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Version 2010-04NW

SeaPerch

Remotely Operated Vehicle (ROV)

Construction Manual

Standard and Selected Optional

Assembly Procedures

August

2010

The SeaPerch educational program was created by Harry
Bohm and Vickie Jensen and published in their 1997 book
"

Build Your Own Underwater Robot and Other Wet

Projects.

" The initial curriculum was developed by the

Massachusetts Institute of Technology, and this version of
the SeaPerch Construction Manual was provided under the
Office of Naval Research National Naval Responsibility for
Naval Engineering (NNRNE) Outreach initiative.

Содержание Remotely Operated Vehicle

Страница 1: ...d by Harry Bohm and Vickie Jensen and published in their 1997 book Build Your Own Underwater Robot and Other Wet Projects The initial curriculum was developed by the Massachusetts Institute of Technol...

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Страница 3: ...3 Added Appendix Containing Troubleshooting Hints I 3 Added Supplement for Construction Options and Enhancements 1 3 The SeaPerch Assembly Process I 5 Three Individual Building Units I 5 Recording Pro...

Страница 4: ...ssembly of Subsystem Two The Thrusters 2 0 1 Tools and Materials Needed 2 0 2 Time Needed to Complete Unit 2 2 0 2 Procedure 2 1 Build a Motor Potting Holder If Not Provided 2 1 1 Procedure 2 2 Test t...

Страница 5: ...ntal Thruster Control Switches 3 5 1 Procedure 3 6 Finish the Control Box 3 6 1 Testing and Ballasting the ROV Time Needed to Complete Testing and Ballasting of the ROV T 1 Initial Electrical Testing...

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Страница 7: ...and then operate it underwater The experience will enable them to explore science and technology both in the classroom and in a pool or for some in natural marine environments The ROVs are built from...

Страница 8: ...uctions for building a SeaPerch from those found in Build Your Own Underwater Robot and Other Wet Projects so that the ROV would be simpler and cheaper to build in the classroom MITSG created a three...

Страница 9: ...ter operation of SeaPerch ROVs the instructions and supplemental information for these activities are now in a separate expanded section of this manual entitled Testing and Ballasting the ROV In addit...

Страница 10: ...Front PVC Tees as Attachment Points and for Fast Draining o Instead of PVC Elbows Use of a Toggle Switch for the Vertical Thruster o Instead of Two More Expensive Pushbutton Switches Use of Alternate...

Страница 11: ...ring and soldering activities and provides an opportunity for them to work with a variety of tools and components used in electrical technologies Recording Progress The checklist style boxes next to e...

Страница 12: ...classroom tools is to arrange to obtain enough to ensure that students do not need to stop long during the build process to wait for availability of needed tools Manual Printing Considerations Please...

Страница 13: ...metal properly Small amounts of flux can occasionally pop out of the melting solder and sometimes travel far enough to reach the eye of the person soldering or even someone nearby Protective eyewear i...

Страница 14: ...sives and PVC primer and cement some versions of SeaPerch ROVs don t use all of these types can present hazards to skin as well as eyes Wearing eye protection and gloves is recommended when working wi...

Страница 15: ...tool in its closed position Safety While Drilling Drilling is perhaps the most potentially hazardous activity involved in the SeaPerch project Some important safety considerations are as follows Get...

Страница 16: ...Wax The standard SeaPerch wax melting approach is to warm toilet bowl ring wax in a heated pot or a metal container placed in a hot water bath usually employing an electric skillet to heat the water...

Страница 17: ...esides resulting in sparks when such an improper connection is made the wire or metal object shorting across the terminal will immediately become extremely hot and may even melt That could obviously c...

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Страница 19: ...t 2010 The SeaPerch educational program was created by Harry Bohm and Vickie Jensen and published in their 1997 book Build Your Own Underwater Robot and Other Wet Projects The initial curriculum was d...

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Страница 21: ...Hanger 20 6 Tie Wraps Zip Ties 8 8 Tie Wraps Zip Ties PVC Primer Cement Paper Towels Rubbing Alcohol Time Needed to Complete Unit 1 Total Construction Time Unit 1 usually requires at least 4 to 5 hour...

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Страница 23: ...y As with all pipe cutters proceed slowly giving the cutter time to do its work Hack Saws and other hand saws can cut through PVC but are the most labor intensive option Band Saws are large pieces of...

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Страница 25: ...good practice to secure the object you are drilling in a vise or clamp before drilling This keeps it steady prevents it from spinning and hurting your hand if the drill should bind and keeps your fing...

