Sgt. Samuel H. Buckstein edited Common.tex  about 10 years ago

Commit id: ee4b6e04aa5ba833e1ebd45e903b47c379d8a9ec

deletions | additions      

       

\section{12 Integration} \section{Integration}  This section describes the process by with the electro-mecahinical components, circuitry and PIC microcontroller were integrated and made to work with eachother.   \subsection{12.1 Integrating \subsection{Integrating  PIC and Circuit Subsystems} The integration plan prioritized integrating the circuits with the PIC off the machine first and establishing that the circuits sent the required signals correctly and that the PIC interpreted the input it recieved correctly. 

For the sensor array; first the light sensors were fed through their respective holes in the shade array, running wires from the sensors to where the sensor board would be, then mounting the sensor board last.   Before the the sensor array was installed, the servo motors were mounted on the bottom of the machine and attached to the switch activation frame. The servos were tested with candlelights in the tray to ensure that they were recieving a sufficient amount of power to provide the required torque. The servos were extensively calibrated with the PIC to start in the appropriate resting position, and to travel the right distance backwards and forwards required to turn the candlelights on and off.   \subsection{12.2 Motors \subsection{Motors  and Actuation} This process was partially accomplished at this stage, but fine tuning issues were encountered because of the different types of candlelights and minor imperfections in the grooves cut for the switches in the switch actuation frame. Some candlelights could be turned on and off in some configurations, so it was decided that the system worked but required further tuning. The tray is easily accessible for modification because of its required detatchability, so it was decided to continue with the integration process and return to this problem later.  Next, the sensor array was mounted by attaching the shades to the bottom of the array, and tying fishing line from hooks on the top of the array to shafts on the stepper motors. The raising and lowering mechanism was tested to ensure that the motors were recieving sufficient power to satisfy the torque requirements of the motors.   It was discovered that the motors were slipping under the weight of the sensor array, so the motors were removed and replaced with an identical model, but with gear boxes to gain mechanical advantage. At this time, the concern of the sensor array crashing down upon engagement of the emergency stop was solved simply due to the high gear ratio of the stepper motors. Serendipitously the holding torque of the gear box was sufficient to maintain the position of the sensor array even in the absense of electrical power.   \subsection{12.3 Re-design \subsection{Re-design  of the Sensor Array} It was at this time that it was discovered that the holes cut for the light sensors were misaligned with the position of the candlelights in the tray, and as a result the photodiodes were too far from the candlelights to detect a strong enough signal for the PIC to interpret.  

This was accomplished by again removing the sensor array and mounting a series of super-bright LEDs beneath the tray, one LED per well. The LEDs provided a gradient of light that allowed the PIC to distinguish whether a candlelight was present or not beneath the light sensor by comparing the voltage seen by the PIC when no candlelight obstructed the LED from the light sensor against the lower voltage seen when a candlelight obstructed the light path. The LEDs were mounted on the switch activation frame. This solution finally solved the light interference issue and simplified the sensor array by elimination half of the circuitry.   \subsection{12.4 Calibration \subsection{Calibration  of the Switch Actuation Frame and Interfacing with the PIC} REIN WRITE HERE ABOUT CALIBRATING THE SWITCH ACTIVATION MECHANISM, ISSUES ENCOUNTERED WITH 'NO FORCE ALLOWED', ETC. 

A dock for the cable bus was made on a circuit board with wireouts to all the subsystems that required communication with the PIC. The circuit board was mounted on the machine and the connections were made to all the various subsystems and components.   \subsection{12.5 Final \subsection{Final  Touches} Then power wires and grounds were run throughout the machine and organized to converge upon a single point. A fully power test was conducted to verify that all systems recieved sufficient electrical power while operating simultanteously. The power supply was then mounted and the wires from the power supply were first connected to the emergency stop and then to the power hubs.   All wires were labled, bundled and organized with zipties.   Finally, the devbugger board containing the PIC was mounted on the front face of the machine.