Human Extraction Rescue Robot Material Handling Methodology & Proof-of-Concept Prototype Matthew P. King Erin B. Rapacki In partnership with… ADVISORS

Human Extraction Rescue RobotHuman Extraction Rescue RobotMaterial Handling Methodology & Material Handling Methodology & Proof-of-Concept PrototypeProof-of-Concept Prototype

Matthew P. KingMatthew P. KingErin B. RapackiErin B. Rapacki

In partnership with…In partnership with…

ADVISORSADVISORS

Prof. Tom CullinaneProf. Tom CullinaneProf. Greg KowalskiProf. Greg Kowalski

17 April 200717 April 2007Matt King & Erin RapackiMatt King & Erin RapackiNortheastern UniversityNortheastern University ATHENA: Final ReportATHENA: Final Report

Problem StatementProblem StatementPerform a Robotic Extraction of a 200lb ManikinPerform a Robotic Extraction of a 200lb Manikin

ATHENA Proof-of-Concept Payload


iRobot WARRIORiRobot WARRIORRobotic Mobility PlatformRobotic Mobility Platform

LengthLength– 40 Inches40 Inches

WidthWidth– 29 Inches29 Inches

HeightHeight– 18 Inches (stowed)18 Inches (stowed)

Distance: Front wheelsDistance: Front wheels– 24 Inches24 Inches

WeightWeight– Vehicle weight:Vehicle weight:

250lbs250lbs Onboard power & Onboard power &

communication for communication for tele-operation tele-operation

Payload Surface TiltsPayload Surface Tilts– Rotates upward around wheel Rotates upward around wheel

hubshubs

Center of Rotation

Tilts Upward

24” Span


Rescue RandyRescue Randy200lb Manikin200lb Manikin

HeightHeight– 73 Inches73 Inches

Width Width – ShouldersShoulders

23 Inches23 Inches Head dimensionsHead dimensions

– DiameterDiameter 7 Inches7 Inches

– Top of head to shouldersTop of head to shoulders 10 Inches10 Inches

WeightWeight 200lbs200lbs


Extraction ScenarioExtraction ScenarioFlat Back & Face Up; Indoor SettingFlat Back & Face Up; Indoor Setting

Established base-line Established base-line scenarioscenario– Rescue RandyRescue Randy

Flat backFlat back Face upFace up

– EnvironmentEnvironment Indoor settingIndoor setting Smooth floorSmooth floor

– Hard flooringHard flooring– Office carpetOffice carpet

Proof-of-concept payloadProof-of-concept payload– Mechanically functional Mechanically functional

systemsystem 200lb manikin200lb manikin


Design ConsiderationsDesign ConsiderationsiRobot WARRIOR & Rescue RandyiRobot WARRIOR & Rescue Randy

Extract manikin in a head Extract manikin in a head first orientationfirst orientation– Utilize WARRIOR’s tilt Utilize WARRIOR’s tilt

capabilitiescapabilities Torque and loading Torque and loading

specificationsspecifications

– Manikin’s physical Manikin’s physical dimensionsdimensions

Center of Rotation

Tilts Upward

24” Span


Material Handling Material Handling Methodology OutlineMethodology OutlineHead-First; Use TiltHead-First; Use Tilt

Head-first extractionHead-first extraction– Use shoulders to initiate liftUse shoulders to initiate lift

23” span to manipulate23” span to manipulate Create access point under Create access point under

the torsothe torso– Extend platform underneath Extend platform underneath

the backthe back Transfer manikin’s mass to Transfer manikin’s mass to

platform surfaceplatform surface– Rescue Randy conveyed up Rescue Randy conveyed up

WARRIOR platformWARRIOR platform


Prototype DesignPrototype DesignHead & Shoulder LiftHead & Shoulder Lift

Linear drive delivers head Linear drive delivers head support and effecting forks support and effecting forks – Head support cushions bias Head support cushions bias

forwardforward– Cushions articulate around Cushions articulate around

headhead– Effecting forks initiate lift by Effecting forks initiate lift by

propping the shoulders off propping the shoulders off the groundthe ground

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Prototype DesignPrototype DesignConvey Rescue Randy up PayloadConvey Rescue Randy up Payload

Extend platform under torsoExtend platform under torso– Utilizing access point created by Utilizing access point created by

shoulder liftshoulder lift– Driven by rack & pinion systemDriven by rack & pinion system

Unfurl conveyor belt under Unfurl conveyor belt under torsotorso– Manikin’s mass on beltingManikin’s mass on belting– Pull belting up platformPull belting up platform

Via linear driveVia linear drive

– Belting stored under payloadBelting stored under payload Spring-loaded rollerSpring-loaded roller

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Prototype DesignPrototype DesignConveyor FunctionConveyor Function

Conveyor belting (yellow line) loaded onto a spring roller at the beginning of extraction

Conveyor belting (yellow line) unfurled 80” at the completion of an extraction


Extraction DescriptionExtraction Description

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Component DefinitionComponent DefinitionFour Sub-AssembliesFour Sub-Assemblies

Head Support / ForksHead Support / Forks

Motors & Linear Motors & Linear DrivesDrives

SpatulaSpatula

Litter


Litter DesignLitter DesignComponents & Structural Analysis: 200lbsComponents & Structural Analysis: 200lbs

