Underwater Remote Operating Vehicle.
UNDERWATER REMOTE OPERATING VElllCLE
MOHAMMAD AFIQ BIN HASlllM
This report is submitted in partial fulfillment of the requirements for the award of
Bachelor of Electronic Engineering (Telecommunication Electronics) with Honors
Faculty of Electronic and Computer Engineering
Universiti Teknikal Malaysia Melaka
May 2008
UNlVERSTI TEKNIKAL MALAYSIA MELAKA
FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER
BORANG PENGE AHAN STAT S LAPORAN
PROJEK SARJANA MUDA II
TajukProjek
UNDERWATER REMOTE OPERATING VEHICLE
Sesi
Pengajian
200712008
Saya MOHAMMAD AFrQ BIN HASHIM mengaku membenarkan Laporan Projek Srujana Muda ini
disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:
1.
Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.
2.
Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3.
Perpustakaan dibenarkan membuat salinan laporan iill sebagai bahan pertukaran antara institusi
pengajian tinggi.
Sila tandakan ( ..J ) :
4.
D
D
[£]
SULIT*
(Mengandungi maklumat yang berdarjah keselamatan atau
kepentingan Malaysia seperti yang termaktub di dalam AKTA
RAHSlA RASMJ 1972)
TERHAD*
(Mengandungi maklumat terhad yang telah ditentukan oleh
organisasi/badan di mana penyelidikan dijalankan)
TIDAX TERHAD
ｾ＠
Ｈｍｏｾａｦｉｲｩ｜＠
Alamat Tetap: NO. 60 TMN FORTUNA FASA I JLN
PENAMPANG. 88200 KOTA KJNABALU. SABAH.
ｔ｡ｲｩｫｨ
ＺＮ ｾＮｬ
Ｎ ｉＮｾ＠
(EN.
HASHIM)
......
RAN BIN MOHD IBRAHIM)
IMRAN BIN MOHO IaftAHIM
ｆｾ＠
Pensy.rah
dan Kej. Komputer (FKEKK),
Uruversitl TeI!.nikil ｍ｡ｬｾ＠
Melakl (UTeM).
Karung ｂ･ｾ＠
1200.
Ayer KerIh, 75450 Melaka
Kei: Ｎ ｅｾ＠
. ( b/l/Ot
Tankh: ............................ .
III
"I hereby declared this report is the result of my own work except for quotes as cited
in the references."
ｾ＠
Signature
:.................
.................•.......
Author
: MOHAMMAD AFIQ BIN HASHIM
Date
:...ＧＮ＿ｪｾｬ＠
......................................... .
IV
"I hereby declare that I have read this report and in my opinion this report is
sufficient in terms of the scope and quality for the award of Bachelor of Electronic
Engineering (felecommunication Electronics) With Honors."
Signature
Supervisor Name
Date
. IMRAN BIN MOHD IBRAHIM
:.........ｾ Ｎ ｾＨ
Ｎ ｲＡｾ
Ｎ ｾ＠
...................................
v
For my lovely family
VI
ACKNOWLEDGEMENT
Praise to God the Almighty for His mercy; I could finish my Industrial
Training Program successfully.
I would like to deliver my heartiest appreciation to Mr. Imran bin Mohd
Ibrahim, Vice Dean (R&D) of Faculty of Electronic and Computer Engineering for
accepting my request to be my supervisor, for his helpful thought and motivation
throughout completing this project.
I dedicate my deepest gratitude to Mr. T. L. Lee of Unipac Engineering
(Melaka) Sdn. Bhd. for his advices, guidance and his effort in helping me in
designing and developing parts for this project.
A countless appreciation dedicated to my beloved family and all my friends
for their endless support and for being there for me through thick and thin.
And again my appreciation to those already mentioned and to those who are
not mentioned. Thank you very much.
Thank you.
Vll
ABSTRACT
The remote operating vehicle (ROY) is designed to be used for an underwater
surveillance such as in ecological studies or environmental parameters survey. For
that reason, the ROV will be equipped with suitable tools such as a video camera and
robotic arm to accomplish its mission. Several limitations are made as a guideline in
designing and developing the ROV. Most ROV must be big enough to accommodate
adequate tools for surveillance. As their functions increase, the size will also increase.
Consequently the cost for producing such vehicle will also expand. Based on the
situations mentioned above, the goals for this project are to design and develop a
small and effective ROV and to produce it with expenses as low as possible. In order
to meet the objectives, research regarding to the design and developing the ROV is
mostly depends on internet resources. These resources are from an internet forum
which discuss mainly on homebuilt ROV, journals and research paper that are related
to the project. The secondary resources are from books available locally. The
outcome is expected to meet all objectives mentioned above and the limitation
should be obeyed. Constructed ROV should be reliable with the help of real-time
monitoring system to aid controller. It also should be safe to use and operated by
human as well as do not harm the environment at any cost.
