Presentation delivered during the Karel Robotics Symposium, Katerini, 14.10.2014

1. KAREL
First implementation year
Mihai Agape, Project Coordinator
Palatul Copiilor Drobeta Turnu Severin
KAREL Symposium
Katerini, 14.10.2014

2.  This project has been funded with support from the
European Commission.
 This communication reflects the views only of the
authors, and the Commission cannot be held
responsible for any use which may be made of the
information contained therein.

3. The Purpose of the
Presentation
Overview the KAREL project
Show some of the work done
Specifications
Karelino - first controller
prototype of Karel robot
Solving math problems
The second design of Karel
platform

4. KAREL PROJECT OVERVIEW
General Information
Karel Project in Numbers
Partners
Objectives
Results & Outcomes
Robot Requirements
Tasts Distribution
Work Breakdown Structure

5. General Information
 Programme: LIFELONG LEARNING
PROGRAMME
 Sub-programme: COMENIUS
 Action type: PARTNERSHIPS
 Action: COMENIUS Multilateral school
partnerships
 LLP Link No: 2013-1-RO1-COM06-29664 1
 Project title: Karel - Autonomous Robot for
Enhancing Learning
 Project acronym: KAREL
 Implementation: 01.08.2013 – 31.07.2015

6. Karel project in numbers
Countries: 4
Partners: 4
Teachers: 21
Students: 50
Mobilities: 96
Robots: 20
Lessons: 21

7. WHO?
Partners, pupils, teachers
1. Palatul Copiilor
(Drobeta Turnu Severin, România)
2. Platon Schools (Εκπαιδευτηρια Πλατων)
(Katerini, Grecia)
3. Beypazari Teknik Ve Endüstri Meslek Lisesi
(Beypazari, Turcia)
4. Technikum nr 1 im. Stanisława Staszica w
Zespole Szkoł Technicznych w Rybniku
(Rybnik, Polonia)
Pupils (aged from 14 to 19 years old) & Teachers

8. WHY?
Objectives
 Improve teaching and learning of science and
technology using robotics as integrator
 O1. Apply practical math and scientific
concepts while learning to design, build, test
and document KAREL.
 O2. Create an interdisciplinary curriculum to
use with KAREL robotic platform.
 O3. Improve confidence and fluency in English
and learn scientific and technical vocabulary in
partners’ languages.

9. WHAT?
Results & Outcomes
 Robotics Dictionary in English and each
partner’s language.
 Robotics Platforms designed and
manufactured (20).
 Robotics Platform User Manual.
 Curriculum with at least 21 lesson plans, in
English and each partner’s language . At
least 2 lesson plans for each of following
fields: physics, biology, programming,
mechanics, electronics, and robotics.
 Website.

10. WHAT?
Robot Requirements
 Climb a surface with a 30 % slope.
 Maximum speed more than 0.5 m/s.
 Battery autonomy at least 2 hours.
 Open source programming software.
 Cost of raw materials less than 99 EUR.
 Performances better than of similar priced
robots.

11. HOW?
Tasks Distribution
 Robotic platform design, manufacture, test
and document:
 a) Mechanical system
 Turkey
 b) Electronic system
 Poland (input / output devices)
 Romania (controller, motor drivers, power supply,
communication)
 d) Software
 Greece (codes for lessons)
 Romania (codes for input / output devices)

12. HOW?
Tasks Distribution
 Curriculum for robotic platform design and
document:
 a) Physics: Greece, Romania
 b) Biology: Greece
 c) Mechanics: Turkey, Poland
 d) Electronics: Poland, Romania
 e) Programming: Greece, Romania
 e) Robotics: Poland, Romania

13. HOW?
Tasks Distribution
 Pupils:
 Create robotics dictionary
 Research, design, build, test, and program
robotic platform
 Test curriculum
 Teachers:
 Design curriculum
 Guide pupils

15. SOME OF THE WORK DONE
Specifications
Karelino - first controller prototype of Karel robot
Solving math problems
The second design of Karel platform

16. KAREL SPECIFICATIONS
Agreed at the first project meeting in Beypazari
Available at http://sdrv.ms/170NTak

17. Kick-off Project Meeting
Beypazari, 10-16.11.2013

18. Karel
Mechanical Specifications

19. Karel
Electrical Specifications

20. Karel
Input Devices

21. Karel
Output Devices

22. Karel Curriculum

23. Karel Challenges

24. Karel
Other Specifications

25. FIRST PROTOTYPE OF THE
ROBOTIC PLATFORM
Schematic
3D Views
PCB manufacturing
Board Testing
Mechanics, Electronics, and Software Integration (Rybnik meeting)
First Karel prototype

26. Schema electrică

27. First prototype - Karelino
3D Top View

28. First prototype - Karelino
3D Bottom View

29. PCB manufacturing
method & materials
 Method = Transfer Toner System
 Materials = Pulsar kit (PCB Fab-In-A-
Box) http://www.pcbfx.com/

