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Bruce’s Status Report for 11.30

This week I worked closely with my teammates to ensure that the gantry system, a critical component of our design, became fully operational. Together, we collaborated to identify and address mechanical and software-related issues that were hindering its performance. By developing and fine-tuning the gantry control code, we achieved smooth and precise movement, ensuring the charging pad can accurately align with the detected device’s position.

(The problem is the deformation of this 3d part, which makes the belt hard to rotate smoothly)

On the vision system front, I successfully deployed our object detection software onto the Raspberry Pi. During the deployment process, I noticed that the original code caused high latency when running on the Pi’s constrained hardware resources. To address this, I reviewed and optimized the code, making key modifications that significantly improved its efficiency and performance. These changes have resulted in faster detection and response times, which are critical for seamless interaction with the gantry system.

The final step this week involved integrating the software and hardware subsystems to evaluate the entire system’s functionality. I conducted extensive testing, including a comprehensive suite of unit tests to ensure the individual components were functioning correctly and integration tests to validate the interaction between subsystems. These tests demonstrated promising results, with the system operating effectively and meeting our performance expectations.

I am currently on schedule. there isn’t many specific tasks left for next week, since we have done most of them. Therefore, for next week, I am going to focus on testing, and resolve some minor issues for system integration.

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Steven’s Status Report 11.16

Weekly Progress and Testing Plans

Harry and I spent about 30 hours this week building and testing the gantry system. We completed the hardware construction and testing of two sets of motor drives and belt drive systems. Currently, our motors can drive the manipulator to move smoothly. We encountered very many technical problems during the building process. First of all, our motor drive had the problem of insufficient torque at the beginning and could not drive the belt system during the actual system verification. I reduced the number of microsteps in the stepper motor drive from 6400 to 3200 and increased the drive voltage from 9V to 12V. We verified that this configuration could successfully drive the system by linking the motor to the belt and testing it with the whole gantry system.

We are still trying to test if we can control the end effector using the difference in speed and direction of rotation of the two motors because of a delay in the end effector part we 3D printed at Techspark.In the meantime, we have been verifying the charging of our wireless charging pads this week. We tested our 5W and 12W wireless charging modules as well as Apple’s original wireless charging module. The 12W charging module had the best results. We tested it on 3mm and 5mm acrylic boards, and with the 12W charging pad, we were able to charge a phone without a case on both thicknesses of acrylic boards very smoothly. For phones with cases, charging on 5mm acrylic requires a very tight fit between the phone and the charging pad. We will be printing out the charging plate pallets next week for the 5mm charging experiment to see if the 12W module can fully meet our needs. We plan to complete the gantry system to grab and release the charging pad next week and provide an API for the computer vision system to move the pad.

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Bruce’s Status Report for 11.16

This week I focus on charging app development and CV development, and did some testing related to the subsystem.

Charging App Development

  • Completed the development of the iOS and macOS apps, enabling users to monitor their phone’s charging status in real-time.
  • Successfully integrated Google Cloud Firebase storage, providing a centralized system where users can view and manage the charging statuses of all their devices from the macOS app.
  • Added features to enhance the user experience, such as real-time updates and seamless synchronization across devices.

    Computer Vision System
  • Finalized the object detection module, achieving approximately 90% accuracy in detecting phones on the table.
  • Implemented a two-frame difference technique to identify significant changes between video frames, signaling the potential placement of a phone, and also avoid using yolo model at all frame to save performance.
  • Incorporated a YOLO model to confirm the detection, identify the phone, and calculate its center coordinates for precise localization.
  • Enhanced the detection pipeline to minimize processing time while maintaining high accuracy.

The project is on track, with key software systems functional and aligned with the project timeline. Significant progress has been made on both the app and vision subsystems, ensuring they are ready for integration.

Next Week’s Plan:

  1. Enhance Charging Pad Stability:
    • Focus on improving the stability and reliability of the charging pad system to ensure consistent wireless charging performance.
  2. Optimize Phone Detection:
    • Fine-tune the YOLO model to reduce false positives and further improve accuracy.
    • Test the system with various phone models and orientations to enhance robustness.
  3. Integrate Vision and Gantry Systems:
    • Begin integrating the computer vision system with the gantry system, enabling the seamless transfer of phone location data to control the movement of the charging pad.

Test the communication between the vision system and Raspberry Pi to ensure smooth coordination.

Testing
Software Testing (iOS and macOS Apps) (Already did):
Ensure real-time updates of charging status for multiple phones through Firebase. Therefore, for this test, we need to test multiple different devices (iPhone 12 Pro, iPhone 13 Pro, iPhone 14) charging simultaneously, and we need to measure the time taken for status changes to reflect on the apps and repeat for 10 times. The test result shows an average update delay <500 million seconds, meeting real-time requirements, and it verified seamless synchronization across iOS and macOS platforms.

