Team 23 Enterprises Presents…

™

Outline of PresentationOutline of Presentation

Objectives / ParametersObjectives / ParametersRobot Prototype DesignRobot Prototype Design

HardwareHardwareSoftwareSoftware

Cost and FeasibilityCost and FeasibilityPrototype System AnalysisPrototype System AnalysisEvaluation and ConclusionEvaluation and Conclusion

ObjectivesObjectives

• To demonstrate the feasibility of an To demonstrate the feasibility of an autonomously operated robotic retrieval autonomously operated robotic retrieval system (AORRS)system (AORRS)

• To move manufactured products from To move manufactured products from specified storage locations to a centralized specified storage locations to a centralized repository within a warehouse facilityrepository within a warehouse facility

ParametersParameters

operate within 12” wide corridor operate within 12” wide corridor travel to a calculated “home location”travel to a calculated “home location”minimum running velocity of 0.5 ft/sminimum running velocity of 0.5 ft/s total average velocity of 0.3 ft/stotal average velocity of 0.3 ft/s travel to binstravel to bins transmit a signal at binstransmit a signal at bins return to home location. return to home location.

Robot DesignRobot Design

Lucky III (Final Design)

Preliminary Hardware DesignPreliminary Hardware Design

Design XDesign X No turning / locked axlesNo turning / locked axles Operated on 1 motorOperated on 1 motor Distance based on timeDistance based on time

Lucky ILucky I 2 drive wheels plus 2 guiding wheels2 drive wheels plus 2 guiding wheels lifting motor to allow turninglifting motor to allow turning Distance and turning based on timeDistance and turning based on time

Preliminary Hardware Design Preliminary Hardware Design (cont.)(cont.)

Lucky IILucky II 2 drive wheels plus 2 2 drive wheels plus 2

guiding wheelsguiding wheels More stable and More stable and

accurate lift motor accurate lift motor mechanismmechanism

Synchronizing drive Synchronizing drive wheel mechanismwheel mechanism

Distance and turn Distance and turn based on timebased on time

Lucky III (Final Design)Lucky III (Final Design)

Two Chassis DesignTwo Chassis Design4 wheels per Chassis (2 drive / 2 guiding)4 wheels per Chassis (2 drive / 2 guiding)Light Sensor Odometer SystemLight Sensor Odometer SystemLift motor for changing chassisLift motor for changing chassis

Lucky III special features…Lucky III special features…

Lucky III w/ 2 chassis design

N/S chassis

E/W Chassis

Lift Mechanism / Guide Rails

Light Sensor Odometer

Accurate TurningAccurate Turning

Software Design (Fortran)Software Design (Fortran)

Inputs bin information Inputs bin information from the userfrom the user

Creates a C header Creates a C header filefile

Outputs movement Outputs movement mapmap

Map is well formatted Map is well formatted and easy to useand easy to use

Input

Valid Home Loc.?

Calc Home Loc.

BubbleSort

Adjust Home Loc.

Output

Start

Stop

No

Yes

Software Design (C)Software Design (C)

User-defined User-defined functionsfunctions

Easy to modifyEasy to modify Measures distance Measures distance

with light sensorswith light sensors Only runs necessary Only runs necessary

motorsmotors

#define NUMBINS 4#define NUMRETR { 2, 3, 2, 1}#define LOITERTIME 15.0#define XPOS { 5, 2, 3, 3}#define YPOS { 3, 7, 5, 5}#define HOMEX 4#define HOMEY 6#define FORCE 7

Move to bin

Loiter and transmit

Return Home

Start

Stop

InputMove to home

Is I < Number of Bins?

Is I2 < Number of Retrievals?

I = 0

Incr. I

Incr. I2

I2 = 0No

Yes

Yes

No

Cost and FeasibilityCost and Feasibility

Part Quantity Price SubtotalsRCX 1 $85,000 $85,000

Motor 3 $15,000 $45,000

Light Sensor 2 $10,000 $20,000

Misc. parts (total) - $10,000 $10,000

Assembly - $5,000 $5,000

Total $165,000

Production cost of a single robot:

