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Final Report - Florida Tech - Florida Institute of Technology

1. 39NVWHOdH3d 831VM 333 1H9I3M savo 39vu3dWv SNONNILNOO 39vu3dWv XVW YIMOd 39vL10 1991319373 5 Nid N31SvVW9W 3215 ALO ONILNNOW 31VM ECH SNILVH cu cers WAS D 57 Appendix K Teledyne Impulse Underwater Connector 12 PLUGGABLE impujse NEOPRENE FIELO INSTALLABLE BOOT 65 CONTACT CONFIGURATION MP FACE VIEW NEOPRENE NEOPRENE MOUNTING TORQUE not to exceed FOR BH FS MP 100 in lbs NEOPRENE FIELD DUMMY PLUG FOR INSTALLABLE BH FS IL FS OM FS BOOT DUMMY PLUG FOR BH MP IL MP Techical Bult 6 31 1 800 327 0971 2006 Enterprise Inc 58 Appendix L Foam Properties GENERAL PLASTICS MANUFACTURING COMPANY LAST A FOAM R 3318 PENETRATION TEST BUN 032486 16 sl OO OH D mum coucmg wu 0 00 5 00 10 00 15 00 20 00 VOLUME CHANGE Vwater Vspecimen 12 3 87 9 16 59 Appendix M Users Guide ModROV MK 1 User s Guide Power on Sequence Plug in the monitor the box and the twelve volt converter contained inside the box Turn on the box using the switch above the plug Allow a few seconds for the vehicle to power up and begin testing motion and came
2. 36 E Ee EE EE He 14 1 9 Hull Cleaning Brush and Underwater Vacuum 37 141 10 Tether ed eode dert elec ee Lee oae ue etel ee ee decente Boe 37 14 1 11 Deployment Recover Device d e redo ease s o prete 38 15 0 References sess d 38 cadre hec ec e Mod ese rose abd 39 Appendix Slime Shark Final 40 Appendix B Resumes aisi sien ree cm eerie tiq 4 Appendix Weekly Time ua usq ms ER OA 4 Appendix D safety Plan Requirement cs ead tides teca 43 Appendix E Basic Code Nei DT 47 Appendix Bill of Materials Slime Shark seen 51 Appendix Bill of Materials MOdROV 52 Appendix Inventory uoce bo tS es e tu NEA v Un dS 53 Appendix I Procedure for Hyperbaric Chamber 56 Appendix J SeaBotix BTD 150 Thruster 57 Appendix Teledyne Impulse Underwater Connector 57 Appendix Foam Ta EE 59 Appendix M ser Manual EE 64 1 0 Executive Summary Our senior design group planned to complete the remote operated vehicle ROV that was worked upon by the previous year s senior design group Our primary objective was to get the ROV to a point where the team has created a finished product that is able to be utilized by the Department of Mar
3. Hing Ful Surface Black 1XLY2 1018 Steel Stock Rod 1 2 Diameter Electronics for Main ROV Board Connector Haader 2pos 156 VERT Tin WMA620 Connector Haeder 4pos 156 VERT WM 4622 ND Connector Header 156 VERT WMAE24 ND Connector Haader Tpos 100 Gold WM2738 ND Connector Housing 2pos 156 veRemp WM2100 ND Connector Housing 4pos 156 ve polar WM2113 Connector Housing 6pos 156 w polar WW115 Connector Housing Tpos 100 wiramp rib WM2005 Connector Term Female 22 204WG Tin WM1114 ND Connector Term Female 18 244WG Tin WM2300 Mosfet P CH 40V 14A FDO4243CT ND Mosfet N CH 20V 354 DPAK FDD8580CT ND DRX RS435 RS422 LOWPWR amp DIP MAX485CPA ND PICTEF876 D4 SP ND MCU FLASH 8 14 EE 2801P Pressure Transducer Model MSP 300 05K P 5 N 1 Electronics Main Board Custom made at Larry s 300VDC to 12 0 V300AL2C500AL Bechter Rocker Switches Pt 2750693 SPST BLK Rocker Cable Labels White Quanity of 24 Green LEDs 5mm 2 1V 30mA White LEDs Simm high bnght 3 25 LED Snep holders 5 Pack 1 4 drilling hole for Smm LEDs AC to 300v DC Enmod OFFICE SUPPLIES Copies for design notebook CD Pagas 5 Pk for design notebook 2 Binder for design notebook FOR BOLLARD THRUST TEST Fish Scale Supphed by 55 Clamp Hose Clamp From Lab 3 4 inch PVC Tee 3 4 inch PVC Cross 3 4 inch PVC Pipe Supphed by Amy 1 2 inch PVC Pipe Supphed by Amy 12 Vot Marine Battery OBTAINED
4. the ROV This allows the ROV to serve a more versatile role than a single purpose built vehicle with some of the potential additional features consisting of anything from a brush assembly for cleaning boat hulls to manipulators to sample baskets to additional lights or cameras The default ROV was equipped with a camera and in the future a compass pressure transducer and flood lights This allowed the default configuration to be used for general inspection purposes and underwater observations Team ModROV pursued this design due to an apparent lack of ROVs in industry with this modular capability We hoped that the modular abilities of the ROV would be useful for future university work in addition to being potentially commercially marketable 2 2 Objectives The primary objective for this senior design project was to field a working ROV for the Marine Field Project cruise to ensure the proper deployment of an ADCP sensor at the beginning of the cruise and to make any necessary observations during the cruise After the cruise we hoped to design and construct additional modular components 2 3 Timeline Our timeline gives details to what was completed in the timeframe we were given Many things that were completed were contingent on previous tasks being finished by the previous team and other people who helped on our project The Gantt chart below explains these tasks with respect to dates 10 Jan Created Executive summary Creat
5. 10 ROVs use a frame to mount the pressure housing motors and other systems not contained in the pressure housing The frame also protects parts of the ROV and holds everything together The frame is the base for our modular design The frame creates a great surface to mount mounting rails to attach modular systems to The purpose of the ROV is to be completely modular able to swap out any part for different applications This is mainly seen in larger systems however there are a few systems such as VideoRay s systems are being made now to be able to be modified to different applications The housing is made out of T6 6061 Aluminum It has a camera dome on one end as well as flanges on both ends The maximum depth was calculated using the hoop stress equation by the previous years team The hoop stress equation is o Pr t where o is hoop stress P is pressure r is radius and t is thickness The pressure housing was then tested to approximately 200 feet using the schools hyperbaric pressure chamber ModROV is driven by the control box on the surface The control box is where all the video topside electronics and controls are located The ROV is controlled using two joysticks that give us directional control of all four motors This gives a six axis control for the whole vehicle The VRAM that was created by the previous years team also has an on off switch The coding for the electronics was completed in Basic by the previous years team as
6. 4 4 Pool Trials When ModROV had its electronic components thoroughly tested and installed along with its structural features water proof tested it went through its first set of pool trials to ensure that all of the ROV s systems function in unison These tests were done to ensure that the motors provided adequate thrust and were properly calibrated The pool trials were also done to test the maneuverability and allow time to practice steering the ROV in preparation for the Marine Field Project Some of the things that were planned to test in the pool were the speeds at which the ROV was capable of moving along with its thrust However the ROV s initial test failed due to faulty steering control The ROV could not move multi directionally and thus was unfit to go on the Marine Field Project cruise In the future further tests will be conducted with the new control boards to test the vehicle s speed and maneuverability 5 0 Care and Maintenance During the construction of the ROV we were careful to try to make a final product that is as modular as possible It was hoped that the final product would allow components to be added or removed relatively easily so that they could be replaced rearranged or upgraded In addition to this the team attempted to use standard off the shelf components that could be found in most hardware stores should a component need to be replaced or serviced With the current system the only difficulty in maintaining the ROV w
7. 52 88 30234 220 MOV 220V 10mm Dis Vicor Corp 8 50 75 500 30076 Metal Oxide Varistor MOV Vicor Corp 4 075 300 30262 051 DTVS 51 5 1 5 kW 00 201 Vicor Corp 4 50 75 53 00 00670 Diode 1 Vicor Corp 4 0 80 320 26108 1145817 Schottky Bamer Rect Vecor Corp 4 59 38 5152 MHB 11953 Cap 470 uF 350V Ogi Key 4 55 82 23 28 2939 1000 pF SOV 10 rad De Key 3 5050 150 JP 726 350kC 0 SW Carb Comp Den Key 4 054 52 16 BH 12FS Underwater Connector female Teledyne Impulse 1 565 00 565 00 IL 12 MP on 2 18 12 SO Underwater Connector male Teledyne Impulse 1 42 50 42 50 DLSCM locking sloove male Teledyne Impulse 1 512 00 12 00 OA S CF locking slae female Teledyne Impulse 1 12 00 12 00 S H Shipping and Handling Teledyne Impulse 1 15 10 51510 SH Shipping and Handling General Plastics Manufactunng Co 1 516 00 516 00 921744460 Brass 5 0 10 nut 5 pack McMaster Carr 1 51291 51291 O ings 5 0 dia Ace Hardware 6 0 69 Report Binding Spring Printing and binding of report Stables 1 32 17 32 17 Bolts 38x16 2 1 4 Ace Hardware 5 0 15 50 75 Machine Screws 34 x6 Ace Hardware 15 112 16 80 Nyloe Nuts He Ace Hardware 10 50 65 6 50 Washers v Ace Hardware 5 022 1 10 895 4321 250 0 0 125W Amed Electronics 3 101 3 03 Shipping and Handling Abed Electiomes 1 35 83 35 83 Washers Ace Hardware 8 0 45 3 50 7 4 Hardware 012 2 88 WM2100 ND cann housing 2 Dep Key 100 50 09 9 08 WM2113
8. 6061 T6 6 nom 46 Length Bearings polyethylene Uhmw Pe Bearings Trrusters SeaBotx BTD150 Camera Wi Night Vision Compass Board Vector 2X Bilge Pump 1600GPH Pt16004W 7923642 Vidao Overlay Board Repair Completed by Sam Anthony Requred Chips for Completed by Sam Anfhony Ducted Fan For use with SAD Mounting Boards 8300 5 PROV Overlay XBOB NTSC PROV Clear dome Dia 4 Depth 2 Tether 3 60 sections 15 shipping Tether Spice Kits to connect 60 sectons Corton Box Monitor LCD display Pelican Bax Used as Contori Box Case Rings Dia 7 375 Thick 157 ABS Plastic 316 X 31 x 33 Brush RB618 Screws Round Head slotted 10 32 15 coated 1600 GFH Bilge Pump 16004 1045 Steel Keyed Shafting x36 Gabenized Steal L Bold 6 Diameter Zinc Plated Mak A Key Barstock V4 x 144 Pins 18 8 Stainless Steel 3 8 Diameter x 1 1 2 368 70 O Rings 6 pack Uhmw Pe Baenings 1 Diameter Gearbet XL 21532 Flet Washer 9 32 ID x 5 8 Fender Washer 9 32 ID x 1 Flet Washer 13 64 ID 7 16 Split Lock Washer 2001 Split Lock Washer 2601 Hex Cap Screw V4 20x 34 Flet Washer 11 16 ID x 1 1 2 Hex Nurt Machine Screw 10 Flet Washer 9 16 ID x 1 1 4 Gearbet XL 2 527 XL 105 Teeth Length Hex Cap Screw V4 20x 1 Machine Screw Round 10 24 x 34 Machine Screw Round 10 24 x 1 1 4 Retaining Ring Ext Shaft 1 Diameter
9. Decomposition SIT CtUte cie eren ei 23 SM Chez cA E UTER 24 8 l l ThTUStETS 24 8 2 Pressure 25 25 8 4 E TE 26 Mesh eu T 27 8 4 2 E 28 8 4 3 Underwater Connectors eee eter edes cr Pee tor PEE tea 30 8 44 PEO ST ANTOLIN E 30 30 ISSUES E 32 TE RE 34 BUD eee asino aperta ern DOR ar resa ert ae 33 ina eem n NR dti tes eue yendo sace elo so 33 12 2 Time Expenditt eg Rd HARI vani eats 33 150 RESUS e 34 14 0 COM CIOS IO 34 14 1 34 T4 1 1 Pressure Transducer uuo e e eia 34 E 1 2 COMPASS o 35 14 Beer c PR p 35 35 14 1 5 Addition Of a Second 35 E Cathodic Protect Onyx asma eere pae oth dde pee d e ret e en 36 Ta E BASE edd e TA