Data Consistency Testing (Already did)
Verified data consistency between Firebase and app interfaces by making real-time changes to device charging status and observing updates on both IOS and MacOS platform. The test was conducted 15 times, and the data are all consistent and updated in a very short time period. (< 500 milliseconds)

Object Detection Accuracy Testing (Already did)
Evaluated the accuracy of the YOLO model with a dataset of 3 phone placements in various conditions such as different lighting, orientations, and phone models. The test was conducted 20 times, and in 18 of the times all phone locations are correctly identified, achieving an overall detection accuracy of 90 percent with occasional false positives for phone-like objects.

 

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Team Status Report for 11.16

This week, our team made significant advancements in hardware construction, software development, and system testing. Below are our progress:

Hardware Progress

  1. Gantry System Development and Testing
    • Completed the hardware assembly and testing of the gantry system, focusing on the X and Y axes.
    • Addressed initial issues with belt vibrations caused by loose components. Adjustments, including tightening belts and securing nails, resulted in smooth and quiet movement.
    • Adjusted the motor configuration by reducing microsteps from 6400 to 3200 and increasing the voltage from 9V to 12V to overcome torque limitations. This configuration successfully drives the belt system.
  2. Manipulator and Z-Axis Preparation
    • 3D printed and assembled parts for the central manipulator to enable Z-axis movement. The manipulator will allow the charging pad to move up and down.
    • Testing of the Z-axis is planned for next week upon obtaining the remaining components.
  3. Charging Coil Verification
    • Tested 5W, 12W, and Apple’s original charging coils under 3mm and 5mm acrylic boards.
    • Verified successful charging with the 12W coil for phones without cases on both thicknesses and with cases on 3mm acrylic. For 5mm acrylic, precise alignment is needed to charge phones with cases.
    • Ensured charging safety by monitoring phone temperatures and confirming no overheating during operation.

Software System Progress

  1. Charging App Development
    • Completed the development of iOS and macOS apps for real-time monitoring of charging status.
    • Integrated Google Cloud Firebase for centralized data storage, enabling users to view and manage charging statuses across multiple devices.
    • Conducted software testing to ensure real-time updates with an average delay of less than 500 milliseconds and consistent synchronization across platforms.
  2. Computer Vision System Development
    • Finalized the object detection module, achieving 90% accuracy in phone detection.
    • Implemented a two-frame difference technique to identify significant changes and avoid unnecessary YOLO model usage, improving performance.
    • Enhanced the YOLO pipeline to detect phone locations and return their center coordinates with high precision.

System Validation

  1. Gantry System Testing
    • Conducted repeated forward and backward movements to ensure smooth, consistent motion on the X and Y axes without pauses or obstructions.
    • Confirmed that the gantry aligns with the intended design goals for X-Y movement, with full system requirements to be met after Z-axis integration.
  2. Charging Coil Testing
    • Verified that the charging coils meet design requirements for charging through acrylic boards without overheating.
    • Confirmed compatibility with different phone cases and thicknesses of acrylic, with further testing planned to gather time-to-charge data.
  3. Software Testing
    • Verified real-time status updates for multiple devices and confirmed data consistency between Firebase and app interfaces.
    • Tested object detection under various lighting conditions and orientations, achieving high accuracy and minimal false positives.

Since we have not complete our project yet, it is hard for our current implementation to validate all the user requirements and the design requirements specified in our documents. Currently, we only validate that our system can detect phone < 1 seconds, software app information update < 500 milliseconds, and vision detection system has accuracy > 90%.

We believe we are currently on track.

Next week’s plan:

  1. Gantry System
    • Assemble and test the Z-axis manipulator to enable full 3-DOF movement.
    • Combine the central manipulator with the existing gantry system for complete testing.
  2. Charging Coil and Pad
    • Redesign and 3D print the charging pad holder for the 5mm acrylic setup.
    • Conduct experiments to determine the time required to fully charge phones with the 12W charging module.
  3. System Integration
    • Begin integration of the computer vision system with the gantry system.
    • Test communication between the vision system and the gantry for seamless control of charging pad movement.
  4. Further Testing
    • Perform end-to-end testing to validate the entire workflow, including phone detection, pad movement, and real-time status updates on the apps.


Here are some pictures of our system:

Corners:

Software:

Charging:

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Harry’s Status Report for 11.16

First, the manipulator for the center part (moves up and down) is drawn and printed. Shown as below:

The third motor will allow the center part to move up and down. The motor will be connected to a shaft. We will obtain the shaft when the central manipulator is printed out.