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Страница 27: ...d from Procedure 1 2 6 PVC Tees Figure 1 3 1 Assembled Vehicle Frame Construction Steps 1 Assemble the frame using the PVC parts as shown in Figure 1 3 2 below Do not glue any of the connections Orien...

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Страница 29: ...oyancy 2 Work in a WELL VENTILATED area outdoors or under a vent hood with several layers of paper towel or newspaper to protect the work surface and floor area from stains Apply a VERY SMALL amount o...

Страница 30: ...rter turn and hold it firmly in place for 30 seconds Put the cap back on the adhesive container as soon as possible to minimize the escape of vapors and to prevent the contents from drying out Remove...

Страница 31: ...ame sections appear to be getting loose Unless you are building a larger frame or have a PVC component that remains loose it is not necessary to glue or screw the joints Construction Steps 1 Push all...

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Страница 33: ...f the ROV What angles will get you the best forward and backward thrust What angles will get you the best turning ability What is the best compromise for your mission needs Construction Steps 1 Hold a...

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Страница 35: ...the ROV should be avoided if parts such as PVC tees and elbows will later be recycled for use on another SeaPerch ROV Construction Steps 1 Check the frame to ensure that all pipe sections and fittings...

Страница 36: ...post and attach it with tie wraps in two places be sure to pass the tie wraps through the net mesh on both sides of the post as shown In Figure 1 6 3 Pull them tight using pliers Figure 1 6 3 Capture...

Страница 37: ...ure 1 6 4 Figure 1 6 4 Wire Stiffener for Payload Net 8 Attach the stiffener to the front of the payload net using six 6 wire ties one on each side and four along the payload net as shown in Figure 1...

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Страница 39: ...2010 The SeaPerch educational program was created by Harry Bohm and Vickie Jensen and published in their 1997 book Build Your Own Underwater Robot and Other Wet Projects The initial curriculum was dev...

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Страница 41: ...y 1 2 5 cm Butyl Rubber Tape 24 61 cm 22 Stranded Hook Up Wire Red 24 61 cm 22 Stranded Hook Up Wire Black 1 12 Volt Battery 1 8 20 cm or Longer Wood Block 2x4 2x6 or 4x4 Electrical Tape Rubbing Alcoh...

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Страница 43: ...a cardboard stand If a motor potting holder is not already available one can be quickly constructed by following the procedure below The holes may be placed in any configuration convenient for placing...

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Страница 45: ...ay come with wire leads already attached In that case the wires must be removed prior to testing the motors and assembling the thrusters Some motor shells may have more holes to cover than others Some...

Страница 46: ...bserve which direction the flag on the motor shaft turns when looking into the front long shaft end of the motor The shaft should spin rapidly If it doesn t re check the wire connections If they are s...

Страница 47: ...nough room for the waterproofing wax to flow around them it is important to perform the wrapping process very carefully to minimize the overall diameter of each wrapped motor Construction Steps 1 Make...

Страница 48: ...ully place each piece up along the side of the motor shaft boss usually a raised flange area around the rear end of the shaft in the center of the motor Do not cover the rear tip of the motor shaft if...

Страница 49: ...that extends past the end of the motor to aid in folding it down without wrinkles Then fold it over the end as smoothly as possible Figure 2 3 4 shows the final taping process for both ends of the mot...

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Страница 51: ...tor shafts will not be too tight for the holes drilled in the thruster housings Drill Safety Reminder Always get your teacher s permission before using a drill or other power tool Check to verify that...

Страница 52: ...crape off any burrs that come through with that solid part of the bit Repeat this process until the hole is completely clear 4 Polish the holes that you drilled in the bottoms of the thruster housings...

Страница 53: ...for soldering the next connection Soldering Besides protecting the tip from oxidation applying a little solder to the tip of the soldering iron helps to transfer heat to the junction being soldered A...

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Страница 55: ...5 or CAT 6 cable types have four wire pairs inside Three of them will be used for the standard SeaPerch ROV Construction Steps 1 On one end of the tether cable strip off about 15 38 cm of the outer s...

Страница 56: ...2 5 3 A Motor s Wires Passed Through a Thruster Housing Cap 4 Strip about 7 mm of insulation from the end of each wire for all three wire pairs that are used for the thrusters green blue and orange pa...