Vlll
ABSTRAK
Remote operating vehicle (ROY) atau kenderaan kawalan jauh yang dibina
adalah bagi memenuhi keperluan dalam membuat kajian ekologi dan tinjauan ciriciri persekitaran di dalam air. Bagi mendapatkan hasil kajian yang terbaik, ROV
tersebut akan dilengkapi dengan peralatan yang sesuai seperti kamera video ataupun
lengan robotik. Beberapa had batasan telah digariskan sebagai panduan dalam proses
mereka dan membina ROV tersebut. Pertambahan bilangan peralatan yang akan
digunakan secara lazimnya akan menyebabkan saiz ROV turut bertambah dan secara
tidak langsung akan meningkatkan kos pengeluaran ROV tersebut. Oleh yang
demikian, projek ini adalah dicadangkan untuk membina ROV yang efisyen dalam
bidang tugasnya dan dihasilkan menggunakan modal serendah yang mungkin. Bagi
memenuhi objektif-objektif projek, kajian berkenaan rekabentuk dan pembikinan
ROV tersebut adalah bergantung kepada sumber daripada forum internet, jurnal dan
kertas kajian berkenaan projek ini. Surnber kedua merupakan buku-buku yang
berkaitan yang boleh diperolehi secara percuma di perpustakaan. Pada akhir semester
ke-2, adalah diharapkan supaya projek ini akan memberikan hasil yang memenuhi
objektif ini secara menyeluruh. Penggunaan ROV yang dibina diharapkan adalah
efisyen dengan bantuan sistem pengawasan secara real-time. Hasil projek ini juga
diharapkan dapat berfungsi tanpa memberikan ancaman keselarnatan kepada
pengguna dan juga kepada alam persekitarannnya.
IX
CONTENTS
CHAPTER
CONTENTS
PAGE
PROJECT TITTLE
I
DECLARA TION
ii
DEDICATION
v
ACKNOWLEDGEMENT
vi
ABSTRACT
vii
ABSTRAK
viii
CONTENTS
ix
LIST OF TABLE
xii
LIST OF FIGURE
xiii
LIST OF AB BRE VIATION
xv
LIST OF APPENDIX
xvi
INTRODUCTION
1.1 Introduction
1.1.1
Micro Class
2
1.1.2
Mini Class
2
1.1.3
General Class
2
1.1.4
Light Work Class
3
1.1.5
Heavy Work Class
3
1.1.6
Trenching Burial Class
3
1.2 Objective
4
1.3 Problem Statement
5
1.4 Scope
5
x
CHAPTER
n
CONTENTS
PAGE
1.5 Methodology
6
BACKGROUND OF STUDIES
8
2.1 Basic Components
8
2.1.1
Frame and Housing
8
2.1.2
Buoyancy
9
2.1.3
Control System
11
2.1.4
Propulsion
13
2.1.5
Tools and Equipments
16
2.2 Additional Components and Consideration
ill
17
2.2.1
Vehicle Teleoperation Interfaces
17
2.2.2
Low Drag and Mechanical Symmetry
19
METHODOLOGY
21
3.1 Data Acquisition Method
21
3.1.1
Internet Forum
21
3.1.2
Articles, Journals and Reports
22
3.1.3
Books
22
3.2 Data Processing Method
23
3.2.1
Discussion
23
3.2.2
Comparison
24
3.2.3
Design, Simulate and Construct
24
3.3 Electronic Circuit Development
26
xi
CHAYfER
IV
CONTENTS
PAGE
RESULTS AND DISCUSSION
31
4.1 Project Specification and Results
31
4.1.1
V
Frame and Watertight Housing
31
4.1.1.1 ROV Frame
32
4.1.1.2 Main Watertight Housing
35
4.1.1.3 Buoyancy and Stability
38
4.1.2
39
Main Controller and Control System
4.1.2.1 Main Processor
39
4.1.2.2 Motor Controller
41
4.1.2.3 Ground Controller
44
4.1.3
48
Propeller and Propulsion
4.1.3.1 Vertical Motion
48
4.1.3.2 Horizontal Motion
49
4.2 Discussion
51
CONCLUSION
6S
5.1 Conclusion
65
5.2 Future Works
66
REFERENCE
68
xii
LIST OF TABLES
NO
TITLE
PAGE
4.1
Comparison of frame materials
33
4.2
Proto typed frame comparison
34
4.3
Comparison of control system type
39
4.4
Submerged unit and surface unit components
52
4.5
ROV final dimension
57
Xlll
LIST OF FIGURES
NO
TITLE
PAGE
2.1
Air pressured ballast tank
11
2.2
6-channel RF transmitter
12
2.3
DC motor with Electronic Speed Controller unit
14
2.4
6-DOF
15
2.5
Thruster configuration and allocation of RRC ROV II
16
2.6
CCD camera
17
2.7
ROV REV II user interface
19
3.1
ROV development flowchart
25
3.2
Electronic circuit development flowchart
26
3.3
Printed layout on transparency paper
28
3.4
Circuit layout on the copper side
28
3.5
Circuit arrangement in the UV exposure machine
29
3.6
Developing process
30
3.7
Developed circuit
30
4.1
First frame prototype
32
4.2
Final frame designed
34
4.3
Frame comparison
35
4.4
Watertight compartment
36
4.5
1" extension
36
4.6
Elevations
37
4.7
Drilled holes
38
4.8
The ROV system
40
4.9
The co-processing system
41
4.10
PC fan
42
XIV
4.11
MDlOA motor driver
43
4.12
Motor driver circuit schematic
44
4.13
PS2 game controller
46
4.14
PS2 - Bs-ll interface circuit
47
4.15
KYOSHO propeller
50
4.16
Propulsion unit assembly
51
4.17a
Front view
53
4.17b
Back view
53
4.17c
Side view
54
4.17d
Aerial view
54
4.17e
Bottom view
55
4.18a
Main watertight compartment circuit arrangement
56
4.18b
Surface control box circuit arrangement
56
4.19a
Weighed ROV
57
4.19b
Measurement close-up
58
4.20a
Output voltage
59
4.20b
Input voltage
59
4.21
BS-JI output test
60
4.22a
Captured video in normal light
61
4.22b
Real image
61
4.23a
Captured video with light assistant
62
4.23b
Captured video without light assistant
62
4.23c
Real image
63
4.24
Light trajectory
64
xv
LIST OF ABBREVIATION
BS-ll
- Basic Stamp II
CAD
- Computer Aided Design
CCTV
- Closed Circuit TeleVision
CCW
- Counter Clockwise