This week we focus on the gantry system by combining all the printed parts. We went to the machine shop to cut the aluminum extrusion, the rail. We use zip ties to tighten the belt. we test x-axis and y-axis and the gantry can move very smoothly on both axis.

Large amount of time was put into gantry testing. The belt vibrated a lot at the beginning but we found out the problem was caused by nails and belts that are not tight enough. Many trails were implemented and now the gantry can move without restriction quietly.

Steven and I worked on the gantry system together this week and more details will be included in his report. Notice we made the whole gantry system together so there isn’t clear work division between us. Since the gantry system is quite complicated, two people are needed to complete it.

Next week, we will begin assemble the center part for z-axis movement testing. Charging pad holder will be redesigned ant printed. Camera will be introduced to combine with the existing gantry part.

Verification

  1. Gantry System: gantry system can move freely and smoothly on x and y axis. This situation is desired. We let the gantry move forward and backward a lot of times to view the movement. We intend to ensure the gantry is move straight back and forth without pause and stuck. The part we did aligns with our goal for gantry system design. However, because our gantry system can only operate on x and y axis, the system requirements is not fully met until the central manipulator is built and tested.
  2. Charging coil: We bought two types of charging coil and verified them  1) they can charge the phone when placed beneath the acrylic board. 2）The phone does not heat up to a very high temperature. As shown below when the blue light turns on, the phone is being charged. When the red light is on, the phone is not charged. For the 3mm acrylic board, phone can be charged with back cover or non precise alignment. For the 5,, acrylic board, phone can be charged without back cover. Relative precise alignment is needed.      5mm board:   3mm board:   This meets the design requirement of successful charging. Further data will be obtained regarding the time to fully charge the phone.
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Team Weekly Status Report 11.09

One of the highlights for our group this week was the development and completion of the mechanical hardware for the automated charging table. Utilizing aluminum extrusions, we built a robust and reliable platform that supports data acquisition and machine vision training while ensuring the necessary strength and durability.

Along with hardware advances, substantial progress has been made in the gantry system, particularly in the integration and control of stepper motors. By integrating the motor drivers with the Jetson Orin Nano, the motor control code has been enhanced to greatly increase the functionality of the system. A prototype of the gantry system has been produced and the conversion between the step length of the stepper motor and the corresponding conveyor travel distance was successfully realized. In addition, the PID control algorithm was fine-tuned to improve the motor accuracy, reducing the margin of error to within 5 millimeters over a distance of 30 centimeters. While this level of accuracy meets our basic control requirements, we plan to make further adjustments to achieve even higher accuracy for more demanding tasks.

On the software side, we completed the design of the iPhone app, which now allows users to monitor the current state of charge, the estimated time to full charge, and the thermal state of the device. Future work will focus on integrating the app with web browsers and the macOS platform, allowing users to access device information while charging on their computers.

Looking ahead to next week, the plan is to mount the prototype gantry system to the main frame, using 3D printed parts to securely fasten components such as motors and belt gears. This step is critical to minimize vibration and ensure proper alignment during operation. Comprehensive performance tests will be performed on the assembled frame to assess the stability, accuracy and reliability of the system under real-world conditions. These tests will provide valuable insight into identifying sources of error and areas for improvement in the motor control algorithms and mechanics.

All in all, progress was made this week on both the mechanical and software portions of our project. The completion of the mechanical construction and enhancements to the gantry system’s motor controls have prepared us for the upcoming integration and testing phases. In the coming week, we plan to complete the overall construction of the system to ensure that the subsystems we designed in the mid-term demo are ready for basic functionality.

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Steven’s Weekly Status Report 11.09

This week, my primary focus was assisting Harry in developing the overall framework of our project. Together, we dedicated a substantial amount of time to completing the mechanical hardware build for our automatic charging table. By utilizing aluminum extrusions, we were able to construct a sturdy and reliable platform that not only supports data acquisition an

 

d machine vision training but also maintains the necessary strength and durability required for our operations. The modular design facilitated by the aluminum extrusions allows for easy adjustments and future scalability, ensuring that our framework can adapt to evolving project needs.

In addition to the mechanical advancements, I made significant progress on the gantry system, particularly concerning the stepper motors. I enhanced the motor control code by integrating motor drivers with a Jetson Orin Nano, which improved the overall functionality of the system. A key achievement this week was the successful conversion between the step size of the stepper motors and the corresponding belt travel distanc

 

e. This was accomplished by constructing a simple prototype of the gantry system, which served as a proof of concept for our control mechanisms. Furthermore, I tuned a set of Proportional-Integral-Derivative (PID) controllers to achieve more precise motor control. As a result, the motors now operate with increased accuracy, maintaining an error

margin within 5 millimeters over a 30-centimeter distance. While this level of precision meets our basic control requirements, it highlights the need for further adjustments to the control program to achieve higher precision for more demanding tasks.