10. Marine Field Projects Symposium The team plans to continue and ensure completion of the project by the senior design showcase in the spring 14 1 Recommendations The following recommendations for the ModROV would build upon the modular ROV theme and make it more useful in an industrial setting 14 1 1 Pressure Transducer Currently the ROV control board has inputs for a pressure transducer which has been purchased by a previous group This component provides a reading of the water pressure outside the ROV in a video overlay upon the control box s monitor This device allows the ROV operator to know what depth the ROV is at This is useful in the regards to navigation and safety of the ROV The pressure transducer can also be used in tandem with other sensors on board the deployment vessel to show the depths of items of interest underwater 34 14 1 2 Compass Another component that needs to be integrated into the ROV control board is a compass which displays the heading of the ROV on the control screen via the video inlay The compass proves invaluable to underwater navigation and for describing positions of underwater items 14 1 3 Sensors Scientific sensors can be built or bought and added to the frame of the ROV A second pressure housing can be built to house sensors with electronics that need to be dry This would involve running a cable to the main pressure housing and then sending the information up through the main communicat
11. brush similar to those in pool cleaners The bristles would be arranged in a spiral so that the debris would be moved towards the center of the head so that it could be suctioned out through a tube to the containment device The Slime Shark will not currently be equipped with an EPA compliant unit but will be designed to be easily upgradeable This design for the brush was changed due to the provision of Dr Geoffrey Swain as he provided the ROV with a brush It was stated that the brush design needed to have a horizontal axis of 18 inches 17 This design of brush has the bristles oriented in a diagonal pattern which covers the entire brush It will rotate on a steel shaft in an Uhmw Pe Bearings block bearing which will be attached to the head and will be able to be exchanged for other brushes Unfortunately the brush from Dr Swain was unable to be acquired and due to budget constraints a generic brush had to be purchased that was similar to the one that was going to be received The only exception is that the rod that the brush rotated on was one inch in diameter instead of a half inch The head is can be removed from the ROV and exchanged for other heads Additional heads will not be implemented in this project The heads can be changed using square tubing and pins to attach it to the body The body frame and its contents have undergone the most of the design changes for this project The original design for the Slime Shark was to be a recta
12. help and understanding this project would not be possible LIST OF ABREVATIONS CTD Conductivity Temperature and Depth DMES Department of Marine and Environmental Systems EPA Environmental Protection Agency FIT Florida Institute of Technology LCD Liquid Crystal Display LED Light Emitting Diode MFP Marine Field Project ModROV Modular Remotely Operated Vehicle MSDS Material Safety Data Sheet OSHA Occupational Safety and Health Administration PIC Programmable Interface Controller TDS Tether Deployment System ROV Remotely Operated Vehicle Table of Contents T O ExecutrVe S UTE V dose osa 4 PAIR ac ocd dete as 8 uric et bo stan Clad o 8 8 9 24 RRE e H 3 0 Back TT TEE 10 SoM ASIC THE Stato de a Me tse abdito detect ios e ae 10 J2 Used cedet tote cu dada teh 11 4O e EE 14 471 Foam Pressure dad eame d 14 4 2 Pressure Housing ue ne EN Fac t t s EE 14 4 2 Dry Electronics KEE 14 A amp A Pool Eeer satu te d AEN UE 15 6 0 Customer 16 6 1 Future Customer Requirements 16 TO Project tse n ete ioe E ou m de La 17 8 0 Function
13. looped through the back of the frame if the water level is significantly below the deck of the research vessel but if the water level is relatively close the ROV can just be picked up by its frame and lowered into the water by hand To recover the ROV a hook can be used to grab the handle at the back of the frame There are too many things that could go wrong with this method The plastic dome where the camera is mounted can be scratched or broken from improper handling which would endanger the integrity of the pressure housing with this method of deployment Another possible solution is to devise a mounting point or set of points where hooks from a crane can be affixed to raise and lower the ROV from the water The only issue with this system is the need to have a pole or a diver in the water to connect and disconnect the ROV from the lift something that would be potentially dangerous in rough seas 15 0 References American Society of Welding Safety and Health Fact Sheet No 2 Radiation October 2003 lt http files aws org technical facts FACT 02 PDF gt American Society of Welding Safety and Health Fact Sheet No 7 Burn Protection September 1995 lt http files aws org technical facts FACT 07 PDF gt American Society of Welding Safety and Health Fact Sheet No 12 Contact Lens Wear September 1995 lt http files aws org technical facts FACT 12 PDF gt American Society of Welding Safety and Health Fact Sheet No 3
14. the Appendix F and G 12 2 Time Expenditures In some instances it was difficult to log the entire amount of time spent on the project especially with the assistance we received from the previous year s group and the work done outside of class or normal meetings Time logs can be found in the appendix taken from weekly progress reports along with an estimation of our outside consulting work 33 13 0 Results The team was unable to produce any experimental results as we were unable to complete a fully operational ROV by the end date The ROV was designed to be as modular as possible with the ability for components to be easily installed and removed in the future Hopefully future senior design groups will be able to design and integrate additional systems for the ROV such as those outlined in our recommendations 14 0 Conclusion This team s ROV is an improvement of the last team s design There have been significant changes to the design and the electronics are being completed so that there is an operational ROV for the Department of Marine and Environmental Systems Lights a pressure transducer and a compass need to be added to the electronics as well The team was able to perform tests on the ROV with the initial board however there were some difficulties as the ROV was only able to run with three motors and control was not completely functional This issue caused the time needed to complete the electronics to run past the date of the
15. the water with ModROV stays a safe distance while it is being deployed used or retrieved there should be minimal to no issue involved Also while ModROV is in use and being stored there could be issues with causing damage to properties such as the boat and other onboard equipment To avoid these issues the team will keep ModROV away from the boat hull if the conditions are not well enough to conduct a proper hull inspection so there would be no collision between the two and 31 while it is being stored onboard the boat we will keep it strapped down so it cannot be bounced around and cause damage to the boat or other equipment on the deck Also while ModROV is in use there is a chance that it could get snagged or lost and become irretrievable The ethical issues with losing ModROV would be what environment impacts it would have over time as it breaks down Possible impacts over time could be the release of harmful chemicals as it breaks down Another possible impact over time could even be the chance of parts breaking off the main body and causing damage to the environment and marine life These issues would be minimized and avoided by operating it within its limits For more information see Appendix D for the team s Safety Plan which also addresses these issues 10 0 Political Issues The political issues involved with the operation of ModROV include violating privacy and performing illegal activities The ROV could improperly be used to vi
16. well 3 2 History For the initial design of ModROV research was completed in regards to modular ROVs on the market There are currently two main types of ROVs that are considered by most to be modular The first type is built with a certain industry in mind such as the underwater drilling and pipe laying industry An ROV built for this purpose that is considered modular would have everything possibly needed for the job mounted on it already One Such ROV the MR1 Multi Role ROV made by Modus is designed for underwater cable operations such as laying cutting and other various cable applications It is designed so that the company would only have to buy one ROV to handle all the applications and not have to worry about buying and deploying different ROVs for each specific job The Modus ROV can be seen below 11 Figure 2 Modus courtesy of Modus Modular Underwater Systems Ltd The second main type of ROV that is considered modular is a basic frame made by a manufacturer that is constructed to the consumer s specifications This type of ROV is made for a specific purpose and when it reaches the consumer it is no longer modular as the parts are permanently added onto the frame A company that makes these types of ROVs is SharkMarine who boast their custom ROVs are built to your individual specifications This company also has an ROV called the Sea Dragon This ROV is modular in that parts can be added to make it more useful fo
17. 1 Eye and Face Protection for Welding and Cutting Operations December 2006 lt http files aws org technical facts FACT 3 1 pdf gt Florida Institute of Technology Florida Institute of Technology Diving Control 38 Program 2005 Seabotix International Ocean Systems January February 2007 Volume 11 Number 1 Pg 4 General Plastics Manufacturing Company Last a Foam R 3300 26 April 29 2009 lt http www generalplastics com products product_detail php pid 16 amp gt Modus Modular Underwater Systems Ltd MRT Multi Role ROV 26 April 2009 lt http www modus ltd com equipment multirolerov aspx gt SeaBotix Inc AUV ROV Thruster BTD150 26 April 28 2009 lt http www seabotix com products pdf files BTD150 Data Sheet pdf gt Shark Marine Technologies Inc SharkMarine ROV 26 April 26 2009 lt http www sharkmarine com rov htm gt Teledyne Impulse Wet Pluggable 28 April 2009 lt http www impulse ent com products wetplug aspx gt VideoRay VideoRay ROVs 26 April 2009 lt http www videoray com categories overview gt Ward Chris ROV net 2002 Work Ocean Limited 13 Mar 2008 lt http www rov net gt West Systems Inc Material Safety Data Sheet West Systems Inc Resin 105 3 January 2008 lt http www westsystem com webpages userinfo safety MSDS105 pdf gt 16 0 Appendices Attached is additional information necessary to understand the construction and operation of
18. 14 09 FDD4243CT ND MOSFET P CH 40V 14A DPAK Digi Key 100 052 51 98 PIC16F8865 l SP ND IC PIC MCU FLASH 8KX14 28 Digi Key 6 260 1560 296 1633 5 ND QUAD 2 INUT AND GATE 14 DIP Digi Key 10 0 56 5 60 296 1629 5 ND 1C HEX INVERTER 14 DIP Key 10 0 56 5 60 MAXABSCPA ND 1 TXRX 8348583422 LOWPWR 8 Da Key 5 2 76 13 80 MC7B08CT BPMS ND VOLTAGE REG POS 8V 1500 Me Key 5 0 56 2 80 LMTBOSCT ND IC REG POS 5V TO 220 Den Key 5 045 2 25 WI44205 ND CONN HEADER 7POS 100 VERT TOxy Key 10 50 63 5826 WM4622 ND CONN HEADER 4POS 100 VERT Key 10 50 30 53 96 WIMAG20 ND CONN HEADER 2POS 100 VERT TDigi Kay 10 020 51 98 WIM624 ND CONN HEADER EPOS 100 VERT TDigi Key 10 50 60 595 PS OMCT ND RESISTOR 005 OHM TW 1 2512 Digi Key 19 50 82 59 16 296 2066 5 ND IC 24N AND GATE QUAD 14 DIP DigiKey 10 055 550 LM34DZ4lD IC SENSOR TEMP PREC FAHR TO Digi Key 5 251 1255 FODSS80CT ND MOSFET 20V 354 D PAK Digi Key 100 50 32 3240 SH Shipping and Handling Digi Key 1 6 89 6 89 300V 12V Power Converter Ebay 1 51338 1338 S H Shipping and Handling 1 51955 51055 400100097069 T Brush Michaels 3 0 69 207 Custom Unpapulated Control Boards SH Express PCR 2 53 90 107 80 3233733 Resin Epaxy 105 A West Manne 2 2307 46 14 318386 Hardener Resin 206 West Marine 2 1128 22 56 4 944 YA511 Gal Gel Coat Canary Yellow Fiber Glass Flonda 1 5122 5122 202 2oz MEKP Catalyst Fiber Glass Flonda 1 2 05