CW
- Clockwise
DOF
- Degree of Freedom
GUI
- Graphical User Interface
hp
- Horse Power
IC
- Integrated Circuit
IR
-Infra Red
PC
- Personal Computer
PS2
- PlayStation@ 2
PSM
- Projek Sarjana Muda
PVC
- PolyVinylChlorida
RF
- Radio Frequency
TIL
- Transistor-Transistor Logic
UV
- Ultra Violet
xvi
LIST OF APPENDIX
NO
TITLE
PAGE
A-I
Frame cost
71
A-2
Electronic component cost
72
A-3
Miscellaneous item cost
73
A-4
Total cost
74
B
Main processor coding
75
C
MDlOA datasheet
84
D-l
JAWSSROV
90
D-2
'The Hunter' by Paul Konings
91
D-3
Gearbox
91
D-4
Chain drive
92
D-5
Direct drive
92
E-l
Developed ROV system
93
E-2
45° arrangement
93
E-3
Completed horizontal thruster unit
94
E-4
Vertical thruster connection
94
F
BS-II datasheet
95
CHAPTER I
INTRODUCTION
1.1
Introduction
Remote operating vehicle (ROY) technology appears since early 1900's until
become widely used in 1970's [1]. Back then, the underwater ROY is mainly used in
oil industry while manned submersible vehicle is the preferred tools for underwater
scientific studies. As the technology developed, its functions have expanded to be
used in both industries and scientific studies [1][2]. ROY is defined as the
underwater robot that allows the vehicle's operator to remain in contented
environment while the piloted robot performs the work underwater.
In order to perform various task [1][3], suitable tools are equipped to the
underwater ROY. Generally, a camera, depth sensor [1][3] , pressure sensor and
temperature sensor are the main features of a ROY. For special task, tools such as
mechanical ann [2], radiation sensor [3] and sonar is used. As human supervision is
critically needed, the camera and sensors are interfaced using suitable graphic
interface and consoles [1][2][3][4] for monitoring purposes. In addition, various
types of method are developed to meet the needs of reliable ROY maneuvering and
ground control scheme.
2
The underwater vehicle came in various size shape and purposes. While its
ize is depended on its purposes, their shapes are made based on performance factor.
There are six classes of ROV existed which define their size and its mission.
1.1.1
Micro Class
Very small in sIze and weight as it only carry lightweight tools for
surveillance. Most Micro ROV nowadays can weight less than 3kg and used in a
place which are dangerous and too small for a diver such as pipeline, sewer or small
cavity (17] [21].
1.1.2
Mini Class
A Mini class ROV is bigger than Micro ROV with weight less than 50kg.
Mini ROV is also used as a diver replacement and could perform intervention tasks.
As its size is bigger than Micro ROV, it could be equipped with more tools and
equipment. This ROY also could be used where medium water current exists [16]
[17].
1.1.3
General Clas
Work at a depth of less than lOOOm with additional manipulator grippers
on board and may carry sonar unit for light survey applications. More tools and
complex equipment are installed for data collection purposes. The General Class
ROV usually came up with less than 5hp propulsion power [17].
3
1.1.4
Light Work Class
The Light Work Class ROY works at a depth less than 2000m and uses less
than 50hp propulsion power. It can carry more than one manipulator for its light
work missions. For its frame, polymers such as polyethylene is used rather than the
conventional stainless steel or aluminium alloys. Its weight is ranging between
1000kg to 2200kg. Typical tasks for this class are drilling support light construction
support pipeline inspection and general "call out" work [17][19].
1.1.5
Heavy Work Class
Its huge size enables the ROV to carry at least two manipulators for its heavy
work mission. This heavyweight ROV require not more than 220hp thruster power
for movement. For its size and ability the Heavy Work Class ROY usually works at
a depth up to 3500m. With new requirements to perform subsea tie-in operations on
deepwater installations and to carry very large diverless intervention systems this
class of ROV is becoming increasingly large powerful and capable of carrying and
lifting large loads thu the term "heavy work class vehicle" has been adopted by the
industry. These vehicles can weight more than ten thousand pounds and resemble a
minivan in size [17].
1.1.6
Trenching Burial Class
The trenching ROV is used for trenching burial works only. The ROV used
more than 200hp propulsion power with an ability to carry a cable lying sled and
work at depths up to 6000m. Commonly the trenchers are not a free flying ROY
instead it crawls on the seabed cutting trench for cable. Cameras lights sonars and
other sensors necessary to operate at great depths are readily available. Manipulators
capable of lifting hundreds of pounds are commonly installed on these vehicles [6].
4
1.2
Objective
The goals for this project are determined from the problem statements that are
made based on my observation and studies regarding the ROV issues.
