KARELFirst implementation year

Mihai Agape, Project CoordinatorPalatul Copiilor Drobeta Turnu Severin

KAREL SymposiumKaterini, 14.10.2014

This project has been funded with support from the European Commission.

This communication reflects the views only of the authors, and the Commission cannot be held responsible for any use which may be made of the information contained therein.

The Purpose of the PresentationOverview the KAREL projectShow some of the work done

SpecificationsKarelino - first controller prototype of

Karel robotSolving math problemsThe second design of Karel platform

KAREL PROJECT OVERVIEW

General InformationKarel Project in NumbersPartnersObjectivesResults & OutcomesRobot RequirementsTasts DistributionWork Breakdown Structure

General Information Programme: LIFELONG LEARNING

PROGRAMME Sub-programme: COMENIUS Action type: PARTNERSHIPS Action: COMENIUS Multilateral school

partnerships LLP Link No: 2013-1-RO1-COM06-29664 1 Project title: Karel - Autonomous Robot for

Enhancing Learning Project acronym: KAREL Implementation: 01.08.2013 – 31.07.2015

Karel project in numbers

Countries: 4Partners: 4Teachers: 21Students: 50Mobilities: 96Robots: 20Lessons: 21

WHO?Partners, pupils, teachers

1. Palatul Copiilor(Drobeta Turnu Severin, România)

2. Platon Schools (Εκπαιδευτηρια Πλατων) (Katerini, Grecia)

3. Beypazari Teknik Ve Endüstri Meslek Lisesi (Beypazari, Turcia)

4. Technikum nr 1 im. Stanisława Staszica w Zespole Szkoł Technicznych w Rybniku (Rybnik, Polonia)

Pupils (aged from 14 to 19 years old) & Teachers

WHY?Objectives Improve teaching and learning of science and

technology using robotics as integrator O1. Apply practical math and scientific

concepts while learning to design, build, test and document KAREL.

O2. Create an interdisciplinary curriculum to use with KAREL robotic platform.

O3. Improve confidence and fluency in English and learn scientific and technical vocabulary in partners’ languages.

WHAT?Results & Outcomes Robotics Dictionary in English and each partner’s

language. Robotics Platforms designed and manufactured

(20). Robotics Platform User Manual. Curriculum with at least 21 lesson plans, in English

and each partner’s language . At least 2 lesson plans for each of following fields: physics, biology, programming, mechanics, electronics, and robotics.

Website.

WHAT?Robot Requirements Climb a surface with a 30 % slope. Maximum speed more than 0.5 m/s. Battery autonomy at least 2 hours. Open source programming software. Cost of raw materials less than 99 EUR. Performances better than of similar priced

robots.

HOW?Tasks Distribution Robotic platform design, manufacture, test and

document: a) Mechanical system

Turkey b) Electronic system

Poland (input / output devices) Romania (controller, motor drivers, power supply,

communication) d) Software

Greece (codes for lessons) Romania (codes for input / output devices)

HOW?Tasks Distribution Curriculum for robotic platform design and

document: a) Physics: Greece, Romania b) Biology: Greece c) Mechanics: Turkey, Poland d) Electronics: Poland, Romania e) Programming: Greece, Romania e) Robotics: Poland, Romania

HOW?Tasks Distribution Pupils:

Create robotics dictionary Research, design, build, test, and program

robotic platform Test curriculum

Teachers: Design curriculum Guide pupils

SOME OF THE WORK DONE

SpecificationsKarelino - first controller prototype of Karel robotSolving math problemsThe second design of Karel platform

KAREL SPECIFICATIONS

Agreed at the first project meeting in BeypazariAvailable at http://sdrv.ms/170NTak

Kick-off Project MeetingBeypazari, 10-16.11.2013

KarelMechanical Specifications

KarelElectrical Specifications

KarelInput Devices

KarelOutput Devices

Karel Curriculum

Karel Challenges

KarelOther Specifications

FIRST PROTOTYPE OF THE ROBOTIC PLATFORM

Schematic3D ViewsPCB manufacturingBoard TestingMechanics, Electronics, and Software Integration (Rybnik meeting)First Karel prototype

Schema electrică

First prototype - Karelino3D Top View

First prototype - Karelino3D Bottom View

PCB manufacturing method & materials Method = Transfer Toner System Materials = Pulsar kit (PCB Fab-In-A-

Box) http://www.pcbfx.com/

Print the copper layer on paper using a laser printer (600 dpi)

Prepare the single sided board using a sandpaper

Clean the surface with a cloth

Use laminator to transfer the toner from paper to board

Remove the paper using water

The copper layer is transferred to the board

Use green foil (from Pulsar) to seal the toner

Easily remove the green foil

Toner before and after sealing

Etching the board using ammonium persulfate

The uncovered copper was removed (etched)