19. 2 05 SWAXSOL t0Z 402 Wax Solution Fiber Glass Flonda 1 2 10 2 10 007004250047 2 Chip Brush Walman 3 264 007004252576 Paint Roller set Walmart 1 Report Binding Fall Printing and binding of report Stables 1 40 00 40 00 Total 1 338 08 Donations Estimated Cumulative o bye 1 46 R 3310 Foam two Zeg ann 51 600 00 5900 00 General Plastics Manufacturing 2Jub Fiberglass Cloth vanaus pieces 50 00 550 00 Dr Wood Consultants 55 1 300 00 Total 55 for all consultant ime Hours Worked 1081 5 These are your hours Project Value work 10 815 00 3510 00 per hour Total 1 400 00 Remaining 1192 ject Value 14 323 08 Total 25 138 08 Pd Pt gt lt gt lt 52 Appendix H Inventory Item thrusters Frame pressure housing camera with board Ubolt O rings rear pressure house Nylock nuts med Lockwashers washers flat washers 10 24 hex machine screw 15 LCD screen 100 tether flat washer 12V converter 300V converter hex bolts cave light 10w HID joysticks Phillips stainless Phillips stainless seaweed ROV box o stuff 1 2 bell washer Taps Marine tex resin amp hardener Lube nuts zinc bildge pump and housing DC motor spare dome Relay flat head phillips Tether connector PVC cleaner PVC cement Pool trial tape Brush with motor and belt Random AL scrap Electric control mountin
20. 20 3 8 16 Spring 147 Plastic Epoxy Fastcure Pen Gorilla Glue Angle 1 8x1x4 Al Rod 1 4 4 Bondo Repair Kit Quart Ace Extra Time Epoxy Quick Link 1 8 SS 3 8 7 16 x12 300V 15V Power Converter MOSFET P CH 40V 14A DPAK IC PIC MCU FLASH 8KX14 28 DIP IC QUAD 2 INUT AND GATE 14 DIP IC HEX INVERTER 14 DIP IC TXRX RS485 RS422 LOWPWR 8 DIP VOLTAGE REG POS 8V 1500MA 10 220 IC REG 1A POS 5V TO 220 CONN HEADER 7POS 100 VERT TIN CONN HEADER 4POS 100 VERT TIN CONN HEADER 2POS 100 VERT TIN CONN HEADER 6POS 100 VERT TIN RESISTOR 005 OHM 1W 1 2512 IC 2 IN AND GATE QUAD 14 DIP IC SENSOR TEMP PREC FAHR TO 92 MOSFET N CHAN 20V 35A D PAK 300V 12V Power Converter 2 Chip Brush Unpopulated Control Boards S H Hardener Resin 206 B Gal Gel Coat Canary Yellow 20z MEKP Catalyst 100 SCNAAAANSAAWAAHROOANAA gt sch 100 10 10 10 10 10 10 10 10 100 55 Appendix I Procedure for Hyperbaric Chamber Operation l 10 Connect water hose to the inlet value on the pressure chamber making sure the inlet valve is open Fill the pressure chamber with water and insert test samples Lower the lid to the pressure chamber making certain that it is centered above the mouth of the chamber Open outlet valve on the lid of the pressure chamber and wait until water flows out of it for approximately six seconds While chamber fills tighten the pressure chamber s lid in a star pa
21. 5 19 0 22 043 0 65 1 88 0 0874 034 051 051 0 095 0 0626 0 693 0422 276 838 15 50 107 80 27 90 299 31 3149 199 149 91 00 8336 649 8 29 4 0 1 85 033 1 06 1 98 152 200 0 00 0 00 0 00 0 00 0 00 0 00 0 00 30 00 16 99 0 00 0 00 0 00 0 00 0 00 ooooooooooooooooooooooc 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 15 00 0 00 10 43 0 00 0 00 0 00 0 00 0 00 16 56 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 COST TO TEAM 42 00 85 00 25 00 3 01 10 28 0 00 38 84 1 610 00 26 98 0 00 50 39 38 00 3 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 21 96 152 66 1 96 50 99 26 96 1282 122 37 81 1942 2268 289 3 66 205 196 337 122 10 62 488 10 87 19 76 402 17 86 959 13 74 17 92 5 19 0220 0430 0650 1 880 8740 0340 0510 0510 9500 6360 24 048 15552 8 280 41 90 107 80 83833 5 98 1 99 2 98 3 98 2 98 107 56 5 36 649 829 Total Amt 284959 3 500 00 2 849 59 85041 51 Appendix G Bill of Materials ModROV 55 Donations lt COE ModROV 2009 55 Costs 0 00 0 00 540000 5100000 ITEM DETALS 7 OBTANEDFROM QUANTTY COST EACH TOTALCOST _ COST TO TEAM 01000 SFLM 59 4700P 110 250 V Vicor Corp 8 50 99 7 92 34610 Film 0 610 10 250 ROL Corp 4 0 72
22. 520 Then mlspd ch2 520 m2spd mlspd mlD 1 m2d 0 EndIF IF 1 gt 500 AND ch1 520 AND ch2 lt 500 Then mlspd 500 ch2 m2spd mlspd m1D 0 m2d 1 EndIF Moving Forward IF chl gt 520 Then steer motors forward 1 1 520 M2spd ch1 520 M1D 1 M2D 1 direction EndIlIF Moving Reverse IF chl lt 500 Then steer motors reverse 500 ch1 Mlspd M2spd 500 ch1 M1D 0 M2D 0 direction EndIF 49 Basic Code Topside Cont Turning while moving chl gt 520 OR ch1 lt 500 AND ch2 lt 500 Then EndIF calcspd 500 ch2 IF lt calcspd Then mispd 0 Else Mispd Mispd 500 ch2 EndIF chl gt 520 OR ch1 lt 500 AND ch2 gt 520 Then EndIF Pause calcspd ch2 520 IF m2spd calcspd Then m2spd 0 Else M2spd M2spd ch2 520 EndIF display LCDOut fe 80 It Works print lst line LCDOut fe C0 chl DEC4 1 ch2 ch2 print 2nd line LCDOut fe 94 m1 DEC4 mlspd m2 DEC4 m2spd print 3rd line LCDOut fe D4 M1D DEC1 MID M2D DEC1 m2D print 4th line 100 GoTo start 50 Appendix F Bill of Materials Slime Shark ROV DESIGN TEAM SLIME SHARK Allowance 3 500 ITEM DETAILS Channel amp Tubing 15 x25 X 125 T6 6061 Aj Piata IEKA AL Stock 8 5 AL Square Tube 1 1 1 8 AL Square Tute 1 14 X 1 1 47 X 1 87 AL Pipe Sch40
23. D DREG PORTB set data port DEFINE LCD DBIT 4 set starting data bit DEFINE LCD RSREG PORTB set rs port DEFINE LCD RSBIT 3 set rs bit pin 24 DEFINE LCD EREG PORTB set en port DEFINE LCD EBIT 2 set en bit pin 23 DEFINE LCD BITS 4 set LCD buss size 4 or 8 bits DEFINE LCD LINES 4 set number of lines on LCD DEFINE LCD COMMANDUS 2000 set command delay time in us DEFINE LCD DATAUS 100 set data delay time LCDOut fe 1 clear LCD adconl 7 1 TRISA 111111 TRISB 0 TRISC 0 chil VAR WO ch2 VAR WO ch3 VA ch4 VAR WO R R WOR R R U g ch5 VAR WO 47 Basic Code Topside Cont ch6 VAR WORD d tart DCIN 7 DCIN 0 1 DCIN 2 DCIN 3 7 DCIN 5 p Q D p op p EG U DCIN 5 PORTC M1D VAR BIT 2D VAR BIT Mispd VAR WORD M2spd VAR WORD chi ch3 ch4 ch5 0 che Low 0 Pause 10 calcspd VAR WORD pin8 forward reverse numeric front back pin7 forward reverse side side pin6 pind pin9 with RCO low RCO 10 with RCO high Check if in Center IF 1 gt 500 AND ch1 520 Then joystick in center Mlspd M2spd EndIF 0 0 IF ch2 500 AND ch2 520 Then mlspd m2spd EndIF 0 0 48 Basic Code Topside Cont Rotate on Axis IF ch1 gt 500 AND ch1 520 AND ch2 gt
24. FROM Betz Recycling Smitty s Welding SiverHorse Racing Don Don Metcalf 5 Eddy Granger Botix Website Ebay Dr Wood West Manne unknown unknown Astro Too s RO Associates Decade Engnesring UTL PROV UTL PROV UTL PROV UTL PROV UTL PROV Praste Design amp Mfg Inc Home Depot West Merine Port Supply MSC MSC MSC MSC MSC Granger Grainger Grainger Granger Granger Grainger Grainger Granger Granger Granger Granger Granger Granger Granger Grainger Granger Granger Granger Grainger Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Dig Key com Ebay PCB Express Ebay Rado Shack Rado Shack Rado Shack Rado Shack Rado Shack Vicor copy center staples Walmart Home Depot Home Depot Home Depot Home Depot Home Depot QUANITY COST EACH SHIPPING 2 NS 111 1 111 e 100 100 36 36 mI gt gt gt gt gt gt ERES 200 35 00 25 00 8 90 1142 209 65 8971 395 00 39 99 50 00 5039 38 00 8 00 1 00 409 95 149 95 10 00 195 00 27 72 149 99 112 19 21 96 130 00 098 50 99 26 96 641 1 22 1 85 8 1 9 71 22 69 2 89 3 06 205 196 3 37 12 2 10 62 4 88 1087 19 76 4 02 17 86 959 13 74 199 8 96
25. ModROV Included is information on the teammates materials used and information from the work done by the previous teams 39 Appendix A Slime Shark Final Report Please see end of ModROV report for entire Slime Shark report 40 Appendix B Resumes Resume s removed for student confidentiality 41 Appendix C Weekly Time Log Morgan James Miller Marmitt Rick Paradis Zach Barton 19 Jan 3 3 3 3 26 Jan 4 5 4 4 2 Feb 7 8 5 5 16 Feb 5 4 4 5 23 Feb 3 5 3 3 9 Mar 0 3 0 1 16 Mar 3 4 5 3 3 23 Mar 4 4 4 4 30 Mar 5 5 5 5 6 Apr 9 9 10 8 13 Apr 5 5 5 5 20 Mar 9 8 9 8 27 Apr 9 5 20 9 5 11 11 May 0 0 0 0 18 May 2 1 5 1 5 2 26 May 25 25 10 5 25 1 Jun 20 37 15 20 8 Jun 32 48 11 32 15 Jun 6 25 16 75 6 25 5 5 22 Jun 4 2 2 4 29 Jun 10 10 10 10 6 Jul 10 17 10 10 13 Jul 16 40 12 75 20 20 Jul 45 35 45 45 27 Jul 27 25 25 25 Total 263 75 340 75 213 5 263 5 Gross 1081 5 Appendix D Safety Plan Requirement Senior Design 2008 2009 Zach Barton Morgan Marmitt James Miller Rick Paradis 1 1 1 Project General Description Our senior design group plans to complete the ROV that was worked upon by the previous years senior design group Our primary objective was to get the ROV to a point where we have a finished product that is able to be utilized by the Department of Marine and Environmental Systems in the field The scope of this project entailed taking what the current group has been able to develop and from there finishi
26. ND cann housing 4 pas Den Koy 10 031 313 WM2115 ND cann housing 6 pos Dot Key 10 50 47 170 WM2005 ND cana housing 7 pos Digi Key 10 047 5570 1114 40 tem famale Digi Key 100 0 10 59 93 WI42300 ND conn tem female Digi Key 100 0 07 96 57 00927 SFLM 69 32 10 250 V RFI Vicor Corp 4 524 5856 32006 IND 19817 19817 W TAPE 03347 Vicor Corp 4 51250 50 00 SH Shipping and Handling Vicor Corp 1 1395 13 95 Nuts 14720 Ace Hardware 4 017 060 5117874 Rod 3874 Ace Hardware 2 7 99 15 98 SAS45 Spring 45 Ace Hardware 4 1 09 4 35 Screws 440x127 Ace Hardware H 0 17 153 Nuts 440 Ace Hardware H 1 71 Bolts 6 32 1 127 Ace Hardware 4 020 0 80 Nuts 6 32 Ace Hardware 12 50 13 51 56 Bolts 1 47 20 2 1 2 Ace Hardware 1 0 72 0 72 Nyloe Nuts 147 20 Ace Hardware 1 5037 50 37 Nuts 3816 Ace Hardware 8 50 12 0 96 3147 Spang 147 Ace Hardware 4 131 524 007535306820 Plastic Epoxy Walmart 1 5377 377 005242752011 Fastcure Glue Walmart 2 388 7 76 5118153 Angle 1 8x1x4 Al Ace Hardware 1 514 99 514 99 5117858 Rod 1 4x4 Ace Hardware 1 149 1 49 09696 Bondo Repair Kit Quan Ace Hardware 1 1149 11 49 16611 Ace Extra Time Epoxy Ace Hardware 1 5299 52 99 5336870 Quick Link 1 6 SS Ace Hardware 2 53 99 57 96 Washers 3 5 Ace Hardware 10 5022 5220 Drill Bit 7 16 12 Ace Hardware 1 16 99 16 99 V300A 15CS00BN 300V 15V Power Converter Vicor Corp 1 269 00 5269 00 S H Shipping and Handling Vicor Corp 1 14 09
27. TRANSMITTAL Florida Institute of Technology Department of Marine and Environmental Systems OCE 4915 TO Dr Stephen Wood Dept of Marine and Environmental Systems Florida Institute of Technology 150 W University Blvd Melbourne FL 32901 FROM Senior Design ROV Team ModROV Department of Marine and Environmental Systems 150 W University Blvd Melbourne FL 32901 RE Final Report DATE SUBMITTED July 23 2009 Dr Wood Please review the attached Final Report for the ModROV team The ROV Team James Miller Zach Barton Morgan Marmitt Rick Paradis Florida Institute of Technology Ocean Engineering Design 2009 OCE 4915 ModROV Final Report Presented by The ROV Team Zach Barton James Miller Rick Paradis Morgan Marmitt ACKNOWLEDGEMENTS We would like to thank Dr Wood for his advice encouragement understanding and time in all the areas of building this project He helped keep us going when we did not know if we could Everyone in the Machine shop for their machining expertise and especially their patience Most of all Larry Buist for giving us advise support and expertise in building the ROV He took time out of his busy schedule and helped up us finish the ROV electronics We would like to thank all the companies Teledyne Impulse inc and General Plastics Manufacturing Co that gave us a donation or discount on materials used in building this project Without your