30. Print the copper layer on paper
using a laser printer (600 dpi)

31. Prepare the single sided board
using a sandpaper

32. Clean the surface with a
cloth

33. Use laminator to transfer the
toner from paper to board

34. Remove the paper using water

35. The copper layer is
transferred to the board

36. Use green foil (from
Pulsar) to seal the toner

37. Easily remove the green foil

38. Toner before and after sealing

39. Etching the board using
ammonium persulfate

40. The uncovered copper
was removed (etched)

41. Remove the toner from the
board using thinner

42. Drill the holes

43. Test the traces for continuity
and short circuits

44. Use a soldering iron station to
solder the components
 Hot Air Gun
 Soldering (Hot) Iron

45. First solder the jumper
wires

46. Add the components and solder
them (SMD first & THD last)

47. Karelino (TOP)

48. Karelino (BOTTOM)

49. 3D Views vs Real Board

50. Karelino Testing

51. Second Project Meeting,
Rybnik, 06–13.04.2014

52. Integration & Testing
(Rybnik meeting)

53. First Karel Prototype
(Rybnik meeting)

54. Proposed Improvements
(Rybnik meeting)
 Integrate new blocks (e.g. Motor voltage
regulator, UART connector, Battery
management system)
 Make changes to the initial design (e.g.
replace USB micro B connector with an USB
mini B connector)
 Redesign the PCB (components places and
traces) according to the chassis shape
 Add LEDs to show the state of Bluetooth
module

55. Useful Links
 Drawings for manufacturing the Karelino
controller http://1drv.ms/1jet3ci
 Bill of materials for all designs
http://1drv.ms/1oAF8hr

56. MATH PROBLEMS
Climbing an inclined plan
Karel Base Designs
Animation created in Geogebra
Problems Solved

57. Climbing a 30 % inclined plan
 A requirement which seems to be related just
to the power of the motors.

58. Karel Base Designs

59. Karel Base

60. Animation created in
Geogebra

61. Theoretical problems related to
geometrical constraints study
 Ground clearance
 Front overhang
 Rear overhang
We will use the work for some Math lesson plan

62. Karel Base Dimensions

63. Calculus of
Rear Overhang

64. Calculus of
Rear Overhang

65. Calculus of
Departure Angle

66. Ramp Angle
Ground Clearance

67. Calculate Ground Clearance (h)
with Wolfram|Alpha knowledge
motor

68. Calculate Ground Clearance
(h) with Geogebra

69. KAREL SECOND PROTOTYPE
(WORK IN PROGRESS)
New Approach – Two Boards
Schematics
PCB’s Design
PCB’s Manufacturing

70. Karel second prototype
approach
 2 boards
 Lower board
 Battery management system
 Motors
 Upper board
 Controller
 Regulators
 I/O devices
 Motor regulators

71. Karel Battery Management System - Schematic

73. Board dimensions

74. PCB Design
 Double Side PCB laminate
 Components
 SMD
 THD
 Software
 Target3001! - version limited at 400 pins /
pads

75. Lower board
3D bottom view

76. Lower board
3D top view

77. Lower board
Design problem

78. Upper board
3D bottom view

79. Upper board
3D top view

80. Upper board
 What is missing from the upper board?
 Electronic switch
 Why?

81. Upper board
Copper Top Layer

82. Upper board
Copper Bottom Layer

83. Boards manufacturing
 Older printer (Samsung) – 600 dpi resolution
 New printer (HP) - 1200 dpi resolution
 Very good results after some tests
 Problems – printer driver for Windows 7

84. Printing problems
 MS Word (doc)
 Different results
 Picture (png)
 Scaling problems
 Good results with
pdf files

85. After we’ve learned how
to do it (printing)

86. After we’ve learned how
to do it (printing)

87. Alignment of TOP &
BOTTOM Layers

88. Toner Transfer problems

89. Toner Transfer problems

90. After we’ve learned how
to transfer the toner

91. After we’ve learned how
to transfer the toner

92. Seal the toner

93. Seal the toner

94. Quite good alignment
between top and bottom

95. Final upper board (top) with
min 0.6 mm tracks (top)

96. Final upper board (down) with
min 0.3 mm tracks (bottom)

97. Karel Second Prototype
Problems & Future Work
 Some circuits (e.g. for battery
management) not tested yet
 Some integrated circuits are not so easy
to procure (e.g. the ones made by Seiko)
 Possible new changes in design using
new integrated circuits (e.g. boost
regulator supplied from 1 Li-Po battery
with high output current capabilities)

98. Karel Project Meeting
Katerini, 12 – 19.10.2014

99. Bibliography
 Agape, Mihai. Agape, Maria-Genoveva.
“KAREL Specifications”, agreed in Karel
Project Meeting, held at Beypazari on 10–
16.11.2013. http://sdrv.ms/170NTak
 Agape, Mihai. “Karelino—One Step in Karel
Robotic Platform Developing”, presentation
given at National Symposium IPO-TECH,
Tirgu-Neamt, 29.03.2014

100. Bibliography
 Agape, Mihai. “KAREL
Controller Design”, presentation delivered
at Karel project meeting, held at Rybnik, 06-
13.04.2014
 Agape, Cristina-Maria. “KAREL Controller
Manufacturing”, presentation delivered at
Karel project meeting, held at Rybnik, 06-
13.04.2014

101. Bibliography (cont.)
 *** ATmega32U4, 7766G–AVR–02/2014. Atmel.
http://www.atmel.com/Images/Atmel-7766-8-bit-AVR-ATme
 *** DRV8833, SLVSAR1C. Texas Instruments.
http://www.ti.com/lit/gpn/drv8833.
 *** LM2940, SNVS769I. Texas Instruments.
http://www.ti.com/lit/gpn/lm2940-n.
 *** LM1117, SNOS412M. Texas Instruments.
http://www.ti.com/lit/gpn/lm1117-n
 *** Bluetooth Module BTM-112. Rayson.

102. Questions?