Страница 57: ...et temperature to low or medium so that the wax just reaches its melting point or a little higher about 160 degrees F The goal is for the wax to be hot enough that it will not harden immediately when...

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Страница 59: ...V Electrical Tape Petroleum Jelly Water and Paper Towels Figure 2 6 1 Motor Waterproofed by Potting in Wax NOTE Each motor will be potted into its thruster housing using melted wax as shown in Figure...

Страница 60: ...he wax and give you a little more time to settle each motor into position at the bottom of its thruster housing 7 Place a small dab of petroleum jelly at the base of the motor s shaft as shown in Figu...

Страница 61: ...sh on the motor shafts and break the seals Once all three of your housings have a motor in them and have cooled you will fill them the rest of the way with wax in two steps 12 Place a dab of petroleum...

Страница 62: ...n preparation for the final wax pour Keep the coiled wires away from the top edge of the housing where they could be pinched 16 Carefully fill one thruster housing to the very top with wax creating a...

Страница 63: ...a 12 volt battery the polarity does not matter The motor shaft should spin rapidly indicating that the thruster is good If it does not spin or spins slowly gently twist it in both directions by hand o...

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Страница 65: ...jelly that may be left after the potting process 2 Use a small piece of sandpaper or steel wool to roughen the surface of each of the motor shafts Then wipe them again with alcohol and a clean paper t...

Страница 66: ...motor shafts held steady in the grip of the locking thin nosed pliers as shown in Figure 2 7 3 It should take a few seconds of very firm pressure to slide it on If it is too small to go onto the shaf...

Страница 67: ...ts depends upon the size of the thruster housings as well as how far apart the mounting holes were drilled If after tightening a thruster into its mount it is still too loose remove it and put a few w...

Страница 68: ...ly re drill the holes at another location around the pipe 4 You can now use pliers to turn the PVC pipes that the thrusters are mounted on in order to get the thruster angles that you want This is a g...

Страница 69: ...le frame so you can waterproof that opening using butyl rubber tape 2 Locate in your kit or cut from a roll a 1 2 5 cm piece of butyl rubber tape 3 Stretch the tape to about twice its relaxed length t...

Страница 70: ...hown in Figures 2 9 1 and 2 9 3 This is important to keep the tether cable pointing straight back from the ROV so that its drag in the water does not tend to pull the ROV more to one side than the oth...

Страница 71: ...t 2010 The SeaPerch educational program was created by Harry Bohm and Vickie Jensen and published in their 1997 book Build Your Own Underwater Robot and Other Wet Projects The initial curriculum was d...

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Страница 73: ...als 1 Fuse Holder and 10 Amp Slow Blow Fuse 1 12 Volt Battery 1 Double Pole Double Throw DPDT Center Off Toggle Switch Non Momentary Type Preferred 2 Double Pole Double Throw DPDT Center Off Toggle Sw...

Страница 74: ...s a technical representation to show the components and how they are connected but is not drawn to scale and it leaves out everything but the wires and electrical components You can always refer back...

Страница 75: ...witch 2 Quick Disconnect Terminals 1 Fuse Holder 1 Fuse 10 Amp Slow Blow 6 2 m 18 Speaker Wire or Lamp Cord 24 61 cm 22 Red Hook Up Wire 24 61 cm 22 Black Hook Up Wire Figure 3 1 1 Completed Control B...

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Страница 77: ...t to lose the small lid screws during the assembly process 2 Using the marker or a pencil mark the locations of the holes on the control box as shown in Figure 3 2 2 There should be one hole in the ba...

Страница 78: ...arger than the usual holes called for in these instructions you may need to use a different drill bit 4 Secure the control box in a vise or clamp but not too tightly and drill holes in the locations m...

Страница 79: ...61 cm Red 22 Hook Up Wire 24 61 cm Black 22 Hook Up Wire 1 DPDT Center Off Toggle Switch 2 DPDT Center Off Toggle Switches Momentary Contact Preferred Electrical Tape Figure 3 3 1 Completed Power Cor...

Страница 80: ...he ribbed marked or copper side the positive side and the smooth unmarked or silver side the negative side 6 On each end of the power cord wire carefully separate the two conductors for about 1 2 5 cm...

Страница 81: ...however try not to overheat the terminal s colored identifying insulation 12 Slide the quick disconnect terminal onto the negative side of the power cord and crimp it and optionally solder it as abov...

Страница 82: ...ree black wires and twist the bundled end onto the wire from the negative smooth unmarked silver side of the power cord Solder the two connections and cover them each separately with electrical tape a...