28. aluminum frame similar to that of the ROV that has mounting points to allow for easy installation and removal of the entire system The final component to the Hull Cleaning Brush is the SAD assembly The SAD is a large ducted thruster that is mounted to the underside of the ROV within its frame and helps aid in the hull cleaning process by providing suction pulling the ROV close to the ship s hull so that it can clean the ship For commercial applications it would be necessary to mount a vacuum and filter system on the ROV in order to collect the debris removed from the ship hull As the ROV currently is a research device this EPA compliance is not necessary For more information see the Slime Shark ROV report where these details originated 14 1 10 Tether Extension Currently one of the major limiting factors of this ROV s design is the length of tether available Only 100 feet long and somewhat stiff one of the greatest areas of improvement would be to replace the current tether with a longer more flexible one This 37 would allow the ROV greater freedom of movement in addition to a greater operational depth that would be limited by the pressure housing s capabilities rather than the tether s length 14 1 11 Deployment Recovery Device A better method of deploying and recovering the ROV could be made A frame of its own that the ROV may sit in and be lowered into the water needs to be built At the present the ROV can be lowered via a rope
29. and that poses a potential danger if proper care is not executed making sure that live wires are not touched and that circuits have been fully discharged before handling University Insurance We do not believe that this project poses any new insurance risks that the university is not already covered for Our travel is going to be already a part of another university sponsored event therefore already covered We are not working with any outside companies or organizations and our vehicle is relatively small 1 1 4 Failure Modes and Effects Analysis Failure Mode Effects Analysis Failure Mitigation Cable detachment Loss of vehicle Ensuring secure Electrocution connection Whip like effect Maintain slack in the Damage to cable or tether connector Electrical short Electrocution Make sure electronic Shock components are properly Damage to electronics installed Ensure tether is free of damage Water damage to control Damage to electronics Secure control box to deck box Electrocution Keep control box in a dry area Bolt failure Loss of part or all of ROV Ensure bolts securely Injury to individuals fastened 45 Damage to ROV or ship Adequate bolt strength Deployment recovery Loss of ROV Ensure proper procedure is Damage to ship followed Use correct lifting points Foam crush Loss of buoyancy Keep ROV within Fail
30. ariety of design changes The first problem that was faced with this ROV was how the cleaning heads were to be oriented One idea was to have several brushes that spun about a vertical axis This design is already in use and is proven to be effective The problem with this design was the difficulty designing a brush orientation that would prevent the angular momentum from the brushes from turning the cleaner The second design that was eventually adopted was to have a long brush spin about a horizontal axis much as a vacuum cleaner would This design was favored due to the simplicity of the design as well as the smaller chance of the brush getting clogged by clinging slime as the spinning will produce enough force to expel it from the bristles Another reason that this design was favored was that in order for this machine to EPA compliant there would need to be a way to contain the expelled scum and this would allow for there to be a containment unit around the head without much difficulty The brush would be attached to the front of the ROV and the body would contain all of the necessary parts for functionality The third design that was conceived was using a stream of pressurized water much like a power washer to remove the scum This idea was also EPA compliant but ultimately rejected as well due to the complexity of the design After the horizontal axis brush was decided on the brush also underwent several changes The initial design was to use a
31. as assimilated from last year as well A Polaroid LCD screen and video overlay board were already installed but the controls had to be constructed from scratch The control panel was created from ABS and contains two joysticks two dial knobs two rocker switches as well as the tether connection and a power supply The topside control also has a converter from AC 120V to twelve volts DC to power the circuitry in the box and an AC 120V to 300 volt DC converter to send down the tether The final aspect of this design is the hull of the ROV As the name Slime Shark suggests the machine will be in the shape of a shark specifically a hammerhead This design was chosen because the wide head allowed an ideal setup for the brush and the body provided adequate space for the other components The hammerhead shark also has good hydrodynamics which is ideal for the ROV to operate However due to the complexity of the shell it had to be postponed for a later project as the other aspects of the ROV demanded more time Appendix Slimeshark The above paragraphs are from the last group to work on the ROV so this was where the evolution of ModROV began For further information regarding this quotation see Appendix A 19 It was originally planned to weld some of the ROV components onto the frame however this was soon scraped as the act of welding items permanently to the frame would undermine our goal of modularity and ease of maintenance Among the ite
32. called the changed this design and was to be provided by Dr Swain This device is more efficient and smaller The VRAM however is no longer available so the design once again had to be modified The replacement was the Suction Attachment Device or SAD The SAD 18 consists of a ducted fan powered by a bilge pump attached to the frame Due to the measurements of the frame the SAD had to be placed inside the frame which may weaken the attraction power but the current design allows for a skirt to be added increased suction Two cameras were initially going to be attached to the frame one in the pressure housing and another in its own housing The design was modified and the second camera removed because of limited funds and the complexity of the design The camera in the main pressure housing will be retained though The circuitry contained in the housing has also undergone some changes as well Originally there was a ROV from where the circuitry was going to be provided However this was changed as the other ROV is going to be kept in commission and new parts have to be obtained The circuit boards were designed to support six motors which required three PICs to allow for six channels of pulse width modulation The water proof connectors to allow for the wires to enter and exit the pressure vessel were provided from the previous ROV as well as some that were provided by Dr Wood The box that will house the controls on the surface w
33. clearance with the pressure housing supports the initial design had a radius taken out of the center of each of the support brackets that would lower the pressure housing and bolts out of the way In order to simplify the machining process and to improve the strength of the support brackets small cutouts were instead milled on the brackets in order to allow bolt clearance Figure 6 Pressure Housing Supports The floatation system was designed to give the ROV neutral buoyancy with a slightly positive trim such that in the event of loss of power or of the tether the ROV will should return to the surface where it may be recovered The design of the ROV s floatation went through a number of iterations as new materials were considered and selected for use The first plan was to utilize epoxy resin and glass microspheres to create syntactic foam that would then be molded and machined to the final shape After creating a number of potential designs it was found that a large volume and mass of foam would be required to provide adequate floatation for the vehicle which would inhibit its performance underwater and make transportation and deployment more difficult When 22 examining different options high density urethane foam was found that was easy to machine and considerably lighter than the previously considered syntactic foam The floatation provided was General Plastics Manufacturing Company s R 3318 Hydrostatic Pressure Resistant Foam which was a
34. d brass A cathodic protection plan should be initialized in the future and since almost every part of the frame and pressure housing are aluminum the protection plan will not be that extensive The bolts and some parts of the underwater connectors are stainless steel so therefore when the protection plan is implemented these will need a zinc sacrificial metallic anode to protect them An anti fouling paint can be applied in the future if deemed necessary but since ModROV will be in the water for only a minute period of time and not continuously it would be highly unlikely that any bio fouling will occur Even if there are anodes set in place other precautions should be taken such as rinsing the ROV and its cable with fresh water every time it is removed from the water When not in use it should be stored indoors in a cool dry place Following just these simple measures will help prevent corrosion The revised details in this section are taken from last year s ROV team report that is located in Appendix A 14 1 7 Basket A basket would be a useful addition to the ROV in the future It would allow for the collection and storage of samples either collected by divers operating in conjunction with the ROV or by future add ons such as a manipulator arm or scoop system This addition would be rather easy to implement with the only difficulties arising from the device needed to collect the samples 14 1 8 Manipulator Arm A manipulator arm could be
35. designed for future use with ModROV It could be used for the righting of ADCP s to an acceptable angle for collecting data It could also 36 be used with a basket being especially helpful with the collection of specimens such as rock or plant life and recovering items from the bottom To install a manipulator arm certain steps would need to be accomplished First extra electronics and code would have to be written and installed in ModROV and its control box Secondly another hole would have to be strategically drilled into the pressure housing so as not to weaken the structural integrity Finally there would need to be a counter weight added to the opposite side that the manipulator arm would be attached to 14 1 9 Hull Cleaning Brush and Underwater Vacuum The hull cleaning brush assembly was originally designed and partially constructed by the Slime Shark team for their senior design project The brush core is made of polyethylene and is 18 long by 4 4 in diameter with nylon bristles that extend and additional gt making the brush s total diameter 6 This brush was chosen so that it would be less likely to damage ship hulls during the cleaning process The shaft upon which the brush rotates is made of 304 stainless steel with overall dimensions of 25 length and 1 diameter The shaft spins with the aid of two Uhmw Pe Bearings which are made of polyethylene and stainless steel housing The entire brush assembly is mounted on an
36. dules and convert and the AC input to 300V DC output The high voltage and low current is used so power is not wasted by keeping the tether resistance low The technical details in this section are taken from last year s ROV team report that 1s located in Appendix A 8 4 2 ROV Electronics The ROV s electronics are located inside the pressure housing They are connected to two underwater connectors one connects the 100 ft tether to the control box and the other one connects the motors and additional accessories lights etc 28 Located in the pressure housing is another power converter that lowers the voltage to 12 V to power the electronics It is a Vicor maxi family type 300V DC to 12V DC converter The communications from the tether connect to another 485 and 3 PIC16F876 chips that are used to control the thrusters and other components The technical details of the operation of the PICs are located in Appendix A where the last year s ROV team report is Below is the schematic which was designed by Larry Buist Figure 9 ROV Electronic Schematic Figure 9 shows the old design of the ROV electronic board This design is flawed in that only three out of the four motors work Besides less power and mobility the flaw makes the ROV unable to go in the forward direction Currently this group with the help of Larry Buist is designing and o
