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Sensitive Calligraphy Robot & Design Review Creation

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Sensitive Calligraphy Robot & Design Review Creation Sensitive Calligraphy Robot & Design Review Creation A Major Qualifying Project Report Submitted to the Faculty of WORCESTER POLYTECHNIC INSTITUTE in partial fulfillment of the requirements for the Degree of Bachelor of Science by: Carly J. Buchanan Date: May 1, 2014 Report Submitted to: Eduardo Torres-Jara, Advisor Ryan Madan, Advisor This work represents the work of one WPI undergraduate student submitted to the faculty as evidence of completion of a degree requirement. WPI routinely publishes these reports on its website without editorial or peer review. 1 | Page CONTENTS Introduction: Calligraphy Robot .................................................................................................................................... 4 Motivation & Background ............................................................................................................................................. 4 Applications of Control System for Calligraphy ......................................................................................................... 5 Possible Applications for Surgical Robotics ............................................................................................................... 7 Task and Scope .............................................................................................................................................................. 8 Design Overview ............................................................................................................................................................ 9 The End Effector .......................................................................................................................................................... 11 The Pen .................................................................................................................................................................... 11 Pen Holder ............................................................................................................................................................... 14 Series Elastic Actuator ............................................................................................................................................. 17 Supporting Bracket .................................................................................................................................................. 20 Gantry System ......................................................................................................................................................... 21 Motor Selection ........................................................................................................................................................... 24 Electrical system ...................................................................................................................................................... 27 Control Architecture ................................................................................................................................................ 28 Bezier Curves ...................................................................................................................................................... 31 Results ......................................................................................................................................................................... 32 Budget & Sponsors ...................................................................................................................................................... 34 Recommendations and Next Steps .............................................................................................................................. 34 Conclusion ................................................................................................................................................................... 35 Nomenclature Glossary ............................................................................................................................................... 36 References ................................................................................................................................................................... 37 Introduction: Design Review Creation Process ............................................................................................................ 40 Background & Literature Review ................................................................................................................................ 41 What are Design Reviews?...................................................................................................................................... 42 Why Cornell Cup Requires Design Reviews .......................................................................................................... 43 Importance of Design Reviews ............................................................................................................................... 44 Prior Knowledge ..................................................................................................................................................... 46 Methodology Overview ............................................................................................................................................... 53 Method of Analysis ................................................................................................................................................. 54 Methodology of this Study ...................................................................................................................................... 57 2 | Page Analysis of the First Design Review ........................................................................................................................... 58 Stakeholders ............................................................................................................................................................ 60 Purposes .................................................................................................................................................................. 62 Pressures .................................................................................................................................................................. 67 Features ................................................................................................................................................................... 69 Documents............................................................................................................................................................... 70 Results from First Design Review ............................................................................................................................... 74 Analysis of the Second Design Review ....................................................................................................................... 77 Iterative Refinement and Balancing ........................................................................................................................ 79 Context: Timing, Pressures, and Constraints .......................................................................................................... 81 Results from Second Design Review ........................................................................................................................... 84 Conclusion ................................................................................................................................................................... 88 References: .................................................................................................................................................................. 92 3 | Page SENSITIVE CALLIGRAPHY ROBOT Development of a Platform for Combined Force & Position Control INTRODUCTION: CALLIGRAPHY ROBOT The calligraphy robot was developed as a proof-of-concept for a compliant platform with a control system that maintains accuracy of position. The end-effector was designed to utilize a rotary series elastic actuator (SEA) for compliance and force-sensing. The mechanical system that supported the end-effector was a gantry system designed for smooth motion and accurate positioning. The mechanical platform and force-sensing software were designed to support the full integration with a PVT controller. The PVT software that created the motion paths and controlled the accuracy of the positioning was not a part of this MQP. It was programmed by Ennio Claretti and Allen Blaylock who were part of the team that prepared this robot for the Cornell Cup Competition. The Cornell Cup Competition, presented by Intel, accepts 30 teams from universities across the United States to participate in an embedded design competition that spans one academic year and culminates in an exposition and final judging. The competition required several design reviews to be conducted over the development of the design, in order to mimic a professional engineering process. However, there is not a significant body of examples and references that are helpful guides to critically approaching the creation of a design review. The Cornell Cup design reviews formed the analytical basis for a study on the choices that must be made during their creation and the forces that influence those choices,
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