Remove the toner from the board using thinner

Drill the holes

Test the traces for continuity and short circuits

Use a soldering iron station to solder the components Hot Air Gun Soldering (Hot) Iron

First solder the jumper wires

Add the components and solder them (SMD first & THD last)

Karelino (TOP)

Karelino (BOTTOM)

3D Views vs Real Board

Karelino Testing

Second Project Meeting,Rybnik, 06–13.04.2014

Integration & Testing(Rybnik meeting)

First Karel Prototype(Rybnik meeting)

Proposed Improvements(Rybnik meeting) Integrate new blocks (e.g. Motor voltage

regulator, UART connector, Battery management system)

Make changes to the initial design (e.g. replace USB micro B connector with an USB mini B connector)

Redesign the PCB (components places and traces) according to the chassis shape

Add LEDs to show the state of Bluetooth module

Useful Links

Drawings for manufacturing the Karelino controller http://1drv.ms/1jet3ci

Bill of materials for all designshttp://1drv.ms/1oAF8hr

MATH PROBLEMS

Climbing an inclined planKarel Base DesignsAnimation created in GeogebraProblems Solved

Climbing a 30 % inclined plan

A requirement which seems to be related just to the power of the motors.

Karel Base Designs

Karel Base

Animation created in Geogebra

Theoretical problems related to geometrical constraints study Ground clearance Front overhang Rear overhang

We will use the work for some Math lesson plan

Karel Base Dimensions

Calculus of Rear Overhang

Calculus of Rear Overhang

Calculus of Departure Angle

Ramp AngleGround Clearance

Calculate Ground Clearance (h) with Wolfram|Alpha knowledge motor

Calculate Ground Clearance (h) with Geogebra

KAREL SECOND PROTOTYPE(WORK IN PROGRESS)

New Approach – Two BoardsSchematicsPCB’s DesignPCB’s Manufacturing

Karel second prototype approach 2 boards

Lower board Battery management system Motors

Upper board Controller Regulators I/O devices Motor regulators

Karel Battery Management System - Schematic

Board dimensions

PCB Design

Double Side PCB laminate Components

SMD THD

Software Target3001! - version limited at 400 pins /

pads

Lower board3D bottom view

Lower board3D top view

Lower boardDesign problem

Upper board3D bottom view

Upper board3D top view

Upper board

What is missing from the upper board? Electronic switch

Why?

Upper boardCopper Top Layer

Upper boardCopper Bottom Layer

Boards manufacturing

Older printer (Samsung) – 600 dpi resolution New printer (HP) - 1200 dpi resolution

Very good results after some tests Problems – printer driver for Windows 7

Printing problems MS Word (doc)

Different results Picture (png)

Scaling problems

Good results with pdf files

After we’ve learned how to do it (printing)

After we’ve learned how to do it (printing)

Alignment of TOP & BOTTOM Layers

Toner Transfer problems

Toner Transfer problems

After we’ve learned how to transfer the toner

After we’ve learned how to transfer the toner

Seal the toner

Seal the toner

Quite good alignment between top and bottom

Final upper board (top) with min 0.6 mm tracks (top)

Final upper board (down) with min 0.3 mm tracks (bottom)

Karel Second PrototypeProblems & Future Work Some circuits (e.g. for battery

management) not tested yet Some integrated circuits are not so easy

to procure (e.g. the ones made by Seiko) Possible new changes in design using

new integrated circuits (e.g. boost regulator supplied from 1 Li-Po battery with high output current capabilities)

Karel Project MeetingKaterini, 12 – 19.10.2014

Bibliography

Agape, Mihai. Agape, Maria-Genoveva. “KAREL Specifications”, agreed in Karel Project Meeting, held at Beypazari on 10–16.11.2013. http://sdrv.ms/170NTak

Agape, Mihai. “Karelino—One Step in Karel Robotic Platform Developing”, presentation given at National Symposium IPO-TECH, Tirgu-Neamt, 29.03.2014

Bibliography

Agape, Mihai. “KARELController Design”, presentation delivered at Karel project meeting, held at Rybnik, 06-13.04.2014

Agape, Cristina-Maria. “KAREL Controller Manufacturing”, presentation delivered at Karel project meeting, held at Rybnik, 06-13.04.2014

Bibliography (cont.)

*** ATmega32U4, 7766G–AVR–02/2014. Atmel. http://www.atmel.com/Images/Atmel-7766-8-bit-AVR-ATmega16U4-32U4_%20Datasheet.pdf

*** DRV8833, SLVSAR1C. Texas Instruments. http://www.ti.com/lit/gpn/drv8833.

*** LM2940, SNVS769I. Texas Instruments. http://www.ti.com/lit/gpn/lm2940-n.

*** LM1117, SNOS412M. Texas Instruments. http://www.ti.com/lit/gpn/lm1117-n

*** Bluetooth Module BTM-112. Rayson.

Questions?