ECE 511: FINAL PROJECT REPORT GROUP 7 MSP430 TANK

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1 ECE 511: FINAL PROJECT REPORT GROUP 7 MSP430 TANK Team Members: Andrew Blanford Matthew Drummond Krishnaveni Das Dheeraj Reddy 1

2 Abstract: The goal of the project was to build an interactive and mobile toy using our personal hardware and software skills in conjunction with the MSP430 microprocessor discussed in ECE 511. We decided to make a tank to fulfill the goals of the project. The basic functionality are as follows: two drive motors control the tank treads for movement. A foam disk launcher that is triggered with by a solenoid mounted on the top. The weapon is mounted on a rotating turret that is controlled by a servo motor. There are two states of the tank which is shown by two LEDs. The red LED serves for the armed state in which the weapon can fire. The green LED serves for the turret control state in which the turret can be rotated. All control signals are sent from the MSP430. All drive motors, the trigger solenoid, and the state indicators are controlled by an RF controller. All parts were successfully integrated and the completed tank worked exactly as expected. Table of Contents: CONTENTS PAGE NO. ABSTRACT 02 I. MOTIVATION 03 II. PROPOSED SOLUTION BLOCK DIAGRAM 03 III. COMPONENTS 04 POWER DISTRIBUTION 04 RECEIVER 04 MOTOR CONTROL 05 FIRING MECHANISM 06 STATUS LIGHTS 06 WATCHDOG 06 IV. RESULTS AND CONCLUSIONS 06 V. APPENDIX 08 1.LIST OF TEAM MEMBERS AND TASKS 08 2.PARTS LIST 08 3.SCHEMATIC 09 4.PCB DESIGN 10 5.CODE 11 2

3 I. Motivation Project guidelines in ECE 511 required us to create an interactive toy controlled by an MSP430 microprocessor. When finished with the project we hoped to have learned the skills required to utilize a microprocessor in all aspects, both in hardware and software, as well as have a fun toy with which to display our accomplishment. II. Proposed Solution To achieve the goals set forth in our motivation we decided to create a remote controlled tank. A tank provided a way to utilize many microprocessor components, giving us the practice and knowledge we hoped to obtain, as well as a tangible and usable result that we and others could enjoy. The components of the tank proved to be perfect for a toy: Remote control for interactivity. Tread and drive motors, key to every tank. Foam disk launcher for real firing action. Turret control for firing flexibility. Status lights for user feedback and a bit of flash. A block diagram of the MSP430 Tank is shown below in Figure 1.1. Figure 1.1 Block Diagram 3

4 III. Components Power Distribution: The MSP430 tank was comprised of a wide variety of hardware components. The diversity of these components necessitated multiple power sources. The final configuration made use of three power sources; one 7.2V VEX battery pack, two 9V batteries connected in series to provide 18V, and finally two AA batteries built in to the weapon. The 18V source was used to directly power the solenoid used in the firing mechanism and the AA batteries were an internal part of the weapon. The 7.2V supplied by the VEX battery pack was used as a direct power source for all of the motors. Both drive motors and the turret motor required a voltage between 4.5V and 9V, so the 7.2V from the battery pack provided sufficient power and good performance. The battery pack also provides power to the MSP430 and to the RF receiver. The 7.2V was regulated to a constant 5V by the L7805CV 5V Voltage Regulator. This output is used directly to power the RF receiver, which requires 5V. A variable voltage regulator was also used in order to generate a constant 3.3V which was then used to power the MSP430. One final addition to the power was a 47k resistor and 1nF capacitor on reset pin or the MSP which was required in order to be able to use the MSP removed from the launchpad. Receiver: In order to provide a control interface to the tank, the VEX transmitter and receiver were used. The transmitter provides six separate control signals multiplexed into a 75MHz frequency band. The first four channels are analog and represent the horizontal and vertical axis of the two control sticks. The remaining two channels are digital, each representing a pair of buttons on the rear of the remote. This signal is received and decoded by the VEX receiver and translated into a Pulse Position Modulation (PPM) signal. The receiver connects via an RJ 10 port (4P4C) which includes the power, ground and PPM signals. Due to the VEX power requirements, 5V was used as input to the decoder resulting in a 5V PPM output which was stepped down to the required 3.3V using a Logic Level Converter from SparkFun. The PPM signal was routed to Pin 4 (port 1.2) on the MSP430. Once in the MSP430, the PPM signal was routed to timer 0, capture channel 1 which was configured to capture the rising edges of the signal. Using the default SMCLK, the timer was capable of providing resolution to ~1us which was more than sufficient for the decoding process. Figure 3.1 shows the signal as it was received by the MSP430. The long sync pulse of ~9ms indicates the start of the command sequence. Each channel is encoded as a high pulse of 500us followed by a variable low period of 500us to 1500us, resulting in a total period of 1000us to 2000us. When used in conjunction with the VEX motors, this duration corresponds directly with the required PWM on time, allowing precise control from the analog channels. The digital channels give 1000us when the top button is pressed, 2000us when the bottom button is pressed and 1500us when neither is being pressed which allows for easy threshold based interpretation. It should be noted that the observed values of these pulses deviated slightly from the expected theoretical values such that a neutral command value was actually 1650us rather than the expected 1500us. For the sake of clarity, the theoretical value will be used in following discussions, but the code defines neutral as 1650us and compensates accordingly. By using an interrupt to capture the time of each rising edge, the duration of each channel can be measured. As each channel was measured, the value was placed into a global command array which served as the communication mechanism between the interrupt and the main processing loop. Once all six channels had been measured, low power mode was disabled allowing the interrupt service routine to remain as simple as possible to reduce latency and timing errors. The main processing loop is responsible for interpreting and distributing the commands, allowing all of the updates to be made at once. Once all the commands have been assigned, the main loop returns to low power mode 0 to wait for the next set of commands. 4

