Shorten mission distance to make testing feasible Two methods will be used to account for the reduced mission length 1. Perform mission at 10 m circuit test length Extrapolate to 80 m length 2. Perform 80 m mission in consecutive 2.5 m segments Add data segments to form data set for complete 80m mission Project Overview Test Readiness Schedule Budget

29 29 Rover takes a photo and transmit 50 o 70 o 30 o 2.5 m Level Platform Project Overview Test Readiness Schedule Budget

30 RECUV lab Vicon optical positioning system Infrared imaging Precise position data Indoor facility Controlled environmental conditions Safety Concerns Battery electric shock to people and components Improper set up of testing ramp Particles ejected at high velocity from exhaust Improper handling of the CR Project Overview Test Readiness Schedule Budget ASEN 4028: TRR 3/3/

31 Project Overview Test Readiness Schedule Budget ASEN 4028: TRR 3/3/

32 32 Legend = Assembly = Test = Software = Procurement = Baseline Project Overview Test Readiness Schedule Budget

33 Project Overview Test Readiness Schedule Budget ASEN 4028: TRR 3/3/

34 34 CDR Proposed Budget ($) Primary extra expenses: Spare Chassis Spare Batteries Spare Machining Metal Power Conditioning Board TRR Expenses ($) Parts Expected Cost ($) Current expenditure Misc. Nuts and Bolts TOTAL 4, Remaining Budget: $ Project Overview Test Readiness Schedule Budget

35 ASEN 4028: TRR 3/3/ [1] STARR Project Team. Spring Project Review: STARR: Sample Targeting and Retrieval Rover. University of Colorado. April [2] TREADS Project Team. Spring Project Review: RADS: Rover Acquisition & Deployment System. University of Colorado. 23 April [3] DARE Project Team. Project Definition Document: DARE: Descending/Ascending Rover for Exploration. University of Colorado. September [4] DARE Project Team. Conceptual Design Document: DARE: Descending/Ascending Rover for Exploration. University of Colorado. 30 September [5] DARE Project Team. PDR. University of Colorado. 10/2/13. [6] Murray, Michael et al. STARR Critical Design Review. 05 Dec University of Colorado at Boulder AES. 12 Oct

36 ASEN 4028: TRR 3/3/

37 ASEN 4028: TRR 3/3/

38 38 ASEN 4028: TRR 3/3/2014 References: 1, Developed: 1 st generation Mother Rover (MR) Optical navigation system Purchased: 2 COTS Child Rover (CR) Developed: 1 st generation CR 2 nd generation MR 2D ultrasonic cricket navigation system CR imaging system Developed: 3 rd generation MR Deployable MR ramp Enhanced relay COM system 2 nd generation CR CR rocker-bogie suspension Developed: 3 rd generation CR Sample identification based on color CR sample collection and retrieval Developed: 4 rd generation MR Sample storage Multiple CR storage Retractable ramp Driving LEDs for deployment and retrieval of CRs The legacy Mother Rover (MR) and Child Rover (CR) developed for JPL by CU.

39 39 robomain parse read_motor Motor Status or Command Status Motor, Encoder, or Fan Encoder read_encoder Command Fan read_fan command_fan Fan Fan, Camera, or Motor? Camera command_camera Motor command_motor Project Overview Schedule Manufacturing Budget

40 40 User GS computer FireSTORM COM RoboVero gsmain Port Communication Firestorm Library RoboVero Library Legend Software Hardware Firmware robomain command_motor Command Status or Command parse RoboVero RoboVero Library Status Motorcontroller1 Faulhaber Library Motorcontroller2 Faulhaber Library read_motor RoboVero Motorcontroller1 Faulhaber Library Motor1 Motor1 Motor2 RoboVero Library Motorcontroller2 Faulhaber Library Motor2 Project Overview Schedule Manufacturing Budget

41 R.1) The CR shall fit within the TREADS MR docking bay. R.1.1) The CR shall have an area no greater than m x m R.1.2) The CR mass shall not exceed 8 kg. R.5) The CR shall communicate with the MR. R.5.1) The CR shall transmit images to the MR. R.5.2) The CR shall receive commands from the MR. R.5.3) The CR shall transmit telemetry data to the MR. R.5.5) The CR shall be capable of transferring 10kbps R.16.1) The CR shall communicate with the MR while within the maximum range of 40 m from the MR R.6) The CR shall perform navigation. R.6.3) The CR shall know the distance travelled before the ascent or descent. R.13.1) The CR shall know its relative position to the MR to within ±1 m. R.13.2) The CR shall know its elevation angle to within ±5 o. R.17.1) While within a 1m radius from the MR ramp, the CR shall know its relative position to within 25 cm. R.7) The CR shall capture color images. R.7.1) The image shall have a resolution of at least 160x120 pixels. R.10) After ascending or descending a slope the CR shall return to within 1 m of the MR. R.12) The CR shall communicate with the GS. R.12.1) The CR shall receive commands from the GS. R.14) The CR shall travel a maximum of 20m from the MR prior to descent or ascent. R.15) The CR shall descend or ascend a slope. R.15.1) The CR shall descend a slope of 30 o for 20 m. R.15.2) The CR shall descend a slope of 50 o for 20 m. R.15.3) The CR shall descend a slope of 70 o for 10 m. R.15.4) The CR shall ascend a slope of 30 o for 20 m. R.15.5) The CR shall ascend a slope of 50 o for 20 m. R.15.6) The CR shall ascend a slope of 70 o for 10 m. Legend Blue = Critical to Project *Refer to backup slides for tiered requirements References: 3, 4, 5 ASEN 4028: TRR 3/3/

