Production Plan¶
Prototype¶
COMPLETED: See History of this page for records
Testing/Validation¶
ESD Protection¶
- Need to plan this
Power System/Charging¶
- Need to plan this
- Test batteries (loading, charge cycles, etc.)
- Test power switching (brownout detection?)
Support ACPI?[updated 10-04-2010]- No need, gumstix and avr can shut off when power removed without corruption
- Test motor current draw at (no load, loaded (normal), and stall)
- Target current limiting is 1.4A per 2 motors (~700mA each) [updated 10-04-2010]
- Under 15lb loading the (150:1) motors drew <1000mA overall, so this should not be a problem
- We are switching gearing to (50:1 or 100:1) so the current load could change. Will update when testing is completed.
- Target current limiting is 1.4A per 2 motors (~700mA each) [updated 10-04-2010]
Chassis/Drive System¶
- Tested extensively on carpet, concrete, tile, grass, pebbles, and rock.
- All tests passed
- Tested over wires/cables, random clutter, door thresholds, rugs, etc.
- All tests passed
- Tested under heavy (over that expected) load (mounted on chassis) and pulling load from rear
- All tests passed
- 15lbs carrying, 18lbs pulling on wagons with no additional mass on Scout.
- Tested driving up an incline, unloaded, at various voltages
- All tests passed
- Can climb a 80% grade (40deg slope) unloaded on a painted surface
- Results from rocky or slippery surfaces (like kitty litter) are inconclusive about slope, but maximum angle is sig. reduced
Senors¶
- Need to plan this
Final Production¶
Mechanical¶
- Chassis components are waterjet at NREC
- Acrylic & polypropylene components are laser cut at the Collaborative Machining Center (DH B211)
- All parts are assembled in the robotics club
- At this point no specialized tools are required
- Depending on required volume, may use a hydraulic press to shape the chassis
Board (Scoutfly)¶
- Boards will be printed at GoldPhoenix (4 layer board @ $280/155sq inches + fees)
- At 3.5x4.5", we have 15.75sq inches per board
- Pick and place at GoldPhoneix?
- Probably won't do this
- Require us to purchase and send all components to China for assembly
- Need to check on cost
- If we perfect the in-house process, making 10 boards may not be too bad
- Probably won't do this
- Assembly will be done at the robotics club
- We have purchased an oven for reflow, and will acquire a kapton stencil for the dev board
- Still need a stereo microscope
GoldPhoenix Ordering Process¶
As detailed on http://www.goldphoenixpcb.biz/placeorder.php- Assuming Gerber files have been generated and passed www.freeDFM.com
- Email GoldPhoenix with zip file, must detail layers, board size, silk, soldermask, trace width, etc
- After quote comes back, need to pay
- Accept american express, or payal -> mastercard, visa, bank account
- Extra (3.4% at time of writing) charge for using credit card
- Money transfer to their email address (cash/credit@goldphoenixpcb.biz)
- Again detail all the specs in the description on the paypal website, and provide the board name and rev number
- Print and save confirmation
- Email them and tell them you accept the quote and the email address for your paypal account (and that you have paid :))
Board (BreakFly)¶
- Boards will be printed by ITeadStudio ($24.90 for 10 boards + shipping)
- Turnaround can take up to a month (including shipping), so plan accordingly