5 Since timer 0 was also being used to drive the turret PWM, it was necessary to configure timer 0 in count up mode with channel 0 being used to set the period. Additional care was required when measuring the commands to ensure that the timer rollover was handled correctly. This also meant that there were some restrictions on the minimum PWM period. For example, it was found that 10ms was too short to allow the commands to be interpreted correctly, but 20ms was sufficient. Motor Control: Two drive motors and a single turret motor were utilized in the tank. Both drive motors were identical 3 wire Vex Motors. They were powered directly from the 7.2V battery pack and controlled by the MSP430 using Pulse Width Modulation. The PWM was sent from the MSP from pins 9 and 12. Pin 9 (port 2.1) controlled the left motor and pin 12 (port 2.4) controlled the right. The motor used to control the turret mount was a 3 wire Vex Servo Motor. This motor is also directly powered from the 7.2V battery pack and controlled using PWM. The PWM signal transmitted to the drive motors consisted of pulses in a 1 2ms range. A pulse of 1.5ms corresponded to a neutral, or stop position. Signal lengths longer than this, up to 2ms, caused the motor to move forward and lengths less, down to 1ms, caused reverse motion. Both motors were mounted to the inside of the chassis, causing the right drive motor to be reversed. Software allowed an opportunity to reverse the signal values provided to the motor. By taking the difference between the neutral position value and the actual commanded value the result could then be added to the neutral command value. This provided motion to the right motor of the same force but opposite direction of the left motor. To control the PWM signals the MSP made use of the built in Timers A module. Specifically, timer 1 was dedicated to controlling the driver motors. The timer was configured in count up mode using channel 0 to specify the overall PWM period as 20ms. SMCLK was chosen to provide a 1us tick which allowed the commands received from the RF decoder to be directly translated into motor commands without any additional calculation. Timer 1 channel 1 controlled the left motor and channel 2 controlled the right motor; these were routed to P2.1 and P2.4 respectively via the P2SEL register. Both channels were configured for Reset/set operation which is very convenient for PWM generation. For example, if the left motor is in the default stopped position, TA1CCR1 is set to 1500 which meant that the output would be high until the timer reached TA1CCR1 after which the output would be low for the remainder of the 20ms specified by TA1CCR0, resulting in a 1.5ms duty cycle and a period of 20ms. To adjust the motor speed, TA1CCR1 would be updated during the main loop after a command was received from the remote. Although the chosen MSP430 includes two timer A modules each with 3 channels, in the 20 pin package the final unallocated channel (TA0.2) did not have a direct output pin available. In order to use this channel to control the turret servo motor, a software assisted PWM was required. Output P2.2 was chosen for the turret PWM and configured via the P2DIR register. TA0.2 was configured similarly to the timer channels for the left and right motors except that interrupts were also enabled for the channel, triggering the ISR whenever TA0R reached TA0CCR2 and again when it rolled over back to 0 after 20ms. As shown in Figure 3.2, during the ISR P2.2 was toggled to emulate reset/set operation based on the interrupt source. 5

