HANDHELD CAMERA STABILIZER SENIOR DESIGN II – SUMMER 2014 – TEAM 3 Thomas Mizell Alexander Pennock Ahmed Salih Report Submitted: July 30th, 2014 Project Sponsor: Professor Michael Young, George Mason University SENIOR DESIGN II – SUMMER 2014 – TEAM 3: Mizell, Pennock, Salih SENIOR DESIGN II – SUMMER 2014 – TEAM 3: Mizell, Pennock, Salih TABLE OF CONTENTS 1. EXECUTIVE SUMMARY ..................................................................................................... 1 2. INTRODUCTION ................................................................................................................... 2 2.1. Motivation .......................................................................................................................... 2 2.2. Objectives ......................................................................................................................... 3 2.3. Specifications & Requirements ................................................................................... 3 2.3.1. Customer Specifications ........................................................................................ 3 2.3.2. Pilot & Passenger Use of HCS .............................................................................. 4 2.3.3. Microcontroller ......................................................................................................... 5 2.3.4. Motors ......................................................................................................................... 5 2.3.5. Motor Drivers ............................................................................................................ 5 2.3.6. Sensors ....................................................................................................................... 5 2.3.7. Power Supply & Monitoring .................................................................................. 5 2.3.8. Frame Design ............................................................................................................ 6 2.3.9. PCB .............................................................................................................................. 6 3. RESEARCH & INVESTIGATION ....................................................................................... 7 3.1. Mechanical System Research ...................................................................................... 7 3.1.1. Existing Products & Designs ................................................................................ 7 3.1.1.1. Steadicam ........................................................................................................... 7 3.1.1.2. Fig Rig.................................................................................................................. 8 3.1.1.3. Glidecam HD 1000 ............................................................................................ 9 3.1.2. Proposed Designs ................................................................................................. 10 3.1.2.1. Arm Cuff Camera Stabilizer ......................................................................... 10 3.1.2.2. D-Grip Camera Stabilizer .............................................................................. 11 3.1.2.3. Gyro-Based Servo Camera Stabilizer ........................................................ 12 3.1.3. Customer Review & Feasibility .......................................................................... 13 3.1.4. Objective and Specification Modification ........................................................ 15 3.2. Electrical System Research ........................................................................................ 16 3.2.1. Control ...................................................................................................................... 16 3.2.1.1. Output System ................................................................................................. 16 3.2.1.1.1. DC Motors .................................................................................................. 17 3.2.1.1.2. Motor Drivers ............................................................................................ 23 i SENIOR DESIGN II – SUMMER 2014 – TEAM 3: Mizell, Pennock, Salih 3.2.1.2. Input System .................................................................................................... 29 3.2.1.2.1. IMU .............................................................................................................. 29 3.2.1.2.2. Hardware Sensors ................................................................................... 34 3.2.1.3. Controller .......................................................................................................... 36 3.2.1.3.1. Microprocessors ...................................................................................... 36 3.2.1.4. Control Theory & Application ...................................................................... 38 3.2.1.4.1. PID ............................................................................................................... 38 3.2.1.4.2. Rolling Average ....................................................................................... 38 3.2.1.4.3. Value Binning ........................................................................................... 40 3.2.2. Power ........................................................................................................................ 40 3.2.2.1. Batteries ............................................................................................................ 41 3.2.2.1.1. Non-Rechargeable ................................................................................... 41 3.2.2.1.2. Rechargeable ............................................................................................ 41 3.2.2.1.3. Lithium Ion ................................................................................................ 42 3.2.2.1.4. Lithium Ion Polymer ............................................................................... 43 3.2.2.1.5. Nickel Metal Hydride ............................................................................... 43 3.2.2.1.6. Alkaline ...................................................................................................... 44 3.2.2.2. Battery Monitoring .......................................................................................... 45 4. PRODUCTION ..................................................................................................................... 47 4.1. Electronic Circuitry ....................................................................................................... 47 4.1.1. PCB Options ............................................................................................................ 47 4.1.2. Layout & Rules of Thumb .................................................................................... 49 4.1.3. Connectors, Cables, Cables & Jumpers .......................................................... 49 4.1.4. Component Packages ........................................................................................... 53 4.1.5. Soldering Methods................................................................................................. 55 4.2. Frame ................................................................................................................................ 59 4.2.1. Materials ................................................................................................................... 59 5. DETAILED DESIGN CONTENT ....................................................................................... 61 5.1. Mechanical System Design ........................................................................................ 61 5.2. Electrical System Design ............................................................................................ 63 5.2.1. Control System ....................................................................................................... 63 5.2.1.1. Output System ................................................................................................. 63 5.2.1.2. Input System .................................................................................................... 64 ii SENIOR DESIGN II – SUMMER 2014 – TEAM 3: Mizell, Pennock, Salih 5.2.1.3. Controller .......................................................................................................... 65 5.2.2. Power ........................................................................................................................ 65 5.2.3. User Interface .......................................................................................................... 66 5.3. Explicit Design Summary ............................................................................................ 67 5.3.1. Block Diagram ........................................................................................................ 67 5.3.2. Electronic Parts List .............................................................................................. 68 5.3.3 Final Design Schematic ......................................................................................... 69 5.3.3.1 Voltage Regulation Subsystem .................................................................... 69 5.3.3.2 Microprocessor Subsystem .......................................................................... 69 5.3.3.3 IMU Subsystem