First objective of this project is to design and develop a small and yet
effective ROV. The ROV will be in a Mini Class ROV which is designed for
observation purposes. For data collection process, the ROV will be equipped with
basic tools such as camera and compass. The operation of the ROV will be equipped
with real-time video monitoring from the camera attached to the ROV to improve the
reliability of the ROV.
The second objective determined for this project is to produce a low cost
ROV which can be obtained by almost everyone. Even though with as small
spending as possible, the first objective of the project will not be sacrificed. The
project should prove that a reliable ROV at its own class can be produced at low
pnce.
Thus, in the end the project is expected to meet all objectives mentioned
above and the limitation should be obeyed. Constructed ROV should be very reliable
with the help of real-time monitoring to aid controller. It also should be safe to be
used and operated by human as well as it do not harm the environment at any cost. In
addition, it is also expected that this project will help to improve my problem solving
skills knowledge on field other than electronic other engineering disciplines and
scientific concepts.
5
1.3
Problem Statement
The following situations stated are the major issues that usually arise among
ROV users based on studies made. There are two main issues which led to the
conception of this project.
Most ROV must be big enough to accommodate tools for surveillance. For
basic observations and data collections, for instance, an observation of environmental
parameters, sets of sensor such as pH sensor, temperature sensor, and salinity sensor
are equipped to the ROV. As data collecting tools increased, so do the frame area or
platform size to accommodate the tools must be sufficiently enough thus increasing
the size of the ROV itself. In returns, much higher propulsion power needed to
mobilize the ROV and thus increasing the total power needed by the vehicle [7].
As the functions increase, the size will also increase. Consequently, every
aspect of producing the ROV also increases. This includes the factor of reliability of
the ROV itself as most tools and equipments that come with high quality and great
performance will be very costly to acquire. It also involves the cost of obtaining
small yet has very outstanding performance equipment. Thus, to produce a very
reliable ROV will be too expensive even though producing a micro ROV class [20].
This scenario can be observed from the production of ROV for educational purposes
which are hardly affordable prices.
1.4
Scope
Limitations below are created based on several purposes. Firstly, it is used to
determine on how reliable the ROV was when operated [5]. Secondly, the limitation
is used as a barrier to avoid materials wasting and unnecessary parts of the ROV
which consequently will reduce the cost of production.
6
First limitation determined is the operating depth. The Mini Class ROV
should be operating in shallow water which the depth is below than 30m. This is due
to the pressure issues that will always appear along the ROV construction process.
As we going deeper underwater, the pressure applied on us will increase. If the ROV
hull cannot withstand the pressure, it will eventually break and water will flood the
hull and consequently destroy all electronic equipments.
Secondly, the ROV is set to be maneuvered inside calm water or with low
current. For an area with such current, the ROV should be able to maneuver free and
easily without a huge drag forces introduced. Even if operating inside calm water,
attention upon current that might exist should be considered during the development
of ROV.
Thirdly, the ROV must have its own clear and defined jobs. Due to lack of
time given to complete the project, the ROV is limited to perform basic data
collection and light observation task. The jobs defined will acquire the ROV to be
equipped with general observation tools or payloads such as video camera, digital
compass and pressure sensor. Additional tools will be equipped if there are ample
times to do so.
Lastly, the ROV developed is small enough to operate inside a test tank. This
is due to the PSM II Seminar that will be held inside Faculty's laboratory which did
not permit a large test area for the ROV.
1.5
Methodology
In this project, methodology can be divided into two parts. The first part
introduced the methodology used for data collecting while the second part describes
the methodology used for data processing.
7
For data collection, there are three main methods used. The flIst method is by
collecting data from internet groups that are dedicated on building their own ROY
and anything related to the project such as sensors and microcontroller. Secondary
method used in order to gather data is from journal, articles and reports of subject
associated with the project obtained from various online database portals such as
IEEE website. This source provides data based on professional analysis and test that
is valid for citation in this report and most importantly can be used for developing the
ROY along with data obtained from the first method. Last method used in order to
complete this project is by referencing to the books that must be related to the project.
Data processing methods also comprise of three techniques. The first
technique is through discussion among experienced person with matters related.
Then, comparison technique is used mainly to choose the best from available choices
of material, tools or modus operandi. The third method is through design, simulation
and constructs the data obtained in order to achieve desired results.
The following part of the report is organized as follows. Chapter IT will
describe the literature review done for this project. Chapter ill is an extended
discussion of methodology used in this project. Chapter IV contains results and
discussions, which mainly describe the project progress and lastly Chapter Y, the
conclusion of the progress report of Underwater ROY project including suggestion
for further improvement of this project.
CHAPTERll
BACKGROUND OF STUDIES
Despite their size and functions, all ROV shares generic building blocks
which consist of major common components. The difference is only how the
manufacturers manipulate these components in designing their own ROV. Usually,
work class ROV are constructed using a same design while smaller ROV are freely
designed to fit its mission.
2.1
Basic Components
Despite their classes and mission objectives, all ROV are build with
consideration of the following matters. These followings matters can be describe as
the basic component of a ROV.