Man HoursMan HoursPurpose # Team members Hours spent Subtotal

Subtask 1 robot construction and programming 4 12 48

Subtask 1 presentation 3 3 9

Subtask 2 robot modifications and programming 4 3 12

Subtask 2 presentation 4 3 12

Complete robot redesign and construction 1 9 9

Subtask 3 robot programming and testing 4 16 64

Subtask 3 presentation 4 3 12

Brick OS meeting 1 1 1

Subtask 4 robot programming and testing 4 5 20

Subtask 4 presentation 2 3 6

Complete robot redesign and construction 1 16 16

Final robot programming and testing 4 18 72

Independent programming 1 2 2

Transmission and distance testing at office hours 2 3 6

Preparation for final presentation 3 2 6

Final presentation 4 3 12

Total 307

Development Cost and Development Cost and Breaking Even Breaking Even

Development cost = (307) × ($17,000) = Development cost = (307) × ($17,000) = $5,219,000$5,219,000

To Break even:To Break even:($250,000) × # of Robots = ($165,000) × # of Robots + ($5,219,000)($250,000) × # of Robots = ($165,000) × # of Robots + ($5,219,000) ] ]

# of Robots ≈ # of Robots ≈ 6262

This is a reasonable number of robotsThis is a reasonable number of robots

Replacing Standard ForkliftsReplacing Standard Forklifts

Cost to operate 1 forklift for 1 yearCost to operate 1 forklift for 1 year2 operators/hr × 24 hrs/day × 349 days/yr × 2 operators/hr × 24 hrs/day × 349 days/yr ×

$18/hr = $301,536 per year/forklift$18/hr = $301,536 per year/forkliftRobot = $0Robot = $0

Multiplied by 62 forklifts (only break even)Multiplied by 62 forklifts (only break even)

Almost $19 million difference. Almost $19 million difference.

Replacing Standard ForkliftsReplacing Standard Forklifts

ProsProsSave moneySave moneyNever get tiredNever get tiredFlat rate (no inflation, benefits, etc.)Flat rate (no inflation, benefits, etc.)

ConsConsTechnicians require more trainingTechnicians require more trainingLoss of jobsLoss of jobsLoss of human judgementLoss of human judgement

Prototype System AnalysisPrototype System Analysis Mechanical design (positive aspects)Mechanical design (positive aspects)

Two chassis-systemTwo chassis-system Light sensor odometer systemLight sensor odometer system Use of higher motor speeds and gearing-downUse of higher motor speeds and gearing-down Reliable lifting mechanismReliable lifting mechanism

Programming design (positive aspects)Programming design (positive aspects) Use of functions for every operation (C program)Use of functions for every operation (C program) Extensive testing (both Fortran and C)Extensive testing (both Fortran and C) Simplistic use of language minimizes errors (Fortran)Simplistic use of language minimizes errors (Fortran) Use of format statements to perfect movement map Use of format statements to perfect movement map

(Fortran)(Fortran) User-Friendly (Fortran)User-Friendly (Fortran)

Prototype System AnalysisPrototype System Analysis

Mechanical design (negative aspects)Mechanical design (negative aspects)Design was relatively frailDesign was relatively frail Incapable of turningIncapable of turningRoom for improvement of light sensor odometer Room for improvement of light sensor odometer

systemsystemSlight tire slippageSlight tire slippage

Programming design (negative aspects)Programming design (negative aspects)Minimal error trapping (both Fortran and C)Minimal error trapping (both Fortran and C)

Evaluation and ConclusionEvaluation and Conclusion

We felt that we had the correct focus for We felt that we had the correct focus for this project— eliminate or minimize errorthis project— eliminate or minimize error

Areas Error was eliminated or minimized:Areas Error was eliminated or minimized:TurningTurningDistance traveledDistance traveledGoing straightGoing straight

Areas where error remainsAreas where error remainsAverage velocity and time to travel to a binAverage velocity and time to travel to a bin

EvaluationEvaluation Overall, Lucky III performed wellOverall, Lucky III performed well

Earned 90 / 100 pts.Earned 90 / 100 pts. ShortcomingsShortcomings

Robot required redressRobot required redress Some time predictions inaccurateSome time predictions inaccurate

ConclusionConclusion Our robot prototype outperformed that of others Our robot prototype outperformed that of others

by a significant margin.by a significant margin. The design we used would be successful in a The design we used would be successful in a

real warehouse setting, with minimal real warehouse setting, with minimal modifications.modifications.

Don’t be a fool, stay in school!