Looking ahead to next week, our plan involves mounting the gantry system prototype onto the main frame. This will require the use of 3D-printed parts to securely fix components such as the motors and belt gears. Ensuring that these components are firmly attached and properly aligned is crucial for minimizing vibrations and misalignments during operation. Once the prototype is mounted, we will conduct comprehensive performance tests on the actual frame to assess the system’s stability, accuracy, and reliability under real-world conditions. These tests will provide valuable data for identifying any sources of error and areas that need improvement in both the motor control algorithms and the mechanical setup.

Simultaneously, I will continue refining the motor control program to enhance precision further. This includes fine-tuning the PID parameters and exploring advanced control algorithms that can reduce the existing error margin. Additionally, integrating more sensors or feedback mechanisms may offer real-time data, allowing for more accurate adjustments and control. Maintaining effective communication with team members remains a priority to ensure cohesive progress across all project aspects. Efficient resource management, including the allocation of materials for the mechanical build and computational resources for code development, has been instrumental in our advancements this week.

In summary, this week has seen substantial progress in both the mechanical and software components of our project. The completion of the automatic charging table’s mechanical build and the advancements in the gantry system’s motor control have established a solid foundation for the upcoming integration and testing phases. Addressing the current precision challenges and continuing to refine the control algorithms will be essential in enhancing the overall performance and reliability of our system in the weeks to come.

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Bruce’s Status Report for 11.09

This week, my main focus was on finalizing the phone app. So currently, I have finalized our design of the app on iPhone, and right now it allows users to see the current changing status, the estimate time to full, and the thermal state of the phone.

App UI when it is charging

App UI when it is not charging

App Icon in phone

So right now the app looks better and contains animation, it also contains an app icon. However, One problem is that for IOS system, in order to provide the privacy, their public API to get the battery percentage only have accuracy of 5%. I also checked the existing app in App Store, and the existing app that can show battery percentage also have this problem.

I am currently on track.

Next week I would mainly focus on integrating this with the web browser and the macOS app, so that user can see their device info when they are charging on their computer. I would also help building the gantry system to make it mostly finished next week.

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Harry’s Status Report for 11.9

This week I primarily work on the gantry system of the charging table, details are demonstrated as below.

Gantry Overview:

Front Corners (they are the same) are compose of 3 pieces:

Bottom:

Top:

Corner Tensioner:

These three pieces already submitted for 3D printing.

Rail Slider – Magnetic system Connector:

Block that fix the left and right end of the magnetic system rail:

Motor Side Corner:  (bottom layout, cap, and tensioner) the other side is symmetric to the side displayed as below:

Magnetic System will be further developed next week.

Overall progress on track.

Plan to finish most parts of the gantry system before next demo.

 

 

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Team Status Report for 11.02

This past week, our team focused on advancing the structural, motor, and charging systems of the table. With the final structural components arriving early in the week, we examined the aluminum extrusions and connectors for the table frame, ensuring they fit within our design specifications. We created detailed 3D models using Fusion 360 and submitted critical parts, like the table corners and charging pad holders, for 3D printing. These components will provide support for the transparent layers and integrate with the gantry system, allowing precise positioning of the charging pad.

For the motor system, we configured the motors on the Raspberry Pi, establishing essential commands like turning and stopping. Leveraging compatibility with the Nvidia Jetson Orin Nano, we extended this motor functionality to the Jetson platform, which will allow us to translate coordinate data from the vision system into precise motor commands.

On the charging module side, we successfully integrated the charging pad with the Jetson Nano, establishing reliable communication between the two. Initial tests show that our setup can charge an iPhone 13 Pro in approximately 45 minutes. However, we identified stability issues with the charging pad, where it occasionally stops charging unexpectedly. We also experimented with materials and configurations to minimize interference from the gantry’s magnetic components, adjusting the design to ensure reliable charging without compromising the table’s layout.

We are currently on schedule.

Our primary objectives for the upcoming week are as follows:

  1. We will continue assembling and testing the structural and mechanical components, including verifying the 3D-printed parts for stability and functionality.
  2. We aim to complete the gantry system’s mechanical assembly and begin functional testing, focusing on motor control and precise movement based on coordinate inputs from the vision system.
  3. Enhancing the charging module’s stability will be a top priority to prevent disruptions in charging. We will conduct further tests to identify the root cause of the charging interruptions and make the necessary adjustments to achieve consistent charging performance.