37. e Tether Length 100 ft e Tether Voltage 300 V DC e Main Power 120 V AC e Motor Thrust 6 4 Ibs ft 61 e Pressure Housing tested to 200 ft Foam Crush Depth 800 ft Troubleshooting Error The monitor is not showing any video Solutions Check to ensure that the monitor is plugged in Check to ensure that the cables are plugged in correctly and tightly Check to ensure that power is going to the unit with a multimeter or other electrical diagnostic device Check to ensure that the unit is turned on Error There is no control for the ROV Solutions Check to ensure that all cables and tethers are plugged in correctly and tightly Check to ensure that power is going to the unit with a multimeter or other electrical diagnostic device Check to ensure that the unit is turned on Check to ensure that the motors are not entangled or damaged Contact For any other questions please contact Dr Stephen Wood at Florida Institute of Technology Department of Marine and Environmental Systems 150 West University Blvd Melbourne Fl 32901 321 674 7244 Or go to http my fit edu mmarmitt Projects senior design senior design htm 62
38. e wanted to conduct a pressure test of it to ensure that it performs according to factory specifications Taking a small sample of the foam the team measured the density of it to see how close to the factory specifications it was in order to plan the floatation design accordingly Using the pressure testing chamber on campus and following the proper procedures listed in the appendix the foam sample was tested to ensure that it followed the company s volume change due to hydrostatic pressure and to see that it was capable of withstanding the pressures required by our design 4 2 Pressure Housing Test The pressure housing had been tested at a limited pressure and passed The pressure housing needed to be retested due to the holes for the tether and underwater connector being drilled in the back plate This was done in the university s pressure chamber following the proper guidelines and procedure in the appendix Additionally the pressure housing was immersed in water in the chamber for an extended period of time to test for leaks using paper towels placed about all possible points of entry 4 3 Dry Electronics Test After connecting all of the electronics component tests were conducted to make sure that the motor controls were connected to the correct motors In addition the camera feed response time and quality was verified Any wiring and program troubleshooting was performed at this point until all components performed correctly 14
39. ed CAD files Presentation Preliminary design review Safety Plan Senior Design Showcase Editing spring report mounting connecters and testing Tested foam samples Recertified in machine shop MFP cruise proposal Final spring presentation Machined ROV components Trimmed control board Soldering converters Redesigned floatation Modified control box Work on floatation foarn Sealed wiring between and thrusters Research Cruises Integrated components dry test ROV wet test 1 Designed new circuit boards ROV wet test 2 Editing final report Figure 1 Gantt Chart 2 4 Organization Team ModROV had a communal organization with all of its members participating in tasks and decisions when possible Each member of the team had their own unique areas of expertise and set of skills that they contributed to the project The team member s resumes are attached in the report s appendix providing additional information as to their experience 3 0 Background The background for this design project can be broken down into two parts The first part is the basic theory of ROVs but more specifically ModROV The second part is all of the history or research done on the project 3 1 Basic Theory The theory behind ModROV was to be a completely modular small scale vehicle that 1s relatively inexpensive ModROV was as its name suggests an ROV This means that it is a Remotely Operated Vehicle that employs a tether system that is
40. g board LED housing Circuit Components Size e 3 8 10 1x1 4 2 5 8 1 1 4 20 1 4x3 4x20 10 24x3 4 10 24x1 1 4 3 8 18 1 4 18 3 4 18 10 32 8 2 1 2 wires resistors diodes capacitors Quantity 6 1 1 1 2 6 0 53 video board Hinge power supply pneumatic rods zinc round Philips 8 32x1 2 emergency stop start button link pins bread board goggles underwater connectors pressure transducer max 889resa Chip Sukafa009a Chip video cables RCA Power cable wire strippers cutters small LCD screens Zip ties Rope thermometer O2 sensor PIC 16LF877 4 MHz timer SFLM 59 4700P 110 250 V Cap Film 0 61uF 1096 250 V RDL MOV 220V 10mm Dia Metal Oxide Varistor MOV DTVS 51V 5 1 5 kW DO 201 Diode 1 amp 1N5817 Schottky Barrier Rectifier Cap 470 uF 350V Cap 1000 pF 50V 10 rad 150kQ 0 5W Carb Comp Underwater Connector female Underwater Connector male Locking sleeve male Locking sleeve female Brass 5 8 18 nut 5 pack 5 8 dia 3 8x16 2 1 4 3 4 x 6 3 8 x16 3 8 250 0 125W 5 8 1 2 x 4 conn housing 2 pos conn housing 4 pos conn housing 6 pos conn housing 7 pos Oo a 2a RWORRAR d ORO N 100 10 10 10 54 conn term female conn term female SFLM 89 33M 10 250 V RFI IND 19447 19417 W TAPE 03347 1 4 20 Rod 3 8 x4 Spring 45 4 40x1 2 4 40 6 32x1 1 2 6 32 1 4 20x2 1 2 1 4
41. h a diameter of 6 that aligns with the inside of the pipe and an outside diameter of 8 To this rear flange another 8 plate is bolted with six nuts and bolts about the perimeter This rearmost flange has a small slot cut in it to house an o ring to seal the rear of the chamber The flange welded to the front of the pressure chamber has a 7 diameter with a small hole for the camera cut in it The dome is placed over the camera and another o ring seal with another 7 flange placed in front of it to secure it to the pressure chamber Another six nuts and bolts are used to fasten these two flanges to one another and keep it sealed The particular hardware used to secure the pressure housing 4 x 20 x 1 4 hex cap screws washers and locknuts The rear flange of the pressure housing also has two holes drilled in it to accommodate the underwater connector for the motors and the tether each 5 8 and 1 respectively The pressure housing has been pressure tested in our hyperbaric pressure chamber to a depth of approximately 200 feet twice the currently planned operational depth giving us a factor of safety of at least two The weakest point on the pressure housing is the plastic dome which the camera sits behind unfortunately there are no specifications as to what depth it is rated so we can only rely on what our tests have proven 8 3 Floatation The floatation system is designed to give the ROV neutral buoyancy with a slightly positive trim s
42. he Marine Field Projects Once completed the team hoped to use the ROV at sea during the Marine Field Projects in order to make observations and to supplement other instruments and hardware onboard the research vessel The dimensions of the ROV are approximately 17 5 in tall by 24 in wide by 32 in long The operating depth of the ROV is 100 ft because of the length of the tether however the pressure housing was tested to approximately 200 ft 2 0 Introduction This ROV senior design project represents the accumulation of four years of design and development There are a number of important subassemblies that have been developed by prior groups and were integrated into a working product This report will detail what progress was made and what plans we have for the future 2 1 Motivation The group s primary design motivation was to create a finished working product that can be utilized by the Department of Marine and Environmental Systems over the years to come This ROV was designed as a vehicle that is as modular as possible allowing for customization by future senior design groups and the department Most ROVs that are constructed are designed to perform specific specialized tasks or to carry every conceivable piece of equipment that they may need during their operational lives Our team s goal was to create a system that will be able to evolve to fit the needs of the school with hardware capable to being easily mounted and installed on
43. ine and Environmental Systems in the field The scope of this project entailed taking what the previous group developed and from there finishing the remaining core systems and make the ROV operational The benefits to society if a completely modular ROV should exist are numerous Such benefits include ocean exploration search and recovery undersea mining cheaper hull inspection cleaning scientific research and many other applications A modular ROV could be tailored to any one of these applications This team was also interested in adding additional lighting to the ROV for work at night or in low light conditions along with looking into using the already planned modular mounting system to affix systems such as a manipulator or a recovery bin Items addressed were the completion of the electronics floatation a recovery and deployment system renovations to the control case welding and finalizing the frame affixing the motors connecting the umbilical to the pressure housing in addition to conducting tests and trials The ROV team hoped to conduct tests on foam samples to determine if the samples can withstand prolonged exposure to pressure without ill effects in addition to additional testing of the pressure housing before installing the electronics There were also plans to conduct extensive pool trials of the ROV to give controlled environment to do tests so the ROV may be easily retrieved and quickly serviced before participating in t
44. ion tether Also the additional pressure housing can be used to store the data and then be transferred to a computer once the ROV is topside Sensors that can be added to this ROV include e Any sonar devices e CTD Mineral metal detector for undersea mining purposes 14 1 4 Lights The ROV needs additional lighting in order for the camera to provide a decent picture in low light conditions There are currently provisions for a default pair of lights to be installed on the underwater connector used by the motors in order to provide the ROV with adequate light These lights will be mounted on the front of the ROV to enhance the picture quality 14 1 5 Addition of a Second Camera An addition of a second camera to the ROV is recommended Placement of the camera could be in two places the back of the ROV or the bottom of the ROV within the frame In keeping with the original idea of last year s team the back mounted camera would help with navigation of the ROV and it would allow the pilot to see what has been cleaned on the hull The bottom mounted camera would be consistent with the modular 35 theme of this year s design The camera would help with navigation of the ROV and or a manipulator arm or basket An additional LCD screen pressure housing electronics board and cable would be needed for this extra camera 14 1 6 Cathodic Protection ModROV is made of mostly aluminum 6061 T6 however there is also some stainless steel an