2.1.1 Frame and Housing
This is the most important part of the ROV, the frame provides a solid
platfonn for attaching necessary mechanical, electrical, data acquisition and
propulsion components. The concept of choosing the best material for the frame is to
give maximum strength to the structure with minimum weight. It is very important
for the weight to be offset with buoyancy of the ROV which will keep it balanced
MOHAMMAD AFIQ BIN HASlllM
This report is submitted in partial fulfillment of the requirements for the award of
Bachelor of Electronic Engineering (Telecommunication Electronics) with Honors
Faculty of Electronic and Computer Engineering
Universiti Teknikal Malaysia Melaka
May 2008
UNlVERSTI TEKNIKAL MALAYSIA MELAKA
FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER
BORANG PENGE AHAN STAT S LAPORAN
PROJEK SARJANA MUDA II
TajukProjek
UNDERWATER REMOTE OPERATING VEHICLE
Sesi
Pengajian
200712008
Saya MOHAMMAD AFrQ BIN HASHIM mengaku membenarkan Laporan Projek Srujana Muda ini
disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:
1.
Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.
2.
Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3.
Perpustakaan dibenarkan membuat salinan laporan iill sebagai bahan pertukaran antara institusi
pengajian tinggi.
Sila tandakan ( ..J ) :
4.
D
D
[£]
SULIT*
(Mengandungi maklumat yang berdarjah keselamatan atau
kepentingan Malaysia seperti yang termaktub di dalam AKTA
RAHSlA RASMJ 1972)
TERHAD*
(Mengandungi maklumat terhad yang telah ditentukan oleh
organisasi/badan di mana penyelidikan dijalankan)
TIDAX TERHAD
ｾ＠
Ｈｍｏｾａｦｉｲｩ｜＠
Alamat Tetap: NO. 60 TMN FORTUNA FASA I JLN
PENAMPANG. 88200 KOTA KJNABALU. SABAH.
ｔ｡ｲｩｫｨ
ＺＮ ｾＮｬ
Ｎ ｉＮｾ＠
(EN.
HASHIM)
......
RAN BIN MOHD IBRAHIM)
IMRAN BIN MOHO IaftAHIM
ｆｾ＠
Pensy.rah
dan Kej. Komputer (FKEKK),
Uruversitl TeI!.nikil ｍ｡ｬｾ＠
Melakl (UTeM).
Karung ｂ･ｾ＠
1200.
Ayer KerIh, 75450 Melaka
Kei: Ｎ ｅｾ＠
. ( b/l/Ot
Tankh: ............................ .
III
"I hereby declared this report is the result of my own work except for quotes as cited
in the references."
ｾ＠
Signature
:.................
.................•.......
Author
: MOHAMMAD AFIQ BIN HASHIM
Date
:...ＧＮ＿ｪｾｬ＠
......................................... .
IV
"I hereby declare that I have read this report and in my opinion this report is
sufficient in terms of the scope and quality for the award of Bachelor of Electronic
Engineering (felecommunication Electronics) With Honors."
Signature
Supervisor Name
Date
. IMRAN BIN MOHD IBRAHIM
:.........ｾ Ｎ ｾＨ
Ｎ ｲＡｾ
Ｎ ｾ＠
...................................
v
For my lovely family
VI
ACKNOWLEDGEMENT
Praise to God the Almighty for His mercy; I could finish my Industrial
Training Program successfully.
I would like to deliver my heartiest appreciation to Mr. Imran bin Mohd
Ibrahim, Vice Dean (R&D) of Faculty of Electronic and Computer Engineering for
accepting my request to be my supervisor, for his helpful thought and motivation
throughout completing this project.
I dedicate my deepest gratitude to Mr. T. L. Lee of Unipac Engineering
(Melaka) Sdn. Bhd. for his advices, guidance and his effort in helping me in
designing and developing parts for this project.
A countless appreciation dedicated to my beloved family and all my friends
for their endless support and for being there for me through thick and thin.
And again my appreciation to those already mentioned and to those who are
not mentioned. Thank you very much.
Thank you.
Vll
ABSTRACT
The remote operating vehicle (ROY) is designed to be used for an underwater
surveillance such as in ecological studies or environmental parameters survey. For
that reason, the ROV will be equipped with suitable tools such as a video camera and
robotic arm to accomplish its mission. Several limitations are made as a guideline in
designing and developing the ROV. Most ROV must be big enough to accommodate
adequate tools for surveillance. As their functions increase, the size will also increase.
Consequently the cost for producing such vehicle will also expand. Based on the
situations mentioned above, the goals for this project are to design and develop a
small and effective ROV and to produce it with expenses as low as possible. In order
to meet the objectives, research regarding to the design and developing the ROV is
mostly depends on internet resources. These resources are from an internet forum
which discuss mainly on homebuilt ROV, journals and research paper that are related
to the project. The secondary resources are from books available locally. The
outcome is expected to meet all objectives mentioned above and the limitation
should be obeyed. Constructed ROV should be reliable with the help of real-time
monitoring system to aid controller. It also should be safe to use and operated by
human as well as do not harm the environment at any cost.
