neic/swagway

Segway clone

Swagway

The Swagway is a Segway clone.

It is a school project at HTX Frederikshavn.

Mechanical

It consists of a welded steel frame with two motors and gearbox assemblies from a powered wheelchair. The motors are 140W each and run on 24V. The batteries are two cheap 12V 18Ah lead batteries.

Electronics

The electronics is build around an Arduino. It gets it input from a ADXL345 accelerometer and a ITG-3200 gyro and drives the motors through two HEXFET bridges.

The schematic and board layouts are in Electronics/

Software

The software for the Arduino onboard the Swagway is located in Software/swagway/

A Processing application with a rolling graph for debugging the angles is located in Software/graph/

Rapport

A rapport (in danish) on the complete build process will be located in Rapport/

swagway's Issues

Calibrate gyro

Make gyro calibration work properly

Gyro calibration

Make a function to calibrate the gyro drift and set the gyro angle to match the accelerometer raiting.

Display board

Design, buld and debug the display board.

LED and contact: 9V

Add a contact and a status led on the mainboard

Circuit around boards

Connect the batteries, motors, circuit breakers, fuses,

The motorcontroller wont turn OFF fast enough

When turning off pin 2 on the motorboard the gate of the FET is still on for some time.

It is the same on the other H-brigde, the same with a new optocoupler,

+ is at the wrong pin on the motorboard v1.0

Distance around the capasitor pads

Add some distance between the capasitor pad and the net beside it on the motorboard.

Motorcontroller mounting holes

Make clearence for mounting holes

Trimpots

Three trimpots are needed on the main board, in order to tune the Kalman filter correctly.

Debugging software is getting slow

After recieving data in some time, the software is getting slow. Most likely due to the tbMonitor getting filled.

LEDs on the motorboard

Add two LEDs to each motor output so it is easy to see what directions the motor travels.

Add reset button

The mainboard covers the reset button on Arduino UNO R2. Add one on the mainboard.

Make the auto scroll checkbox work

New steering component

Make the rolling graph work

Make dataClean() more robust

If the PC can't keep up with the recived data the dataClean() will fail to split the data correct.

New IMU mount

Add connectors to steering

Add 5×2 pinheader to the mainboard to connect two photointerrupters for seering.

Make the polar plot work

Graph for testing

Make a graph for testing the Kalman filter

Redo motorboard

Redo the motorboard with an additional stage of HEX FETs to drive PWM. Closes #28

9V header is too close to gyro header on mainboard

Handlebar lock

Make a mechanic lock for the handlebar

Support for radio

Make the onboard software work with the radio on the new mainboard.

Optocoupler pre-resistors has to be moved to motorboard

Design the PID tab

Redo mainboard and pin assignments

Redo the mainboard and pin assignments to fit the new motorboard #30.

Main contact: 24V

There's need for a main contact for the 24V system.

GyroAngle is ~2 times to large

For some unknow reason the gyroAngle is about two times as large as expected.

Steering

Design and build a solution for the seering.

Possible solutions:
Radial potentiometer
Linear potentiometer
Two opto interupters
Steppermotor
Straingate
Ultrasound range detector
LDR, LED and a thin wegde

Pins for radio

Add a female pinhead to the mainboard to put in a radio.

Vias are to small on mainboard

All of the copper are removed when vias are drilled with a 0,8mm drilbit.

Make the accelerometer data processing work as in the gyro libary

Add LEDs to optocouplers

Add LEDs to the Motorcontroller so it is possible so se what optocouplers are HIGH

Vias are to small on motorboard

Kalman filter

Add the Kalman filter on the accelerometer- and gyro-data.

Inconsistent motor speed

Logic for the motorcontroller on the mainboard is wrong

Make the functions behind the PID tab work

Motorboard

Build the first version of the motorboard

New heat sink.

Make a new heatsink to fit the new motorboard. #30

Balance weights

Make some kind of balance weights

Main board

Design, build and debug the mainboard.

Add PID control

Add PID control for the motorcontrol and tune it.

For tuning procedure se: http://sites.google.com/site/vilorei/fischertechnik/m--models/m11--playing-with-an-accelerometer/08--the-pid-controller

Source and drain are connected opposite

The source and dran on IRF4905 on the motorboard v1.0 are connected opposite. (The eagle symbol and the datasheet symbol are opposite)