45. le in addition to when the ROV has returned from an expedition and is being prepared for storage Special care must be taken to thoroughly wash each of the motors as these are more susceptible to corrosion than other portions of the vehicle 6 0 Customer Requirements At the present there are no customers for this ROV but the ROV is currently being built so FIT can use it for MFP Also it will be a tool for the DMES to use as it sees fit However after the ROV becomes operational there are many ways to use this product The ModROV is designed to be light and compact so that it is deployable on any ship It is designed to be completely modular so the list of potential customers is endless Oil companies can use this design to check piping by using just the video camera on the ROV Mining companies can put a metal detector on the ROV and search the oceans for precious metals These are only a few of the possible customers that are able to exploit the ModROV s capabilities 6 1 Future Customer Requirements A future purchaser of the ModROV may need several accessories added to the ROV that are not included in the default configuration Such additions might be e Manipulator arm with light e Metal detector Another camera e Any kind of sensor package 16 e Brush hull cleaning e Basket Container e Vacuum as well as any other conceivable accessory 7 0 Project Evolution From the beginning the Slime Shark has undergone a v
46. les and springs were added to the surface of the controls to make it easier to get to the circuitry below the surface Underneath the surface of the control box is a large part of the electronics for the entire vehicle This is the communication board that includes several components important to the operation and control of the ROV The PIC 16F876 and the MAX485 chips are the main parts of the circuit that are used to communicate to the ROV underneath the water The schematic for the electronics board is shown below For more technical detail the specifics can be seen in last year s group report found in the appendices 27 Joystick Two Jerstick One Larry Buist Copyright 2008 For Ocean Engineering Florida Tech lpwist fit edu J21 674 7216 Surface Sub Control Figure 8 Schematic of Control Box Electronics Feedback is sent from the ROV below the surface to the control box to be analyzed The monitor itself can be connected to a video overlay system called XBOB This is the system that takes data from a pressure transducer compass or any other real time measuring device used on the ROV and puts it on screen as a heads up display The control box also includes the power source to the ROV The main part of the voltage conversion circuit is located here They are called the Mini HAM and FARM3 mo
47. mponents There are plans to anodize the frame in the future in order to provide a level of protection to the frame due to it not being constructed from a marine grade aluminum alloy 8 1 1 Thrusters The thrusters for the ROV are Seabotix BTD 150 Thrusters which were selected by the previous year s group for their power price and their ease of control see Thruster section of Appendix A The motors are DC Brush motors specifically designed for use in underwater robotics The default ROV configuration uses four of these motors set in pairs of two one pair orientated vertically and the other horizontally Figure 7 Seabotix BTD 150 Thruster courtesy of Seabotix Inc 24 8 2 Pressure Housing The pressure housing was constructed by the previous ROV senior design team and was designed to withstand a minimum of 100 feet of hydrostatic pressure The pressure housing has holes drilled in the backside so that the tether connector could be mounted in addition to an underwater connector for the motors Within the pressure housing are the electronics for the ROV and the camera All these components are located on a platform that can easily be removed from the pressure housing for service or modifications The tube that comprises the primary structure of the pressure housing is a 6 inner diameter aluminum pipe 12 long Welded to the ends of this pipe are a pair of aluminum flanges that are 3 8 thick The rear flange has a hole cut in it wit
48. ms that were planned to be welded included the vertical motor mounts one of which was relocated The reason the back motor was moved to the outside was to improve symmetry aesthetics simplification of floatation design decrease turbulence increase motor efficiency and improve location of the center of gravity The vertical motors were also inverted from their original configuration in order to provide better protection for the propeller cages when the ROV is set down Bumpers and originally cages were to surround the motors to protect them from wear and tear of normal use Also the back bumper will be enlarged to serve as a handle for deployment However only bumpers on the front and back motors will be installed because of time restrictions Generally if the ROV is going to hit anything it will be on the front or back anyway Mounting positions for the pressure housing was drilled to keep with the modular design This gives an allowance for the mounting of various instruments tools in the front of the ROV as well as other areas Below this section are figures of the design elements mentioned above Figure 4 Bumper to Protect the Thruster 20 Figure 5 Relocation of Back Motor and Variable Pressure Housing Mount Originally it was planned to mount the pressure housing to the frame utilizing specially ordered aluminum u channel After pricing this material and examining what was already available in the lab it was decided that the pressu
49. ng i Aluminum may become hot causing burns if handled or fires if placed near flammable items ii Risk or electrical shock from improper use or malfunction of welding equipment 43 iii Retinal scarring could also occur if welding masks are not worn 2 Epoxy Resin and Hardener a Mixing i Contact with skin may cause irritation chemical resistant gloves should be worn in order to prevent this in addition to whatever else is necessary Should be done an area with adequate ventilation to prevent illness iii Spills may occur and require appropriate clean up measures and precautions b Machining Cutting Sanding i Involves working with potentially dangerous equipment which may cause injury or death to operator or those nearby 11 Dust may cause irritation and require proper safety equipment be worn c Storage i Ifstored under inappropriate conditions epoxy may catch fire or explode 3 Syntactic Foam a Machining and Sanding i Dust from foam may cause irritation in ones eyes skin and airways 4 General Plastics R 3318 Last a foam a Machining and Sanding i Dust from foam may cause irritation in ones eyes skin and airways Mechanical air filtering masks may be necessary in instances when high volumes of dust is generated Environmental Impact Analysis Storage Epoxies will be stored in a fire cabinet to help reduce the risk of fire Disposal Give unused materials to university safety department for proper disp
50. ng the remaining systems and making the ROV operational We also were interested in adding additional lighting to the ROV for work at night or in low light conditions along with looking into using the already planned modular mounting system to affix a manipulator or a recovery bin Things which were addressed are the completion of the electronics floatation a recovery and deployment system renovations to the control case welding and finalizing the frame affixing the motors connecting the umbilical to the pressure housing in addition to conducting tests and trials We also conducted tests on foam samples to determine if they could withstand prolonged exposure to pressure without ill effects in addition to testing the pressure housing before installing the electronics We also planned to conduct extensive pool trials of the ROV to give us a controlled environment to do our tests where the ROV may be easily retrieved and quickly serviced before taking it out for a field test 1 1 2 Hazard Analysis Materials and Conditions 1 Aluminum 6061 a In the form of hardware bar stock and rods b Used throughout the ROV for its frame pressure housing hardware and other connectors c Machining Cutting Filing i Involves working with potentially dangerous equipment which may cause injury or death to operator or those nearby ii Sharp edges may form when cuts are made iii Powder from cutting aluminum may cause irritation or catch fire d Weldi
51. ngular frame made from T6 6061 aluminum channel bar This design had to be expanded because all of the components could not be included with the frame and provide the pilot with the needed control over the Slime Shark The proposed solution was to add a second tier also made of channel bar The tiers were to be connected using angle bar and supported by channel bar as cross pieces This design was then changed in part to the location of a cheaper aluminum flat stock which replace the angle bars and the channel bar cross pieces However due to the lack of stability provided by the flat stock it was decided that the channel would serve better to support the tiers and it was also more aesthetically pleasing The channel that was retained in the design was also expanded from 2 x 1 to 2 1 L because of the availability of the material This frame has a pressure housing mounted to it which has a 6 nominal diameter and a length of one foot attached to it The frame will also have two Seabotix motors on the port and starboard sides attached by square tubing to the bottom tier These motors will provide the thrust and turning needed Two additional Seabotix motors will also be utilized to allow for ascending and descending In order for the Slime Shark to effectively attach to the surface of the ships to clean them the use of live well pumps was considered to provide enough downward thrust the keep the ROV in place The discovery of a device
52. olate private property or a restricted wildlife reserve as well as government property such as a naval base The ROV could also be improperly used in illegal activities such as drug trafficking spying or the illegal harvesting of aquatic specimens 11 0 Health and Safety Whenever work is done with machinery or hazardous chemicals there are always the possibilities for causing damage or personal injury Keeping safety priority one the ROV team performed all work on the ROV with at least two people present This way encase an emergency of any sort occurred someone was present to lend aid or go for assistance Individuals worked in well ventilated areas with a telephone line accessible for calling for aid when working with items that have fumes or generate dust The use of proper personal protection equipment was mandatory when applicable to the process or materials that were worked with or on this included items such as closed toed shoes safety glasses respirators welding masks and welding gloves When deploying and operating the ROV caution was exercised there were plans to have certified divers in the water to aid in the recovery deployment process and to help prevent the ROV from becoming fowled when operating underwater however the voltage on the ROV was too 32 high so this idea was abandoned Care was taken when working with electronics to avoid shock and electrocution The ROV uses 300 volts for some applications and that poses a po