Vlll
ABSTRAK
Remote operating vehicle (ROY) atau kenderaan kawalan jauh yang dibina
adalah bagi memenuhi keperluan dalam membuat kajian ekologi dan tinjauan ciriciri persekitaran di dalam air. Bagi mendapatkan hasil kajian yang terbaik, ROV
tersebut akan dilengkapi dengan peralatan yang sesuai seperti kamera video ataupun
lengan robotik. Beberapa had batasan telah digariskan sebagai panduan dalam proses
mereka dan membina ROV tersebut. Pertambahan bilangan peralatan yang akan
digunakan secara lazimnya akan menyebabkan saiz ROV turut bertambah dan secara
tidak langsung akan meningkatkan kos pengeluaran ROV tersebut. Oleh yang
demikian, projek ini adalah dicadangkan untuk membina ROV yang efisyen dalam
bidang tugasnya dan dihasilkan menggunakan modal serendah yang mungkin. Bagi
memenuhi objektif-objektif projek, kajian berkenaan rekabentuk dan pembikinan
ROV tersebut adalah bergantung kepada sumber daripada forum internet, jurnal dan
kertas kajian berkenaan projek ini. Surnber kedua merupakan buku-buku yang
berkaitan yang boleh diperolehi secara percuma di perpustakaan. Pada akhir semester
ke-2, adalah diharapkan supaya projek ini akan memberikan hasil yang memenuhi
objektif ini secara menyeluruh. Penggunaan ROV yang dibina diharapkan adalah
efisyen dengan bantuan sistem pengawasan secara real-time. Hasil projek ini juga
diharapkan dapat berfungsi tanpa memberikan ancaman keselarnatan kepada
pengguna dan juga kepada alam persekitarannnya.
IX
CONTENTS
CHAPTER
CONTENTS
PAGE
PROJECT TITTLE
I
DECLARA TION
ii
DEDICATION
v
ACKNOWLEDGEMENT
vi
ABSTRACT
vii
ABSTRAK
viii
CONTENTS
ix
LIST OF TABLE
xii
LIST OF FIGURE
xiii
LIST OF AB BRE VIATION
xv
LIST OF APPENDIX
xvi
INTRODUCTION
1.1 Introduction
1.1.1
Micro Class
2
1.1.2
Mini Class
2
1.1.3
General Class
2
1.1.4
Light Work Class
3
1.1.5
Heavy Work Class
3
1.1.6
Trenching Burial Class
3
1.2 Objective
4
1.3 Problem Statement
5
1.4 Scope
5
x
CHAPTER
n
CONTENTS
PAGE
1.5 Methodology
6
BACKGROUND OF STUDIES
8
2.1 Basic Components
8
2.1.1
Frame and Housing
8
2.1.2
Buoyancy
9
2.1.3
Control System
11
2.1.4
Propulsion
13
2.1.5
Tools and Equipments
16
2.2 Additional Components and Consideration
ill
17
2.2.1
Vehicle Teleoperation Interfaces
17
2.2.2
Low Drag and Mechanical Symmetry
19
METHODOLOGY
21
3.1 Data Acquisition Method
21
3.1.1
Internet Forum
21
3.1.2
Articles, Journals and Reports
22
3.1.3
Books
22
3.2 Data Processing Method
23
3.2.1
Discussion
23
3.2.2
Comparison
24
3.2.3
Design, Simulate and Construct
24
3.3 Electronic Circuit Development
26
xi
CHAYfER
IV
CONTENTS
PAGE
RESULTS AND DISCUSSION
31
4.1 Project Specification and Results
31
4.1.1
V
Frame and Watertight Housing
31
4.1.1.1 ROV Frame
32
4.1.1.2 Main Watertight Housing
35
4.1.1.3 Buoyancy and Stability
38
4.1.2
39
Main Controller and Control System
4.1.2.1 Main Processor
39
4.1.2.2 Motor Controller
41
4.1.2.3 Ground Controller
44
4.1.3
48
Propeller and Propulsion
4.1.3.1 Vertical Motion
48
4.1.3.2 Horizontal Motion
49
4.2 Discussion
51
CONCLUSION
6S
5.1 Conclusion
65
5.2 Future Works
66
REFERENCE
68
xii
LIST OF TABLES
NO
TITLE
PAGE
4.1
Comparison of frame materials
33
4.2
Proto typed frame comparison
34
4.3
Comparison of control system type
39
4.4
Submerged unit and surface unit components
52
4.5
ROV final dimension
57
Xlll
LIST OF FIGURES
NO
TITLE
PAGE
2.1
Air pressured ballast tank
11
2.2
6-channel RF transmitter
12
2.3
DC motor with Electronic Speed Controller unit
14
2.4
6-DOF
15
2.5
Thruster configuration and allocation of RRC ROV II
16
2.6
CCD camera
17
2.7
ROV REV II user interface
19
3.1
ROV development flowchart
25
3.2
Electronic circuit development flowchart
26
3.3
Printed layout on transparency paper
28
3.4
Circuit layout on the copper side
28
3.5
Circuit arrangement in the UV exposure machine
29
3.6
Developing process
30
3.7
Developed circuit
30
4.1
First frame prototype
32
4.2
Final frame designed
34
4.3
Frame comparison
35
4.4
Watertight compartment
36
4.5
1" extension
36
4.6
Elevations
37
4.7
Drilled holes
38
4.8
The ROV system
40
4.9
The co-processing system
41
4.10
PC fan
42
XIV
4.11
MDlOA motor driver
43
4.12
Motor driver circuit schematic
44
4.13
PS2 game controller
46
4.14
PS2 - Bs-ll interface circuit
47
4.15
KYOSHO propeller
50
4.16
Propulsion unit assembly
51
4.17a
Front view
53
4.17b
Back view
53
4.17c
Side view
54
4.17d
Aerial view
54
4.17e
Bottom view
55
4.18a
Main watertight compartment circuit arrangement
56
4.18b
Surface control box circuit arrangement
56
4.19a
Weighed ROV
57
4.19b
Measurement close-up
58
4.20a
Output voltage
59
4.20b
Input voltage
59
4.21
BS-JI output test
60
4.22a
Captured video in normal light
61
4.22b
Real image
61
4.23a
Captured video with light assistant
62
4.23b
Captured video without light assistant
62
4.23c
Real image
63
4.24
Light trajectory
64
xv
LIST OF ABBREVIATION
BS-ll
- Basic Stamp II
CAD
- Computer Aided Design
CCTV
- Closed Circuit TeleVision
CCW
- Counter Clockwise
