Pirates Team

1. PIRATES REPORT
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PIRATES REPORT
2018
A report to describe the main contents that we make it in our robot.
pirates Team, a Team in TEXIGHT competition at HELWAN Engineering,
wrote this report.

2. PIRATES REPORT
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INTRODUCTION......................................................................................................................................................................................................... 3
SOLAR SYSTEM ........................................................................................................................................................................................................ 4
PUMP .....................................................................................................................................................................................................................................................4
Pump selection ............................................................................................................................................................................................................................4
DC-DC CONVERTER............................................................................................................................................................................................................................5
SOLAR PANEL........................................................................................................................................................................................................................................6
Solar Radiation Calculation...................................................................................................................................................................................................6
MECHANICAL PART INITIAL DESIGN........................................... 8
On our table there are:.............................................................................................................................................................................................................8
Work shop Tools (Mechanical work)..................................................................................................................................................................................8
ROBOT CAR FRAME..............................................................................................................................................................................................................................9
The Frame dimensions .............................................................................................................................................................................................................9
The frame sections.....................................................................................................................................................................................................................9
The frame calculations.............................................................................................................................................................................................................9
Compression failure...................................................................................................................................................................................................................9
TANK..................................................................................................................................................................................................................................................10
PIPE.....................................................................................................................................................................................................................................................10
CAR WHEELS ......................................................................................................................................................................................................................................11
PUMP MECHANISM............................................................................................................................................................................................................................11
SOLAR PANEL MECHANISM..............................................................................................................................................................................................................12
CONTROL PART........................................................................................................................................................................................................13
CAR CONTROL....................................................................................................................................................................................................................................13
MOVEMENT CONTROL......................................................................................................................................................................................................................14
a. Circuit................................................................................................................................................................................................................................. 14
b. Code:................................................................................................................................................................................................................................... 14
I. Declaring the variables of the code and setup Function......................................................................................................................................................14
II. Loop Function...........................................................................................................................................................................................................................................15
III. Move motor function:......................................................................................................................................................................................................................16
IV. Speed control of the motors.........................................................................................................................................................................................................17
1- LIFTING MOTOR CONTROL:.................................................................................................................................................................................................18
PUMP CONTROL.................................................................................................................................................................................................................................19
WIRELESS COMMUNICATION CODE................................................................................................................................................................................................20
RC .......................................................................................................................................................................................................................................................21
POWER DISTRIBUTION ........................................................................................................................................................................................22
BATTERY ............................................................................................................................................................................................................................................22
WIRING CIRCUIT ...............................................................................................................................................................................................................................22

3. PIRATES REPORT
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Introduction
It’s time for us to show our abilities in solving the society problems.
the most important advantage of our car robot is the simplicity in
design, the strong structure and the accuracy control. In addition to
that, this robot can benefit from solar array to turn on the pump which
lift the water from the Tank in high quality.
solar array installations will supply around 45% of energy demand in
the world. It was found that solar thermal is getting remarkable
popularity in industrial applications.
It is very important to apply solar energy for this application and
provide energy solutions by modifying the energy proportion,
improving energy stability, increasing energy sustainability,
conversion reduction and hence enhance the system efficiency. The
present work aimed to study the solar energy systems utilization in
industrial applications and looked into the industrial applications
which are more compatible to be integrated with solar energy
systems.
About 3 weeks, we needed it to build our robot .in this weeks. Many of
problem occur in design and control but it’s solved.

4. PIRATES REPORT
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Solar system
The first thing for building a solar system we have to determine our load (pump)
specifications to select the other elements of the system correctly.
PUMP
Pump selection
After a long searching, we found that submersible bilge pump (360
GPH, 12 Volt) is the suitable one for the competition task and it is
economic for us. The Quantity of water which is lifted by pump about
at maximum = 22 liter in minute

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DC-DC CONVERTER
The DC-DC Converter is used to convert unregulated dc input volt coming from the panel
to a regulated and controlled voltage. We selected this type as it’s range of current and
voltage is perfect for our load, it has an adjustable range of voltage and current but the
output was set to get 12v constant, which the pump need and the current at the maximum
value to make sure that the pump works as efficiently as possible.

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SOLAR PANEL
It is dimension 66*52 cm. With current 2 Ampere and 18volt.it’s the suitable one for
our pump
Solar Radiation Calculation.
 Horizontal Surface
By equations we can calculate the quantity of
solar array (Ht) :
Hon= extraterrestrial solar
radiation
tb=atmospheric transmittance
td= emissivity
Gsc = solar constant ( 1353)
n = day number in year. M= month number.
N=no. day in month

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From this equation. and we know that the competition will be 1/5 /2018. We can say: The
Total quantity of solar arrays in horizontal surface= 143kw/m2.This quantity is suitable to
supply the pump with enough power to work with high efficiency.
.ao,
clim
cor

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MECHANICAL PART
INITIAL DESIGN
On our table there are:
A-Primary model B- Base ALUMINUM
Work shop Tools (Mechanical work)
3- Hummer 4- gloves
5- Riveted bolts

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ROBOT CAR FRAME
The Frame dimensions
Width = 45 ±5 cm Length = 65±5cm
Max Height = 45±5 cm
The frame sections
The Three section is make:
1- control box section (in the back) (15*45) cm
2- pump mechanism section (in the front) (15*45) cm
3- Car Tank section (in the middle) (35*45) cm
The frame calculations
1- Modes of failure
In (AISI Standard material) Nonferrous metal Aluminum alloy 1100 Annealed
u = 90Mpa f.S = 3 *.6= 1.8
y = 35Mpa E= 69MPa
Compression failure
c =
𝑤
𝐴𝑐
≤ σy
𝑓. 𝑠
W= Tank with water weight + mechanism with pump weight + control box with battery weight
W= 20 + 5 + 5 = 30 Kg
Ac (cross section of aluminum rod) = 40*20 – 39*19 = 59 mm2
The front
The middle
The back