42 42 Minimum Level of Success R.1) The CR shall fit within the TREADS MR docking bay. R.1.1) The CR shall have an area no greater than m x m R.1.2) The CR mass shall not exceed 8 kg. R.2) The CR shall travel a maximum of 5 m from the MR prior to descent or ascent. R.3) The CR shall descend or ascend a slope. R.3.1) The CR shall descend a slope of 30 o for 5 m. R.3.2) The CR shall descend a slope of 50 o for 5 m. R.3.3) The CR shall ascend a slope of 30 o for 5 m. R.3.4) The CR shall ascend a slope of 50 o for 5 m. R.4) After ascending or descending a slope the CR shall return to within 2 m of the MR. R.5) The CR shall communicate with the MR. R.5.1) The CR shall transmit images to the MR. R.5.2) The CR shall receive commands from the MR. R.5.3) The CR shall transmit telemetry data to the MR. R.5.4) The CR shall communicate with the MR while within the maximum range of 10 m from the MR R.5.5) The CR shall be capable of transferring 10 kbps R.6) The CR shall perform navigation. R.6.1) The CR shall know its relative position to the MR to within ±2 m. R.6.2) The CR shall know its elevation angle to within ±10 o. R.6.3) The CR shall know the distance travelled before the ascent or descent. R.7) The CR shall capture color images. R.7.1) The image shall have a resolution of at least 160x120 pixels.

43 2 nd Level of Success R.8) The CR shall travel a maximum of 10 m from the MR prior to descent or ascent. R.9) The CR shall descend or ascend a slope. R.9.1) The CR shall descend a slope of 30 o for 10 m. R.9.2) The CR shall descend a slope of 50 o for 10 m. R.9.3) The CR shall descend a slope of 70 o for 5 m. R.9.4) The CR shall ascend a slope of 30 o for 10 m. R.9.5) The CR shall ascend a slope of 50 o for 10 m. R.9.6) The CR shall ascend a slope of 70 o for 5 m. R.10) After ascending or descending a slope the CR shall return to within 1 m of the MR. R.11) The CR shall communicate with the MR. R.11.1) The CR shall communicate with the MR while within the maximum range of 20 m from the MR R.12) The CR shall communicate with the GS. R.12.1) The CR shall receive commands from the GS. R.13) The CR shall perform navigation. R.13.1) The CR shall know its relative position to the MR to within ±1 m. R.13.2) The CR shall know its elevation angle to within ±5 o. ASEN 4028: TRR 3/3/

44 Optimal Level of Success R.14) The CR shall travel a maximum of 20 m from the MR prior to descent or ascent. R.15) The CR shall descend or ascend a slope. R.15.1) The CR shall descend a slope of 30 o for 20 m. R.15.2) The CR shall descend a slope of 50 o for 20 m. R.15.3) The CR shall descend a slope of 70 o for 10 m. R.15.4) The CR shall ascend a slope of 30 o for 20 m. R.15.5) The CR shall ascend a slope of 50 o for 20 m. R.15.6) The CR shall ascend a slope of 70 o for 10 m. R.16) The CR shall communicate with the MR. R.16.1) The CR shall communicate with the MR while within the maximum range of 40 m from the MR R.17) The CR shall perform navigation. R.17.1) While within a 1 m radius from the MR ramp, the CR shall know its relative position to within 25 cm. ASEN 4028: TRR 3/3/

45 45 Initial specification verification Replicated previous experiment to get new measurements for purchased vacuum assembly Test Needed Measured Volume Flow 63 cfm 58.7 cfm Pressure Differential 955 Pa Pa Volume Flow Test Pressure Differential Test

46 Motor Motor System Gearbox Encoder Controller L-bracket Al 6061 Front Wheel Al 6061 Front Drive Chain Front Wheel Assy Tread Cog Lock Cog Tube Al 6061 Drivetrain Front Shaft Cog 316L St. L-bracket Al 6061 Rear Shaft 316L St. Rear Drive Rear Wheel Al 6061 Bearings x2 Rear Wheel Assy Cog Tube Al 6061 Cog Cog Lock Tread Fan Chassis Fan Mounts Al 6061 Foam Core Edge Trim Fan Assembly Rubber Bristles Skirt DARE Rover Silicone Caulking FireSTORM Silicone Caulking Skirt Mount Plexi-glass Caspa FS RoboVero Fan Battery Circuit Fan Battery Power Circuit Electronics EPS Electronics Battery Assembly Electronics Battery Power Conditioning Circuit Standoff Plate Delrin Board Mounts Standoffs Motor Controllers Baseplate Plexiglass Install drivers Software Development Environment Install Client Libraries Software Communication with Electronics Install git RoboVero FireSTORM Mission Class Caspa FS Motorcontrollers GS to CR GS to MR to CR Data Receiving and Handling Status Class History Class Guidance User Interface main.cpp ASEN 4028: TRR 3/3/

47 47 CDR Components CDR Cost ($) Electronics Boards: RoboVero, Overo, Caspa Testing Materials: Wood, Poly, Nails, Screws Vacuum Motor Vacuum Battery Chassis Motor, Motor Controller, Gearbox Wheel Tread Metal for Machining Suction Components Other Mechanical Components TOTAL TRR Components TRR Cost ($) Printing Electronics Boards Vac Motor Chassis Wheel Tread Metal for Machining Suction Components Motor, Motor Controller, Gearbox Power Supplies Testing Materials Spare Metal Spare Chassis Spare Power Supplies Other Mechanical Components TOTAL Project Overview Test Readiness Schedule Budget