CW
- Clockwise
DOF
- Degree of Freedom
GUI
- Graphical User Interface
hp
- Horse Power
IC
- Integrated Circuit
IR
-Infra Red
PC
- Personal Computer
PS2
- PlayStation@ 2
PSM
- Projek Sarjana Muda
PVC
- PolyVinylChlorida
RF
- Radio Frequency
TIL
- Transistor-Transistor Logic
UV
- Ultra Violet
xvi
LIST OF APPENDIX
NO
TITLE
PAGE
A-I
Frame cost
71
A-2
Electronic component cost
72
A-3
Miscellaneous item cost
73
A-4
Total cost
74
B
Main processor coding
75
C
MDlOA datasheet
84
D-l
JAWSSROV
90
D-2
'The Hunter' by Paul Konings
91
D-3
Gearbox
91
D-4
Chain drive
92
D-5
Direct drive
92
E-l
Developed ROV system
93
E-2
45° arrangement
93
E-3
Completed horizontal thruster unit
94
E-4
Vertical thruster connection
94
F
BS-II datasheet
95
CHAPTER I
INTRODUCTION
1.1
Introduction
Remote operating vehicle (ROY) technology appears since early 1900's until
become widely used in 1970's [1]. Back then, the underwater ROY is mainly used in
oil industry while manned submersible vehicle is the preferred tools for underwater
scientific studies. As the technology developed, its functions have expanded to be
used in both industries and scientific studies [1][2]. ROY is defined as the
underwater robot that allows the vehicle's operator to remain in contented
environment while the piloted robot performs the work underwater.
In order to perform various task [1][3], suitable tools are equipped to the
underwater ROY. Generally, a camera, depth sensor [1][3] , pressure sensor and
temperature sensor are the main features of a ROY. For special task, tools such as
mechanical ann [2], radiation sensor [3] and sonar is used. As human supervision is
critically needed, the camera and sensors are interfaced using suitable graphic
interface and consoles [1][2][3][4] for monitoring purposes. In addition, various
types of method are developed to meet the needs of reliable ROY maneuvering and
ground control scheme.
2
The underwater vehicle came in various size shape and purposes. While its
ize is depended on its purposes, their shapes are made based on performance factor.
There are six classes of ROV existed which define their size and its mission.
1.1.1
Micro Class
Very small in sIze and weight as it only carry lightweight tools for
surveillance. Most Micro ROV nowadays can weight less than 3kg and used in a
place which are dangerous and too small for a diver such as pipeline, sewer or small
cavity (17] [21].
1.1.2
Mini Class
A Mini class ROV is bigger than Micro ROV with weight less than 50kg.
Mini ROV is also used as a diver replacement and could perform intervention tasks.
As its size is bigger than Micro ROV, it could be equipped with more tools and
equipment. This ROY also could be used where medium water current exists [16]
[17].
1.1.3
General Clas
Work at a depth of less than lOOOm with additional manipulator grippers
on board and may carry sonar unit for light survey applications. More tools and
complex equipment are installed for data collection purposes. The General Class
ROV usually came up with less than 5hp propulsion power [17].
3
1.1.4
Light Work Class
The Light Work Class ROY works at a depth less than 2000m and uses less
than 50hp propulsion power. It can carry more than one manipulator for its light
work missions. For its frame, polymers such as polyethylene is used rather than the
conventional stainless steel or aluminium alloys. Its weight is ranging between
1000kg to 2200kg. Typical tasks for this class are drilling support light construction
support pipeline inspection and general "call out" work [17][19].
1.1.5
Heavy Work Class
Its huge size enables the ROV to carry at least two manipulators for its heavy
work mission. This heavyweight ROV require not more than 220hp thruster power
for movement. For its size and ability the Heavy Work Class ROY usually works at
a depth up to 3500m. With new requirements to perform subsea tie-in operations on
deepwater installations and to carry very large diverless intervention systems this
class of ROV is becoming increasingly large powerful and capable of carrying and
lifting large loads thu the term "heavy work class vehicle" has been adopted by the
industry. These vehicles can weight more than ten thousand pounds and resemble a
minivan in size [17].
1.1.6
Trenching Burial Class
The trenching ROV is used for trenching burial works only. The ROV used
more than 200hp propulsion power with an ability to carry a cable lying sled and
work at depths up to 6000m. Commonly the trenchers are not a free flying ROY
instead it crawls on the seabed cutting trench for cable. Cameras lights sonars and
other sensors necessary to operate at great depths are readily available. Manipulators
capable of lifting hundreds of pounds are commonly installed on these vehicles [6].
4
1.2
Objective
The goals for this project are determined from the problem statements that are
made based on my observation and studies regarding the ROV issues.