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
𝑤
𝐴𝑐
=
30∗9.8
59
= 5Mpa ≤ 35
1.8
=19.4Mpa ( The Frame is safety. can to carry until 100 kg)
TANK
 Cylindrical Tank with diameter 32cm and height 48 cm.
 Put in the middle section of the car.
 The surface tension will be less.
 The pipe will have interred in the tank from above in the second task
PIPE
 We used a pipe with length of 1.2 meter and diameter ½ inch
 Connected directly to the pump
 It used to transmit water across the width of the car to the empty tank
 It is fixed in the bottom of the holder of the solar panel
 The photo of the pump mechanism

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CAR WHEELS
 The wheel diameter is 20cm.
 Making flanges by the lathe machine.
 Assembly The wheel and motors in the bottom of car.
 Put fiber under the motors works as absorber to prevent the vibration which
occur during motion
 The motor torque is 35kg-cm.
PUMP MECHANISM
 width between the two tanks in first task is 60 cm.
 we need 5±3cm from two sides to inside pump in the Input tank and pipe in the
output tank.
 We need mechanism with angle from the car plate Equal (Tan-1 40/15) = 70±6
degree.
 The component is pump which connect with the end of wire, pulley, pipe with length
150±.50 cm and motor with torque 20 kg-cm.

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SOLAR PANEL MECHANISM
At the first. our plan to achieve the solar mechanism is to
make a solar tracker. But lately after researches and talks,
we found that fixed system is more efficient and
economical for us. as the tracker system will need servo
motors, Ldr sensors and a special requirement for the
solar panel. while fixed system doesn’t have the same
problems. So, the solar panel is just framed and placed on a fiber material (as a vibration
absorber), then fixed it at the top of the car.

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control part
CAR CONTROL
We controlled this car with the aid of:
1. Arduino uno
 c programming used in programming this Arduino kit
 Arduino IDE is used in the programming
2. 2 crython drive (10 A) one channel
3. Three relays
4. Rc controller
We can divide the control into three sections
1. Movement control of the car
2. Pump control

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3. The lifting Motor of the pump control
4. Wireless communication using Rc communication
MOVEMENT CONTROL
The objective of this circuit is controlling the directions of the car (forward – reverse-
left – right)
a. Circuit
b. Code:
I. Declaring the variables of the code and setup Function

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II. Loop Function
This section of the code which has the main algorithm controlling the movement of the
car and this code which repeated while the system is on, and calling of the other
functions in this code

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III. Move motor function:
This function is responsible for moving the left motors and the left motors

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IV.Speed control of the motors
This code is responsible for controlling the speed of the motors and controlling the direction
of the motors.

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LIFTING MOTOR CONTROL:
This control circuit is responsible for controlling the motor responsible for lifting the pump (forward - reverse) using
two relays
 Circuit:
 Code:

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PUMP CONTROL
This control is responsible for operating the pump (on and off ) control using relay module
 Circuit:

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 Code:
WIRELESS COMMUNICATION CODE
 The Rc receiver take a signal from the Rc transmitter each 25 msec and assign it in variables to be used
in the code

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RC
a.receiver
b. Radio-control transmitters
1.
2. /*
3. RC Pulse In Serial Read out
4. By: Nick Poole
5. Spark Fun Electronics
6. Date: 5
7. License: CC-BY SA 3.0 - Creative commons share-
alike 3.0
8. use this code however you'd like, just keep this
license and
9. attribute. Let me know if you make hugely,
awesome, great changes.
10. */
11.
12. int ch1; // Here's where we'll keep our channel
values
13. int ch2;
14. int ch3;
15.
16. void setup() {
17.
18. pinMode(5, INPUT); // Set our input pins as such
19. pinMode(6, INPUT);
20. pinMode(7, INPUT);
21.
22. Serial.begin(9600); // Pour a bowl of Serial
23.
24. }
25.
26. void loop() {
27.
28. ch1 = pulseIn(5, HIGH, 25000); // Read the pulse
width of
29. ch2 = pulseIn(6, HIGH, 25000); // each channel
30. ch3 = pulseIn(7, HIGH, 25000);
31.
32. Serial.print("Channel 1:"); // Print the value
of
33. Serial.println(ch1); // each channel
34.
35. Serial.print("Channel 2:");
36. Serial.println(ch2);
37.
38. Serial.print("Channel 3:");
39. Serial.println(ch3);
40.
41. delay(100); // I put this here just to make the
terminal
42. // window happier
43. }
We'll hook up a few channels from the RC
receiver to get a feel for what the input from the
transmitter looks
like. The RC transmitter/receiver pair that I have
is six channels.
1- The right joystick for motion of car:
- Go front
- Go back
- Return clockwise
- Return counter clockwise
2-The left joystick for mechanism and pump

22. PIRATES REPORT
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POWER DISTRIBUTION
BATTERY
we used battery with 12 V. the two batteries are used to supply 24V for the circuit.so we
connected to batteries in series
WIRING CIRCUIT
Emergency
buttonSupply 24V Drive DC Motors
Regulator 5V
Control 5V
RC
controller
Solar panel 12V Relay
Converter
DC to DC
Pump

23. PIRATES REPORT
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The names of pirates
- Ahmed Hany
- Amr kamel
- Ezzat Ali
- Riyad Abdellatef
- Sayyed Khairy
- Assayyid Fathy
- Reem Ezzat
- Mayar Nasser