AIN SHAMS UNIVERSITY

FACULTY of ENGINEERING
Mechatronics Engineering and Automation Program
MCT 382: Design of Mechatronics(2)
Report on:
Design Concept of the “Night Watch”
Submitted by:
Student name: Moheb Magdy Habib Ishak
Class No.: Section(2)
ID: 13p6050
Table of Content:
1) List of Figure
2) Abstract
3) Mechanical Design
4) Differential Drive
5) Electrical Design
6) Software Architecture
7) Gantt Chart
List of Figures:
Figure 1: Advancing Mode and Automatic Climbing Mode
Figure 2: Mechanical Construction of Locomotion unit
Figure 3: Power Rating
Figure 4: First Shaft Analysis
Figure 5: Second Shaft Analysis
Figure 6: Third Shaft Analysis
Figure 7: Differential Drive
Figure 8: Electric Design
Figure 9: Battery Charging Status
Figure 10: Motor Sizing
Figure 11: Gantt Chart
Abstract:
This paper explains the design of a robot that’s used for surveillance, this robot is designed to
for both even and uneven terrain.
The main aspect covered in this research was how to design a robot that can overcome
obstacles during surveillance and go on different surfaces.
Need:
In the political and socio-economic language, security is the condition of protection against
dangers caused intentionally, for example, by criminal and terrorist actions. In the last
decade, the importance of security has dramatically increased, especially because of the recent
terroristic attacks. A high level of security is commonly perceived as indispensable condition
for a good quality of social life.The concept of security can be applied to different
areas(physical, information, political and economical security). In particular, physical security
is related to the protection against physical attacks; a key issue for physical security is the
video surveillance of critical assets, such as infrastructures and places of mass gathering, for
real-time threat detection. Most modern video-surveillance systems for indoor and outdoor
assets exploit the combined use of static and mobile cameras. The overall representation of
the scene comes from the static cameras, while mobile cameras intervene when some anomaly
is detected, providing high-resolution images of particular people, vehicles, or objects.
Therefore, the use of mobile cameras carried by robots is an effective option whenever it is
useful to monitor a specific zone on-demand. Moreover, a mobile robot can be equipped with
additional sensors in order to detect, for example, chemical or radioactive contaminations,
avoiding the risks related to direct human intervention.
Objective:
For all these reasons, the development of mobile robots capable of carrying cameras and
sensors both in structured and unstructured environments is an interesting research field,
with a wide range of potential applications. In the scientific literature, mobile robots moving
on ground are grouped into three main classes, on the basis of their locomotion system:
wheeled, tracked and legged robots.

Marketing Requirements
1. The robot should be relatively inexpensive.
2. The robot should be able to navigate on even and un even terrain
3. The robot should be intuitive and easy to use for the security personal
4. The robot should include safety mechanisms.
5. The robot should require minimum amount of setup for basic use.
6. The robot should be expandable for increased coverage and security.
7. The robot should can transmit real-time data over some medium.
Technical Requirements:
1) Remotely Controlled Robot
Night
2) Night vision camera
3) 360 rotating camera
4) Tristar wheel
5) Live streaming
6) Rechargeable batteries
7) Solar Charging
8)
Locomotion Unit Design:
The locomotion unit is designed to switch from rolling on wheels (advancing mode) to
stepping on legs (automatic climbing mode) thanks to its mechanical architecture, without
active control intervention. To this aim, the locomotion unit transmission is based on an
epicyclical gearing, and a single motor is sufficient to actuate the locomotion unit both in
advancing mode and in automatic climbing mode.

The Design is based on the following points:

1) Since the robot is not equipped with sensors for obstacle detection and only local
friction and dynamic conditions trigger the transition between wheeled and legged
motion, the locomotion unit motor must rotate in the same direction both in
advancing and in automatic climbing mode.
Therefore, the locomotion unit works properly only if the ratio of the input shaft and
the output shaft of equations (1) and (3) have the same sign; this leads directly to
the condition ke 1
ω𝑜
𝑖𝐴𝑀 = 𝑘𝑒 = ω𝑖
(1)

𝑣𝑎𝑚 = ω𝑜 𝑟𝑜 (2)

𝑘𝑒 ω𝑝
𝑖𝐴𝐶𝑀 = 𝑘𝑒−1
= ω𝑖
(3)

𝑣𝐴𝐶𝑀 = ω𝑝 𝑙𝑝 (4)

2) The ratio between wheel radius ro and leg length lp. The locomotion unit height is hLU
=2 ro + 3/2 lp
3) The Maximum size of the obstacle that can be climbed on during low coefficient of
friction is 0.7 of the height of the hLU
Sprockets were chosen to operate the following mechanism
Mechanical Construction:

The procedure of choosing the sprocket: “According to F ernner”

1. Speed ratio:
It is obtained by dividing the speed of the faster shaft by the speed of the slower
shaft.
The speed ratio is 1:1

2. Calculate the Design Power:

it is determined by multiplying the transmitted power P by the service factor.
The service factor is 1 as it’s a light duty machine as the operating time is less than 10
hours
The Design Power is 36 Watt
3. Selection of the pitch:
The need pitch is 06B

4. Sprocket Size:
No. of teeth of the drive sprocket 10 and the no. of teeth of the driven sprocket is 10

5. Power Rating tables:

Stresses on shafts:
To calculate the stresses on the shaft, first we need to calculate the weight on the front
wheel, the weight transfer on the front wheel is 70% on front 30% on the rear wheels.
Calculating wf= 0.7*9.81*20= 137N
Weight on the front single Wheel = 137/2 = 68.67 N

First Shaft Analysis:

All units are in Nmm

Second Shaft Analysis:

Third Shaft Analysis:
Calculating the shaft diameter based on the shaft with the highest stresses which is the first
shaft.