First objective of this project is to design and develop a small and yet
effective ROV. The ROV will be in a Mini Class ROV which is designed for
observation purposes. For data collection process, the ROV will be equipped with
basic tools such as camera and compass. The operation of the ROV will be equipped
with real-time video monitoring from the camera attached to the ROV to improve the
reliability of the ROV.
The second objective determined for this project is to produce a low cost
ROV which can be obtained by almost everyone. Even though with as small
spending as possible, the first objective of the project will not be sacrificed. The
project should prove that a reliable ROV at its own class can be produced at low
pnce.
Thus, in the end the project is expected to meet all objectives mentioned
above and the limitation should be obeyed. Constructed ROV should be very reliable
with the help of real-time monitoring to aid controller. It also should be safe to be
used and operated by human as well as it do not harm the environment at any cost. In
addition, it is also expected that this project will help to improve my problem solving
skills knowledge on field other than electronic other engineering disciplines and
scientific concepts.
5
1.3
Problem Statement
The following situations stated are the major issues that usually arise among
ROV users based on studies made. There are two main issues which led to the
conception of this project.
Most ROV must be big enough to accommodate tools for surveillance. For
basic observations and data collections, for instance, an observation of environmental
parameters, sets of sensor such as pH sensor, temperature sensor, and salinity sensor
are equipped to the ROV. As data collecting tools increased, so do the frame area or
platform size to accommodate the tools must be sufficiently enough thus increasing
the size of the ROV itself. In returns, much higher propulsion power needed to
mobilize the ROV and thus increasing the total power needed by the vehicle [7].
As the functions increase, the size will also increase. Consequently, every
aspect of producing the ROV also increases. This includes the factor of reliability of
the ROV itself as most tools and equipments that come with high quality and great
performance will be very costly to acquire. It also involves the cost of obtaining
small yet has very outstanding performance equipment. Thus, to produce a very
reliable ROV will be too expensive even though producing a micro ROV class [20].
This scenario can be observed from the production of ROV for educational purposes
which are hardly affordable prices.
1.4
Scope
Limitations below are created based on several purposes. Firstly, it is used to
determine on how reliable the ROV was when operated [5]. Secondly, the limitation
is used as a barrier to avoid materials wasting and unnecessary parts of the ROV
which consequently will reduce the cost of production.
6
First limitation determined is the operating depth. The Mini Class ROV
should be operating in shallow water which the depth is below than 30m. This is due
to the pressure issues that will always appear along the ROV construction process.
As we going deeper underwater, the pressure applied on us will increase. If the ROV
hull cannot withstand the pressure, it will eventually break and water will flood the
hull and consequently destroy all electronic equipments.
Secondly, the ROV is set to be maneuvered inside calm water or with low
current. For an area with such current, the ROV should be able to maneuver free and
easily without a huge drag forces introduced. Even if operating inside calm water,
attention upon current that might exist should be considered during the development
of ROV.
Thirdly, the ROV must have its own clear and defined jobs. Due to lack of
time given to complete the project, the ROV is limited to perform basic data
collection and light observation task. The jobs defined will acquire the ROV to be
equipped with general observation tools or payloads such as video camera, digital
compass and pressure sensor. Additional tools will be equipped if there are ample
times to do so.
Lastly, the ROV developed is small enough to operate inside a test tank. This
is due to the PSM II Seminar that will be held inside Faculty's laboratory which did
not permit a large test area for the ROV.
1.5
Methodology
In this project, methodology can be divided into two parts. The first part
introduced the methodology used for data collecting while the second part describes
the methodology used for data processing.
7
For data collection, there are three main methods used. The flIst method is by
collecting data from internet groups that are dedicated on building their own ROY
and anything related to the project such as sensors and microcontroller. Secondary
method used in order to gather data is from journal, articles and reports of subject
associated with the project obtained from various online database portals such as
IEEE website. This source provides data based on professional analysis and test that
is valid for citation in this report and most importantly can be used for developing the
ROY along with data obtained from the first method. Last method used in order to
complete this project is by referencing to the books that must be related to the project.
Data processing methods also comprise of three techniques. The first
technique is through discussion among experienced person with matters related.
Then, comparison technique is used mainly to choose the best from available choices
of material, tools or modus operandi. The third method is through design, simulation
and constructs the data obtained in order to achieve desired results.
The following part of the report is organized as follows. Chapter IT will
describe the literature review done for this project. Chapter ill is an extended
discussion of methodology used in this project. Chapter IV contains results and
discussions, which mainly describe the project progress and lastly Chapter Y, the
conclusion of the progress report of Underwater ROY project including suggestion
for further improvement of this project.
CHAPTERll
BACKGROUND OF STUDIES
Despite their size and functions, all ROV shares generic building blocks
which consist of major common components. The difference is only how the
manufacturers manipulate these components in designing their own ROV. Usually,
work class ROV are constructed using a same design while smaller ROV are freely
designed to fit its mission.
2.1
Basic Components
Despite their classes and mission objectives, all ROV are build with
consideration of the following matters. These followings matters can be describe as
the basic component of a ROV.
2.1.1 Frame and Housing
This is the most important part of the ROV, the frame provides a solid
platfonn for attaching necessary mechanical, electrical, data acquisition and
propulsion components. The concept of choosing the best material for the frame is to
give maximum strength to the structure with minimum weight. It is very important
for the weight to be offset with buoyancy of the ROV which will keep it balanced