ComponentsComponents– 0.5” Aluminum Side Rails0.5” Aluminum Side Rails

Cut-outs for weight Cut-outs for weight reductionreduction

– 0.5” Aluminum Base Rails0.5” Aluminum Base Rails Interface with WARRIORInterface with WARRIOR

– Top PanelTop Panel 3/16” Aluminum Sheet 3/16” Aluminum Sheet

AnalysisAnalysis– Lowest safety factor: 4.3Lowest safety factor: 4.3

Non-uniform loading on Non-uniform loading on cantilevered portioncantilevered portion

Front Litter Support Analysis: Stress and Deformation

Rear Litter Support Stress Analysis


Spatula DesignSpatula DesignComponents & Structural Analysis: 200lbsComponents & Structural Analysis: 200lbs

ComponentsComponents– 0.5” Aluminum Rails0.5” Aluminum Rails– 3/16” Aluminum Platform 3/16” Aluminum Platform – Spatula-Conveyor Spatula-Conveyor

InterfaceInterface Fixed at end of spatulaFixed at end of spatula

Drawer Slide Capacity:Drawer Slide Capacity:– 280lbs at 24” span280lbs at 24” span

AnalysisAnalysis– Lowest safety factor: 3.6Lowest safety factor: 3.6

Non-uniform loading on Non-uniform loading on tip of front railtip of front rail

Front-Rail Deformation

Front-Spatula Stress Analysis


Head Support & ForksHead Support & ForksBio-metrics & Structural Analysis: 200lbsBio-metrics & Structural Analysis: 200lbs

Head CushionsHead Cushions– Head cushion rails rest on forksHead cushion rails rest on forks

Spring Biasing ArmSpring Biasing Arm– Provide passive head support and Provide passive head support and

biasing along forksbiasing along forks Fork DesignFork Design

– Frelon Slides & BlocksFrelon Slides & Blocks– 3” Wide, 1.5” Thick3” Wide, 1.5” Thick

AnalysisAnalysis– Safety factor: 3.2Safety factor: 3.2

Single fork supporting 200 lb. load Single fork supporting 200 lb. load at endat end

Forks

Head Cushions

Spring Biasing Arm

Fork Deformation Fork Stress Analysis


Linear Drive Linear Drive Assemblies Assemblies Central Lead Screw and Spatula RackCentral Lead Screw and Spatula Rack

0.5” precision lead screw0.5” precision lead screw– 50 in-lb torque50 in-lb torque

Spider couplingSpider coupling– Lead screw–to–motor shaftLead screw–to–motor shaft– misalignment compensationmisalignment compensation

Versa-mount rail and blockVersa-mount rail and block– Buckling resistanceBuckling resistance

Spatula extension and Spatula extension and retractionretraction– Rack and pinion, ½” face Rack and pinion, ½” face

widthwidth– Under mount on spatula Under mount on spatula

surfacesurface


Motor and Control Motor and Control DesignDesignPulse width modulating RC controller and DC gear Pulse width modulating RC controller and DC gear motorsmotors Vantec speed controllerVantec speed controller

– RC to maintain tele-operation RC to maintain tele-operation when mounted to WARRIOR when mounted to WARRIOR

– Dual 20 amp continuous channelsDual 20 amp continuous channels– Pulse width modulation Pulse width modulation

24 vdc gear motor24 vdc gear motor– Torque to 100 in-lbs at 19.12 Torque to 100 in-lbs at 19.12

ampsamps Independent Power SupplyIndependent Power Supply

– Dual 12 vdc motorcycle batteriesDual 12 vdc motorcycle batteries– Provide necessary instantaneous Provide necessary instantaneous

current sourcecurrent source


Final DeliverableFinal DeliverablePayload PrototypePayload Prototype

Demonstrates component functionalityDemonstrates component functionality– Loading and actuationLoading and actuation

Drive systems and structureDrive systems and structure

Functional mechanical system Functional mechanical system – Load capacity for 200 lb manikinLoad capacity for 200 lb manikin– Motor specifications for control integrationMotor specifications for control integration


ProjectionProjectionDesign ImprovementsDesign Improvements

At iRobot At iRobot – Integrate motors and control systemIntegrate motors and control system– Demonstrate extraction methodology with Demonstrate extraction methodology with

WARRIORWARRIOR Long TermLong Term

– Weight reduction:Weight reduction: Custom slide system for spatulaCustom slide system for spatula Light materialsLight materials

– TitaniumTitanium– DelrinDelrin– Aluminum Super AlloysAluminum Super Alloys

– Modify extraction process according to testingModify extraction process according to testing Additional features, details, & appendagesAdditional features, details, & appendages

– Extraction in tighter areasExtraction in tighter areas

Human Extraction Rescue RobotHuman Extraction Rescue RobotMaterial Handling Methodology & Material Handling Methodology & Proof-of-Concept PrototypeProof-of-Concept Prototype

Final ReportFinal Report

QUESTIONS?QUESTIONS?

Documents

Human Extraction Rescue Robot Material Handling Methodology & Proof-of-Concept Prototype Matthew P. King Erin B. Rapacki In partnership with… ADVISORS