16 2 2
σ𝑦 = 3 𝑀𝑡 + 𝑇
π𝑑

Steel 60 was chosen thus the calculated the minimum calculated diameter shaft was
3.69mm.
Selection of Bearing:
1) Dynamic Equivalent Radial Load (Pr)
Pr = XFr + YFa
Pr = 1*212.94 + Y *0
= 212.94 N

2) Calculate the life in hours:

( )* ( 𝐶𝑟 3
6
10
𝐿10 = 60𝑛 𝑃𝑟
)

Based on the following calculations 2 bearings are selected for the first and second shaft
606RS bearing
For the third shaft 608z bearing was used

Differential Drive :
There are three fundamental cases which can happen in a differential wheeled robot:
If the angular velocities are identical in terms of both values and direction, i.e. if both the
wheels are driven at the same speed and same direction (either clockwise or anticlockwise)
then the robot tends to spin around its vertical axis. This complete turn capability is one of the
greatest advantages of a differentially driven robot (a.k.a zero radius turn).
If the angular velocities are identical in terms of values and opposite in direction, i.e. if both
the wheels are driven in the same speed but in the opposite direction (One clockwise and
other anticlockwise) then the robot is more likely to follow a linear path, either forward or
backward based on the motors spin.
If the angular velocities are different in terms of values (same or different direction), i.e. if the
wheels are driven at different speeds in the same direction or opposite direction, then the
robot makes a curve motion. Lastly, if one of the wheels rotate and the other stays still then
the robot almost makes a 90° turn. Manipulating the drive speed and direction can give some
interesting drive paths.
Design, mechanical construction and control algorithm can never get any simpler than this
driving technique, and the concept can be incorporated in almost any kind of robots including
legged robots.
One of the major disadvantages of this control is that the robot does not drive as expected. It
neither drives along a straight line nor turn exactly at expected angles, especially when we use
DC motors. This is due to difference in the number of rotations of each wheel in a given
amount of time. To handle this problem, we need to add correction factor to the motor speed.
For example if you intend to drive your robot in a linear path and feel that the robot is turning
towards one side, then a correction factor can be added to reduce the speed of the other wheel.
The better option is to use dual-differential drive which can mechanically guarantee straight
line motion. In this approach, each wheel has mechanical differentials and differentials
combine the forces from shafts and drive the wheels. In other words, two wheels are
connected to two motors where one motor controls the rotation of both wheels while the
other controls the direction. Few robot builders have implemented 3L differential drive; since
is it not very popular, and the results are not in any way far better than dual differential
drive, we can happily skip that for the moment
Electrical design:

Battery calculations:
2 amp for each motor = 4amp

0.5 amp for 2 servos

2.5 amp to operate the raspberry pi

0.625 for camera So we need about 8 amp

to operate the robot And in the market we did not find battery with that amp so the solution is to have
42batteries connected in parallel to increase their ampere capacity As the 2 battaries will give 1.2 * 8 amp then
the robot Will work for 10 hour continuously and then it needs to be charged

Battery selection:

We chose NIMH : As NiMh batteries are rechargeable and their value (price / capacity / weight) is hard to beat.
There is almost no memory effect, meaning every charge should bring the battery up to full capacity. When we
choosed the motors the nominal voltage to be 12 volt And the ampee
Charging :
We connect two types of charging :

Solar cells

Charger

Battery status circuit:

DC-DC Converter:

We use DC-DC Converter in order to convert from 12 volt to 5 volt in order to give constant voltage and high
ampere
Software architecture:
Gantt Chart
Integration:
Testing:
n the testing procedure, we testing the battery using a multimeter to get the actual working
hours and the actual charging hours

Testing each unit alone in order to make sure that its working

Testing the algorithm in order to make sure that the camera and servos and motors are
working together

The current used by the motor is measured using the multimeter

Bill of Materials “Price in Egyptian Pounds”:
1) Raspberry Pi 1250
2) Motor Driver 75
3) 2 DC Motor 600
4) 2 Servo Motors 260
5) Pan-tilt Kit 90
6) 2 Wheel R12 250
7) 6 Small Wheels 600
8) Aluminium Sheet 950
9) Bearing 90
10) Camera 70
11) Batteries 700
12) Charger 45
13) DC to DC converter 240
14) Manufacturing Cost 2500
15) 2 Coupling 100
16) Wiring 50
17) PCB 30
18) Solar Panels 100
19) Wood 50
20) Screws and Nuts 150
21) Sprocket and Chain 450

Total Cost 8650 EGP