Team A: CreoClean

System Development Review

Oct 21, 2024

The Team

Agenda

• Project Description
• Use Case
• Requirements Modification
• Current System Status
• Project Management

Project Description

Project Description

Koppers’ factory makes railway ties by injecting them with a preservative called creosote

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Railway ties

Creosote injection chamber

Project Description

EPA stipulates the ties must sit on the drip pan for 8 hours before leaving the factory to make sure all creosote has dripped out.

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Railway ties

Drip pan

Project Description

EPA also stipulates Creosote has to be cleaned off the drip pan frequently, so the drip pan can be inspected for cracks

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Currently, this is done manually using squeegees. It requires a total factory shut down for ~4 hours, and exposes workers to hazardous chemicals

Accumulated creosote

Our Solution

A robot will drive on the drip pan and use a robot arm to push creosote into a central drain

• Keeps workers out of harm’s way
• Allows the rest of the factory to keep running during cleaning
• More frequent cleaning → increasing compliance with EPA regulations
• Increase production rate → boost revenue

System

Mobility Platform

Vision & Perception

Robot Arm

Cleaning tool

Testbed

Use Case

Use Case

The Drip Pan is dirty!

Time to put the robot on the rails and start cleaning.

Use Case

Start command received!

Sensing environment and generating cleaning plan

Use Case

I’m 40% done cleaning and successfully cleaned 92% of the area covered. Battery 65%.

Use Case

I’m 100% done cleaning and successfully cleaned 96% of area covered. Battery 15%. Here are three spots I wasn’t able to clean:

Use Case

Charging…

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set arm plan
4. Execute arm plan
5. Displace creosote
6. Move arm to take a picture to evaluate cleaning performance
7. Process image, get creosote locations
8. Repeat steps 1-7

Drain

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

1

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

2

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

3

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

4

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

5

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

6

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

7

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

8

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

9

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture to assess cleaned area
6. Process image, get new creosote locations
7. Repeat steps 1-6

10

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

11

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

12

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

13

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

14

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

15

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

16

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

17

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

18

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

19

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

20

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

21

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

22

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

23

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

24

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

25

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

26

Operation

1. Move mobility platform
2. Move arm to take a picture
3. Process image, get creosote locations, set movement plan
4. Execute movement plan
5. Move arm to take a picture
6. Process image, get creosote locations
7. Repeat steps 1-6

27

Cleaning

Requirements Modification

Changed requirements

• Koppers covered some costs
• We went over budget (more later)

Current System Status

System Recap

Mobility Platform

Vision & Perception

Robot Arm

Cleaning tool

Work Breakdown Structure

Mobility Platform

Drivetrain

Linear Actuator

Cliff (IR) Sensor

Functional description of subsystem: moves on rails and moves arm perpendicularly (linear actuator). Senses edges of pan and pan's brics for localization

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Major remaining challenges: done

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Mobility Platform - Current Stage of Development

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Current level:

• Moves robot
• Moves arm
• Senses pan

Completed tests:

• Moves at desired speed
• Stops at pan's edge

Challenges faced:

• Designing this from zero was not easy

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Robot Arm

Functional description of subsystem: pushes creosote towards the drain

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Major remaining challenges: done

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Robot Arm - Current Stage of Development

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Current level:

• Pushes creosote
• Complies with MoveIt code

Completed tests:

• Different cleaning positions

Challenges faced:

• Arm locks out due to force feedback

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Cleaning Tool

Functional description of subsystem: works with the arm to push creosote. Senses force applied at the end

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Major remaining challenges: design upgraded version

Cleaning Tool - Current Stage of Development

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Current level:

• Pushes creosote
• Accumulates some in rubber

Completed tests:

• Real and fake creosote
• Cleaning with arm
• Force sensing

Challenges faced:

• Creosote is a tricky substance with multiple stages of life (liquid, goo, etc.)

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Vision & Perception

Functional description of subsystem: senses creosote patches on pan and calculates their position for the planner

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Major remaining challenges: done

Creo Mask

Semi Mask

Clean Mask

Original Image

Vision & Perception - Current Stage of Development

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Current level:

• Senses creosote at several states

Completed tests:

• Real and fake creosote
• Different lighting
• Multiple patch types

Challenges faced:

• Adapting to factory conditions

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User Interface

Functional description of subsystem: provides a bridge between users and the system

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Major remaining challenges:

• Finish GUI
• Ensure communication stability
• Relay commands to subsystems

User Interface - Current Stage of Development

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Current level:

• Connected to ROS infrastructure

Completed tests:

• Remote connection

Challenges faced:

• Real-time communication is hard

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Testing Environment

Functional description of subsystem: offers a mockup of the NLR drip pan

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Major remaining challenges: done

Testing Environment - Current Stage of Development

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Current level:

• Close copy of a section of the NLR drip pan

Completed tests:

• Slope accuracy
• Distance accuracy

Challenges faced:

• CMU Real Estate is hard

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Integration

Functional description of subsystem: allows all systems to exchange mechanical and electrical signals

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Major remaining challenges:

• Full system testing
• Orin <-> MCUs

Integration - Current Stage of Development

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Current level:

• Most basic components integrated

Completed tests:

• E-stop safety
• Mechanical assessments

Challenges faced:

• Drivers should not be taken for granted
• ICDs should have been done earlier

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Autonomy

Functional description of subsystem: combines signals from subsystems to come up with:

• Movement
• Localization
• Cleaning pan

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Major remaining challenges:

• Implement feedback
• Complete state machine

Autonomy - Current Stage of Development

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Current level:

• All subsystems talking the same language (ROS)
• State machine sketched
• Motion planning primitives

Completed tests:

• Open-loop cleaning (for PR 10)

Challenges faced:

• Finding correct ROS packages is hard
• ICDs should have been done earlier

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Project Management

Schedule Status

We are behind on our schedule:

• Overworked
• Delays with interfacing components
• Unexpected challenges

Catching up: reducing the scope of deployed product + some reduction in testing

Test plan

Tests to be done until the FVD:

• Full cleaning test
• UI connection test
• Platform localization test
• State machine test

Test Plan - PRs

Test Plan - Fall Validation Demo

Location: NSH B-Level

Sequence of events

1. A creosote simulacrum is placed on the testbed.
2. The robot is given the start command and cleans the drip pan
3. Updates from the robot are shown on a TV

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Metrics: All performance requirements -> ability to fulfill these reqs

Budget Status

Total: $5500 (budget extended)

Spent percentage: 91.6%

Extra: yes. We are being parsimonious with the remaining budget

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Lesson: building hardware is expensive

Risk Management - Risks

Risk Management - Risks

Risk Management - Risks

Risk Management - Risks

Risk Management - Risks (new ones since CDR)

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Risks

Major Selected Risks

• R3: Simulation and Testbed are not representative of factory
• R20: Arm locking out in certain positions
• R19: Burnout and overwork

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Closed since CDR

R6 closed by linear actuator moving the arm

Thank you!

Any Questions?