6 Firing Mechanics: A foam disk launcher was used as the weapon of the MSP430 Tank. This electronic device repeatedly fires small foam disks when the trigger is toggled. This device was powered internally by two AA batteries and was mounted to the chassis using vex components and tie wraps. The trigger of the launcher was toggled by a push/pull solenoid. To provide sufficient force to actuate the trigger the solenoid required a power source of 18V, which was provided by the two 9V batteries connected in series. The solenoid was fastened on to the launcher using duct tape in such a configuration that would cause the solenoid to push the trigger when activated, firing a foam disk. The solenoid could then be deactivated allowing for another disk to be readied for launch and fired again. In order to actually fire a disk (i.e. trigger the solenoid to push) a simple high/low signal was sent from the MSP pin 13, P2.5 when a button on the RF controller was pressed. Status Lights: In order to provide some feedback to the user two LEDs were included in the design. The red LED indicated that the weapon was armed which served as a safety for the trigger mechanism. This meant that it required two buttons on the remote to fire the weapon: one button was held to arm the system and the second was pressed to activate the trigger. If the arm button was not held, the trigger button would have no effect (even though the MSP430 received a button press). The green LED indicated when the user had control of the turret. This was helpful since it was not always practical for the user to be actively controlling the turret position. By requiring that the user hold a button on the remote while they rotated the turret allowed them to release the button and lock the servo into that position. Updates received from the remote while the button was not pressed would be ignored. The green LED indicated when the turret control button was being pressed so the user would be able to know when they could release the control stick. Both LEDs were connected directly to the MSP430 via current limiting resistors of 220Ω. The red LED was connected to pin 11 P2.3 and the green LED was connected to pin 14, P1.6. Watchdog: It was discovered that the VEX receiver would stop producing the PPM signal if the transmitter was turned off or went out of range. Due to the structure of the interrupt based command processing, an absent PPM signal would prevent any further command updates. This resulted in a runaway tank. For example, if the tank were to drive out of range of the transmitter, the motors would remain on since they never received the off command from the remote. This problem was solved by enabling the watchdog timer. Each time a command set was received by the main loop, the watch dog was reset. If a command was not received within one second, the watchdog would reset all the motors to the off/neutral state, return the turret to the center position and disable the firing mechanism. These settings were considered the safe defaults. IV. Results and Conclusions As we had hoped, we acquired the skills required to utilize the MSP430 microprocessor in all aspects, both in hardware and software. Working on the project provided an opportunity to experience the capabilities of the MSP430 launchpad in a very hands on manner and also helped us in understanding concepts such as I/O interfacing, port multiplexing, interrupt handling, and efficient coding techniques. The MSP430 timer modules were an important part of the project and allowed us to efficiently integrate motors, servos and the RF decoder. We had the opportunity to work with a variety of peripherals including an RF decoder, a logic level converter, voltage regulators, and a solenoid. While working on the circuit we revisited basic electrical concepts such as use of pull down resistors, voltage divider theorem, and current limitations of various peripherals. Working on the project also gave us a profound understanding of all the features an IDE such as Code Composer offers to a programmer and how to use it to get the best results. The schematic was designed using the student version of Eagle CAD through which we learnt how to design a schematic and even a PCB. 6

7 As a team we accomplished all the goals we had set for the project. The initial blueprint of the project was not altered and we did not need to shift to a Plan B. There were a few challenges we faced, however. The trigger mechanism for the disk launcher was a challenge we faced since the initial solenoid we hoped to use was not powerful enough and did not have the required amount of travel to trigger the gun. We then used a larger solenoid which required 18V power supply in the project. The introduction of the 18V power supply further complicated the existing challenge of power distribution. Through the use of electrical components as stated above we were able to overcome this challenge. 7

8 Appendix 1. List of Team Members and Tasks Andrew Blanford: RF Receiver/Decoder, Software Integration Matt Drummond: Software integration, Assembly Krishnaveni Das: Motors and circuits Dheeraj Reddy: Firing Mechanism and circuits 2. Parts List Quantity Part Notes 1 VEX Chassis 1 VEX Tank Tread Kit 1 VEX 75MHz Transmitter 1 VEX Receiver 2 VEX Motor Module 1 VEX Servo Module 1 VEX 7.2V Battery 2 9V Battery 1 RJ 10 Cable (with breadboard adapter) Phone handset cord 1 Logic Level Converter (with male headers) SparkFun 1 MSP430G2553 Removed from Launchpad 1 L7805CV 5V Voltage Regulator 1 LM317Y Adjustable Voltage Regulator 1.1uF Capacitor 1 1uF Capacitor 1 1nF Capacitor 1 47KΩ 1/4W Resistor 3 220Ω 1/4W Resistor 1 400Ω 1/4W Resistor 2 10KΩ 1/4W Resistor 1 Green LED (3mm) 1 Red LED (3mm) 1 Foam Disk Launcher Includes ammo, battery 1 N Channel MOSFET 60V 30A 1 Diode Rectifier 1A 50V 1 Large Push Pull Solenoid 1 7.2V Connector Kit Connect VEX battery to breadboard 2 9V Battery Snap Connector Connect 9V batteries to breadboard 1 2 Pin 5mm Screw Terminal Block 1 Breadboard Jumper Wire Kit Table A2.1 Parts List 8

9 3. Full Schematic Figure A3.1 MSP430 Tank Schematic 9

10 4. PCB Design Figure A4.1 MSP430 Tank Board Layout Left: Top of board Right: Bottom of board 10

11 5. Source Code 11

12 12

13 13

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