53. osal or place in proper storage for future use Unused epoxy is a hazardous material and must be given to the university safety office The R3318 high density urethane foam can be disposed of in a landfill as per the material specifications and small quantities used Miscellaneous When deploying an ocean system there is always a risk of loosing the vehicle The aluminum frame will eventually corrode away however the floatation should be impervious to decay and will remain in the ocean indefinably 1 1 3 Human Safety Analysis Personal Protection Equipment Machining Safety glasses Dust Masks foam 44 Sanding Safety Glasses Dust Masks foam Mixing Epoxy Safety Glasses Gloves latex or other Testing ship board Life Vest Close Toe Shoes General Work Safety Keeping safety priority one we will perform all work on the ROV with at least two people present This way if there is an emergency of any sort there is someone present to lend aid We will also work in well ventilated areas with a telephone line accessible for calling for aid We will also make sure that we all wear proper personal protection equipment applicable to the process or materials that we are working with When deploying and operating the ROV we will exercise caution and have certified divers in the water to aid in the recovery process Care must be taken when working with electronics to avoid shock and electrocution We will be working with 300 volts
54. ould be if one of the motors were to fail as it would require resealing the point where they connect between the underwater connector and the rest of the thrusters The rest of the components on the ROV can be quickly stripped with the aid of a pair of 7 16 ratchet and wrench a 9 16 ratchet and wrench an adjustable wrench and a Phillips screwdriver There are also certain steps that can be taken to help prevent damage from occurring to the ROV during normal operations When connecting the tether to the control box it is important that a keyway is aligned as only then will the tether be able to fasten securely The same applies to the tether connection on the back of the ROV there is only one possible orientation for the plug so care must be taken to not bend the prongs 15 while trying to force the plug into its socket It is also important to never attempt to lift or pull the ROV by the tether as it is only secured by friction and a plastic coupling on the back of the pressure housing that can easily break When recovering or deploying the ROV do so either by holding onto the vehicles frame or by a rope attached to the vehicle When the tether is not in use be sure to store it properly on its spool to avoid tangles or damage to the plugs from occurring In order to properly maintain the ROV only a few precautions need to be taken After each deployment the ROV must be washed thoroughly with fresh water in order to wash any salt off of the vehic
55. r your application but there is only a small variety of attachments that can be bought to be added on The Sea Dragon is an example of an up and coming ROV design which the base structure power and propulsion are setup and then there are parts made by the manufacturer that are able to be added on Another company that is forefront in this area is VideoRay Their vehicles boast a small size where most models are able to fit everything needed for a job in three suitcases Also with this 1s the ability to add on modular parts to the vehicle that suit the purpose One of VideoRay s vehicles is the Pro 3 XE GTO which is one of their more advanced models and it is made with a port on the lower part of the structure where the various add ons can be connected The issue with this model is that only one of these systems is able to be added on at once This creates 12 an issue 1f you want to use sonar to image where you are going but also want to use a manipulator The Pro 3 XE GTO can be seen below Figure 3 VideoRay s Pro 3 XE GTO courtesy of VideoRay In our research there has been no modular ROV similar enough to ours that we have found The purpose of ModROV is to have any part system on or in it swapped out whenever needed For example if a company were in need to do a survey of the ocean floor and needed stronger motors to make it there and maneuver in the environment the current motors can be removed and swapped out Obviously there i
56. ra Deployment Connect tether to vehicle and to control box Connect power to the control box including the connections inside the box for the monitor and for the internal power converter Perform a surface test by moving the Joysticks to move the motors and by waving a hand in front of the camera to ensure functionality Power down the unit Using the handles on the ROV place it in the water If on a boat the handles can be 60 utilized to hang the ROV from a lifting structure to be placed in the water Power up the unit Perform a wet test of the vehicle maneuvering it in all directions and checking the monitor for video Perform task Recovery 1 Bring the ROV to the surface 2 Hook the ROV by the handles with a gaff or other hook device 3 Pull the ROV towards you slowly while reeling in the tether 4 Wash the tether with fresh water as you are reeling it in 5 Once the ROV is near enough to grab pull it up by the handles on the ROV DO NOT PICK THE ROV UP BY THE TETHER This can damage the tether and cause further damage to the vehicle If on a boat hook a rope or lifting device to the handles and hoist it up onto the deck 6 Power down the unit 7 Thoroughly wash the ROV with fresh water once on deck 8 Disconnect all cables and power to the control box and the ROV 9 Stow and secure the ROV on the deck Specifications e Length 32 5 in Width 24 in e Height 17 5 in e Weight 80 165
57. rdering a newer simpler circuit board to control the ROV A previous more complicated circuit board was ordered but it did not work once made To make the thrusters go both forward and reverse a method using H bridges was used on the flawed electronic board This is a configuration of transistors that are 29 controlled by the PICs which allow the direction of the current to change and therefore the direction of the thrusters change This is a very precise way of controlling the motors The electronic board will also contain the compass and pressure transducer so the pilot will know how far down the ROV is and which direction it is headed Another accessory that the electronic board can control is a light which can only be turned on and off The video camera itself is not part of the electronic board but it is supplied with 12V from the power converter and has a direct feed to the main tether for communication with the control box The technical details in this section are taken from last year s ROV team report that is located in Appendix A 8 4 3 Underwater Connectors The thrusters as well as any equipment added to the ROV in the future are connected to the pressure housing via an underwater connector Also the main tether that includes all of the communication and video is connected using an underwater connector to the pressure housing Last year s underwater connector was used for the main tether but another underwater connector was p
58. re housing supports would be instead manufactured out of leftover pieces of frame material cut in half to yield two 90 degree bar stock pieces These pieces are then mounted to the frame with a set of bolts that allow the pressure housing to be removed easily On the top of the frame there is then a line of holes drilled which allows the entire pressure housing assembly to be moved forwards or backwards on the frame in order to help compensate for the ROV s trim when additional equipment is mounted to it Originally it was planned to have four bolts for each support however it was decided to reduce that number to only two bolts and to instead increase their diameter from 1 4 to 3 8 This also simplified the work done to the frame by reducing the number of holes that needed to be drilled on the frame ofthe ROV To each of the pressure housing support brackets there are attached two 6 aluminum u bolts that the previous year s team acquired These are mounted in a pair of 5 8 holes drilled in the pressure housing support brackets The manner in which the 21 pressure housing supports are mounted to the frame is also significant the vertical portion of the bar stock is used to help prevent the pressure housing from sliding forward and aft on the ROV while being held in place by the u bolts which prevent the pressure housing from moving vertically or from side to side In order to allow the bolts that are used to seal the pressure housing to have
59. remnant donated by them to the school According to the company s website this product is designed to provide floatation for underwater systems such as our ROV and has a density of 18 1bs ft and can operate at depths up to 800 feet The foam was mounted to the frame of the ROV using six aluminum bolts three to each side that were made from aluminum bar stock that was cut to length then threaded which was much cheaper than having to purchase premade bolts of the required dimensions Calculations were made to determine the strength of these bolts with a factor of safety of three in order to verify that they would be strong enough to support the frame of the ROV In regards to the control box the interior control surface was lowered to accommodate the LCD screen Part of the panel was cut out to make room for various cables or future electronics Also springs and handles were installed to make the control surface easier to remove The topside power converter board was completed and attached to the bottom of the control box It includes a FARM3 and MINIHAM components as well as various resistors capacitors and diode required for the company s circuit design Controls will be labeled before completion Our original design did not include forward lights on the ROV However if time permits a light for the ROV will be designed and mounted An evolution in the bottomside electronics also occurred As we got further into our project it came to our attention
60. s some work that would have to be done to get it all back together however it is preferable to buying a whole new ROV A future solution to this is to have our electronics boards with a specially designed plug for each component built in This way the plug would only be able to go in one spot which makes it hard to cross connect wires and destroying critical parts Along with all of these complications is the back plate of the pressure housing with the addition or changing of different parts of the ROV there may need to be different connectors to accommodate it This would be solved by a series of back plates that are made by our company that have holes pre cut for specific connectors This means that the company would make all the hardware parts and carry other parts such as sensors This way a customer can create their own ROV but if in the future it is needed for a new task that the current ROV is incapable of completing the company could be able to supply new parts to accommodate 13 4 0 Procedures The procedures of this senior design project mainly concerned themselves with the testing and integration of the ROV s components that had been constructed and individually tested by the previous group These tests allowed for troubleshooting of problems and helped make design alterations to mitigate them 4 1 Foam Pressure Test Given that the foam we received for the ROV s floatation had never been worked with by the school before w