Страница 83: ...orarily install the two horizontal thrusters toggle switches momentary contact type if available in the top of the control box and the vertical thruster s toggle switch usually a non momentary contact...

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Страница 85: ...r parts inside the switch Waiting about a half minute before soldering another terminal on the same switch will allow the switch to cool down Keep the stripped part of the wires short 1 4 Bend the wir...

Страница 86: ...E SWITCHES SeaPerch ROV Construction Manual Version 2010 04NW 3 4 2 Procedure 3 4 Continued Figure 3 4 2 Vertical Thruster Control Circuit Diagram Figure 3 4 3 Vertical Thruster Wiring Diagram Crisscr...

Страница 87: ...make the crisscross wires for the toggle switches Unwrap the tether wires and cut 2 5 cm from ends of the orange green and blue pairs Do not cut the brown wire pair it may be needed for a future use 7...

Страница 88: ...similarly connect the other end of the wire to the bottom right terminal Do not solder them yet 15 Connect one end of the orange crisscross wire to the top right terminal of the switch and connect th...

Страница 89: ...al and checking the connection Solder the two wires on this terminal 21 Check all terminals on the switch to make sure that there are no stray wire strands or solder bridges between the terminals The...

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Страница 91: ...e ends of all four wires Set the blue pair wires aside for later use in wiring the other port toggle switch 3 Secure the starboard right control switch or the whole control box if it is being used as...

Страница 92: ...EE TOGGLE SWITCHES SeaPerch ROV Construction Manual Version 2010 04NW 3 5 2 Figure 3 5 2 Horizontal Thruster Control Circuit Diagram Figure 3 5 3 Horizontal Thruster Control Toggle Switch Wiring Diagr...

Страница 93: ...s yet 10 Check to make sure that all four connections are tight and that the wires are out of the way of the other terminals and then solder only the top two connections allowing about 30 seconds betw...

Страница 94: ...terminal of the switch bending it around the terminal as before and similarly connect the other end of the wire to the bottom right terminal Do not solder them yet 22 Connect one end of the blue criss...

Страница 95: ...bridges between the terminals The wired switch should look like the other horizontal thruster switch similar to the one shown in Figure 3 5 1 but with blue pair wire colors If using the control box a...

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Страница 97: ...de the control box as shown in Figure 3 6 1 Orient them such that the ends with the tether wires connected are nearest the back power cable side of the box Turn them until straight and parallel instal...

Страница 98: ...the screws provided 5 Place the fuse in the fuse holder if it is not already in place but do not connect the battery until the testing in the following section has been completed A completed ROV syste...

Страница 99: ...l box and make minor adjustments 2 periods to review buoyancy concepts conducting a hands on buoyancy lab session is recommended determine the amount of ballast needed and install the weights 1 class...

Страница 100: ...s in the wrong direction or does not spin properly see Appendix A Troubleshooting Your SeaPerch ROV for some common solutions Students should try to solve the problems on their own before using that a...

Страница 101: ...r example when the ROV sent to the bottom at the deep portion of a swimming pool often 12 feet or more in depth it may no longer be able to return to the surface easily For this reason it is best to h...

Страница 102: ...heck After attaining neutral buoyancy it is helpful to quickly check that the ROV sits level in the water Simply hold it at a depth somewhere between the surface and the bottom let go and observe it f...

Страница 103: ...ect the thrust stability and maneuverability of the ROV Students should experiment with different thruster angles to find a configuration that provides both good forward thrust and good turning abilit...

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Страница 105: ...ystems to keep their body parts out of the water Keeping the water surface free of disturbance also makes the ROVs and their maneuvers much easier to see Batteries are heavy and if one is pulled off a...

Страница 106: ...e horizontal thrusters simply run at different speeds This can obviously affect the way the ROV moves forward as well as its ability to turn If the difference is significant changing a thruster by cut...

Страница 107: ...l as saltwater can be corrosive to thrusters and other metal parts Biologic or other materials picked up in natural marine environments can be damaging and difficult to clean off later if left to dry...

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Страница 109: ...erfere with any payload being handled by the ROV The ROV Always Seems to Turn More Easily to the Left or Right Check to see that the tether cable is mounted on the ROV in the center of the pipe on the...

Страница 110: ...or about one second at a time can sometimes get a thruster working Failed Thrusters If a thruster simply won t run or runs slowly it should be replaced with a spare thruster Always have a few spare th...

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