61. te electronic boards one in the control box and the other in the pressure housing The ROV s electronics are mounted within the pressure housing on a specially designed platform to allow for easy installation and removal The camera is also mounted to this electronics platform as is the power converter that gives the proper voltage required for the control board The control box s electronics are housed underneath the platform containing the joysticks and buttons that control the ROV There is also a Polaroid LCD screen that shows video output The following sections will explain in further detail the ROV s electronics and the control box s electronics as well as the programming involved 26 8 4 1 Control Box The ROV operator utilizes the control box to maneuver the vehicle underwater The camera feed is displayed on a Polaroid LCD screen that can have a compass and depth reading on the screen with the video overlay board that will be discussed later This ensures that the pilot has as much information as possible to successfully fulfill any mission required The components that are used for control feedback and power supply are encased a Pelican 1550 case Once the case is opened there are many components for control The control is governed by two joysticks that rotate on an X and Y axis The power switch and other buttons that will possibly turn on off a light or any other future components added to the ROV are mounted here as well Hand
62. tential danger if proper care is not executed Caution was exercised by making sure that live wires were not touched and that any circuitry was turned off before handling For more information please see Appendix D for the team s Safety Plan which also addresses these issues 12 0 Budget This project had two budget areas the material costs and the time costs from the team The time costs are based on a ten dollar an hour rate for each team member plus the rate of any outside consulting work which we had done Our monetary budget primarily came from funds allocated by the College of Engineering and the Marine Field Projects Other sources of funds came from donations or funds raised by the team for the project Following is a breakdown of the materials used in the project and their costs 12 1 Bill of Materials The Bill of Materials located in the appendix lists all of the components used to construct the ROV The items listed with a cost of 0 00 are items which have been carried over from the previous year for their costs please see their list of materials Our monetary budget consisted of 400 00 from the College of Engineering in addition to 1000 00 allocated from the Marine Field Projects By utilizing components and materials from the previous year in addition to seeking discounts and donated materials from companies the team was able to stretch the budget to cover all expenses A full list of our expenses and materials can be found in
63. that the bottomside electronics board had a flaw in the design that only allowed three out of the four motors to work The board was redesigned by Larry Buist and all of the components were ordered to populate the circuit The new board however was also non operational Therefore a new simpler board is being designed to replace these and make the ROV operational 8 0 Function Decomposition Structure ModROV is made of a number of components of them are five major assemblies which are listed and outlined below 23 8 1 Frame The frame is the primary structural component of the ROV and it is made of several welded pieces of 6061 Aluminum U channel with the dimensions of 2 7 x 1 by 1 8 thick The frame was TIG welded together to the proper specifications for each weld joint The material itself has reasonable corrosive properties is easy to weld for aluminum and is easy to machine It was originally designed to be a rugged frame capable of withstanding the force and vibrations from a large brush assembly for boat hull cleaning and was also able to have components easily mounted to it which helps keep with our goal of having a final product that is capable of having modular components The wide flat faces of the frame are good for either bolting or welding components onto it The frame is what the pressure housing and floatation systems mount to allowing them to be easily removed should a modification need to be made for any of the co
64. ttern After water flows from the outlet valve close the outlet valve and then the inlet valve Attach an air hose to the inlet of the pressure chamber and the other to the air compressor Open the compressor s inlet valve and begin to pressurize the chamber until the desired pressure is reached When the desired pressure is reached turn off the compressor and then open the water inlet valve to drain the water above the rim of the main chamber Loosen the bolts and lift the lid off the chamber and remove test samples to be analyzed 56 l z 130 1133 HOM 1 31755 venu Aldd Y SNOISN3WIQ 01018 Aaa ON 1894 32 EE SIINA aam 9 19 snuu 3 eee 0315345 0 26 vo ues 02111 eun V 2X Dag zen 627 z xnogees Ces 4ONVT nava nva mdi 587 13 98 v ox 22 69113 v9 39362 086 90 03009 80100 W b NIGE 3 SdWv Sz v QNO93S 06 SdWv 8 s YO NOdN 9 WOWIXVIN KOLF AL t EH NSTIVAIO3 25198106 X 9 SS 91 SdITIHd Qv3H MIYOS WLIW 133HS 1334 005 SH313W 051 SNOIALVOIJI23dS Appendix SeaBotix BTD 150 Thruster SIHONI SNOK SIONVATIOL 37859 3MIM Z G6 W L LSNYHL ASMYHL
65. uch that in the event of loss of power or of the tether the ROV will 25 hopefully return to the surface where it may be recovered The design of the ROV s floatation has undergone a number of iterations as new materials have been considered and selected for use The floatation will be provided by General Plastics Manufacturing Company s R 3318 Hydrostatic Pressure Resistant Foam According to the company s website this product is designed to provide floatation for underwater systems This foam features a density of 18 Ibs ft3 and handle up to 350 psi of water pressure or 800 feet Looking at the water penetration table for the product that can be found in the appendix the foam will exhibit little change in volume from the pressures we expect to experience The R 3318 foam is easy to machine and glue together which will make the construction of the floatation structure fairly easy The exterior of the foam was covered with a layer of fiberglass and epoxy to provide it with a layer of protection from dents and scratches The floatation system was then painted a bright yellow colour to aid in spotting the ROV underwater and on the surface and to provide an additional layer of protection to the foam in addition to making it aesthetically pleasing 8 4 Electronics For a ROV to successfully work the design must include carefully built electronics that are programmed to maneuver the ROV correctly along with other control functions There are two separa
66. urchased for the light and thruster connections All the parts for this connector were ordered from Teledyne Impulse Inc The parts include female connector BH 12 FS male connector with a two foot whip IL 12 MP ON 2 18 12 SO male locking sleeve D LS C M and female locking sleeve D LS C F The technical details for the connectors can be found in Appendix J 8 4 4 Programming The programming was done in Basic which allowed external people with more expertise to help the previous senior design team Larry Buist and Thaddeus Misilo helped immensely with the programming and the electronics in general The Basic code is located in Appendix E 9 0 Ethical Issues There are ethical issues involved in the construction and use of any machine or product With ModROV the ethical issues involved with the construction were excess 30 material left over after the construction of the ROV and work environment The ethical issues pertaining to the use of ModROV include disturbance of wildlife personal safety hazards and property damage There is also the issue of the environmental impact that ModROV would have if it cannot be retrieved and as an example what would be the impact of the foam as it breaks down over time During ModROV s construction phase the team faced the ethical issues of the disposal of extra materials and waste products and personal safety in the work environment First off the team did not face any issues such as poll
67. ure to recover ROV operational depths Pressure housing failure Loss of buoyancy Keep ROV within Loss of electronics and control Potential loss of ROV operational depths Ensure pressure housing bolts securely fastened Electronics malfunction Loss of control of vehicle Personal Injury Damage to ROV Potential loss of vehicle Make sure electronics installed properly Make sure the circuits are coded Motor failure Loss of control of vehicle Personal Injury Make sure motors connected properly Damage to ROV Wash ROV to prevent Potential loss of vehicle corrosion after each deployment Camera failure Loss of vehicle control Make sure camera is properly installed Vehicle entanglement Loss of vehicle Environmental damage Avoid entanglement situations Have recovery divers available Biological interference Loss of vehicle Damage to vehicle or organism Death of organism Be aware of surroundings 46 Appendix E Basic Code Topside KKKKKKKKKKKKKKKK K KAMandAa OE MTOVCON CLO LAM RAR EER DEFINE OSC 4 DEFINE ADC_BITS 10 set to ten bits DEFINE ADC_CLOCK 3 DEFINE ADC_SAMPLEUS 50 gtd CONFIGURE CD DISPLAY Gerni ke DEFINE LC
68. used to control the ROV from the boat The team used the 100 foot tether from the previous years groups The tether allows power and data to be sent up and down it from the boat to the ROV giving the user control over the vehicle The tether connects from the pressure housing on the ROV to the control box on topside The control box was also from previous years projects To prevent damage to the tether a system for managing the cable needed to be implemented This means that there needed to be some sort of reel system to prevent the tether from becoming kinked frayed cut or otherwise damaged One such system for a small ROV is the one employed by VideoRay which is the Tether Deployment System TDS The objective for the VideoRay ROV is to be portable small and to be utilized anywhere around the world The TDS uses a 1660 Pelican case with retractable tether and wheels VideoRay This system is great for low depth systems like ModROV but can also be applied to deeper systems as the TDS is offered in lengths of up to 1000 feet The TDS has a built in slip ring that allows the tether to be let out without becoming a hassle in the reeling process ModROV utilizes a system similar to this The tether management system employed by Team ModROV uses a basic hose reel to hold its 100 foot tether The reel does not use a slip ring However it utilizes a bearing built into the side of the reel to ensure there is no snag during the reeling process
69. uting the environment with the disposal of extra materials and waste products because the team adhered to the school s guidelines and stipulations Some of the excess materials were aluminum high density urethane foam plastic and wire Secondly for personal safety there was always going to be a certain degree of risk whenever work was done with machinery or electric tools The ethical issues that pertained to the team s safety in the work environment were unprofessionalism while working proper knowledge of the use of a tool and a clean work environment These issues became irrelevant for the team kept a professional attitude absolutely NO horseplay while working and used only the tools and machinery that the members of the team knew how to use If a member was not familiar with a tool then assistance was sought from an FIT employee who was familiar with it The team kept our work environment as clean as possible for safety purposes While using ModROV the team could run into ethical issues such as disturbing wildlife personal safety hazards and property damage Although there could be an issue with disturbing wildlife it would be minimal because of the small size of ModROV The ROV should not have any more of an impact on the environment then a scuba diver would The personal safety hazard issues with the use of ModROV would be when there is a diver in the water with the ROV when it is being deployed used or retrieved As long as the diver in

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