Name : Kavin Varma A/L Sukumaran

Student ID : 033236
Group Name : Robo Boys
Group Number : 16
Table of Contents
1.0 Return of Failure (ROF)

1.1 ROF 1 (Ultrasonic sensors)

1.2 ROF 2 ( Motor shield )
1.3 ROF 3 (LiPo battery)

2.0 Meeting Minute

2.1 Evidence 1
2.2 Evidence 2
2.3 Evidence 3
2.4 Evidence 4
2.5 Evidence 5
2.6 Evidence6
2.7 Evidence 7
2.8 Evidence 8

3.0 Team Analysis

3.1 Team analysis 1
3.2 Team analysis 2
3.3 Team analysis 3
3.4 Team analysis 4
3.5 Team analysis 5

4.0 Evidence
4.1 Concept of design
4.2 Coding

5.0 Conclusion
 SCHOOL OF ENGINEERING
PRJ 62404 ENGINEERING DESIGN AND ANALYSIS

Failure Analysis Form

Complete the sections below. You may expand the space and use diagrams and pictures as necessary

Ultrasonic sensors giving inaccurate readings

This error was was caused by technical reasons. The sensors were probably too old or faulty. We tested our
ultrasonic sensors on other groups Arduino and concluded that it was the sensors that were faulty.

Examine what was the Root Cause of the failure

Why did this failure happen?  Ultrasonic sensors gave wrong values
Why did it give wrong values?  The sensors were faulty
Why was it faulty?  Ultrasonic sensors were handled roughly
Why was it handled roughly?  No prior experience
Why no prior experience? Most of them had no experience in handling electronic components

Are there any other ways that you could have failed to achieve your objectives?

We could have also had a faulty Arduino and motor shield which might have gave us the wrong values.

Describe how you will use the insight above so that you eliminate or minimise the possibility of failure
in the future.

We should have checked the sensors when we got them right away and quickly come to a decision if we need
to replace them at the lab or purchase new ones.

What are the other key learnings from this failure?

I learned that we should handle the components with care and not roughly. Since it may spoil the components
and keep us behind on time.
 SCHOOL OF ENGINEERING
PRJ 62404 ENGINEERING DESIGN AND ANALYSIS

Failure Analysis Form

Complete the sections below. You may expand the space and use diagrams and pictures as necessary

Describe the failure or mistake that you are analysing

We had a faulty motor shield which was a technical error. We tried uploading our coding into the Arduino
connected to the motor shield and our robo car was moving in all wrong directions. We tested our coding on
another groups car and it worked perfectly fine. Hence, we decided that we need a new motor shield.

Examine what was the Root Cause of the failure

Why did this failure happen?  Faulty motor shield
Why faulty motor shield?  Very old and has been used alot of times
Why used alot of times? Used by previous semester students?
Why used by them and became faulty?  Mishandling and carelessness
Why careless?  Never considered that new students will be using them

Are there any other ways that you could have failed to achieve your objectives?
Our motor shield could have been spoilt because of the rain. Sometimes it rains when we walk back our
respective homes and the rain could have spoiled the motor shield since it has no cover over it.

Describe how you will use the insight above so that you eliminate or minimise the possibility of failure
in the future.

Handle the motor shield and arduino carefully and cover te car with suitable cover material to avoid rain
droplets from falling into it.

What are the other key learnings from this failure?

We have to all agree upon something before coming to decision instead of taking one without consulting other
members and groups.
 SCHOOL OF ENGINEERING
PRJ 62404 ENGINEERING DESIGN AND ANALYSIS

Failure Analysis Form

Complete the sections below. You may expand the space and use diagrams and pictures as necessary

Describe the failure or mistake that you are analysing

We assumed that our coding was wrong since our car was not making a perfect 90 degree turn. We
took alot of time figuring out on how to fix this error. Later on we discovered that it was caused
because of a weak battery.

Examine what was the Root Cause of the failure

Why was the battery weak ?  It had to be recharged.
Why recharged?  Needs more charge to perform the task of the robocar
Why is that so?  It was overcharged throughout the night
Why is it overcharged?  Forgot to remove from the charger.

Are there any other ways that you could have failed to achieve your objectives?
Battery could have exploded if the positive and negative terminals were connected wrongly.

Describe how you will use the insight above so that you eliminate or minimise the possibility of failure
in the future.

Be very careful as to how long we charge the battery and make sure the terminals are connected correctly
every single time. It is much better to use jumper cables which are black and red to make sure the connections
are done correctly.

What are the other key learnings from this failure?

We have to keep track of time on whatever we are doing so that we know when its time to undo something
crucial or not it could end up leading us into trouble
As seen our robo car looks like a compact 4 wheel drive car. We have decided together as a team to not
make an outer body for the robo car. The wiring of the car will be between the two chassis and the
Arduino will sit on the top. 3 ultrasonic sensors will be placed on the car. One at the front and two more
on the left and right side of the car. We also will be putting an IR sensor on the bottom of the car to detect
the black line. The DC motors are attached to the chassis using a bracket. But to ensure the chassis is
stable in its position we added double sided tape on the bottom of the motor so that its strong and stable.
We have also cut the back end of our car to reduce its size which on return reduces the possibility of it
hitting wall.
Final Design

This is the final design of the robocar. This figure is shown from the side left view of he robocar.We
have managed to complete the car according to iniatial design. Although we could not lay the wires in
between the two chassis as the wires were short and out of reach to the ultrasonic and IR sensors.Our final
design was agreed upon after conducting a SWOT analysis on every component of the car carefully. We
have used double sided tape to attach the ultrasonic sensors since it’s a cost saving method with the exact
same results of having a bracket.
Meeting Minutes

Evidence 1
Evidence 2
Evidence 3
Evidence 4
Evidence 5
Evidence 6

Evidence 7

Evidence 8

Team

Analysis

Evidence 1
Evidence 2
Evidence 3
Evidence 4
Evidence 5
Evidence 6
 Figure 3 shows Kavin assembling the chassis of the car and soldering the
motor wires

Figure 4 shows Sky Tan attaching the wheels to the chassis

Figure 5 shows Abdul Rahman soldering the wires and this was in fact his first
time soldering

Figure 6 shows Arvin soldering the motors with the wires

Figure 7 shows Kavin testing the car on the track and got a successful result.
Coding

[21:25, 21/11/2019] Mazin Taylors: int E1 = 10;

int M1 = 12;
int E2 = 11; ///////////////low/high(right)////high/low(left)
int M2 = 13;
char incoming_byte = 0;
int value = 0;
int irSensorFront = A1;
int Sensorvalue1 = 1;
#define echoPin1 2 // Echo Pin Front
#define trigPin1 3 // Trigger Pin Front
#define echoPin2 7 // Echo Pin Left
#define trigPin2 6 // Trigger Pin Left
#define echoPin3 8 // Echo Pin Right
#define trigPin3 9// Trigger Pin Right
long durationF, distanceF;// Duration used to calculate
long durationL, distanceL;
long durationR, distanceR;

void setup() {
Serial.begin (9600);
pinMode(trigPin1, OUTPUT);
pinMode(echoPin1, INPUT);
pinMode(trigPin2, OUTPUT);
pinMode(echoPin2, INPUT);
pinMode(trigPin3, OUTPUT);
pinMode(echoPin3, INPUT);
pinMode(irSensorFront, INPUT);
}

void loop() {
digitalWrite(trigPin1, LOW);
delayMicroseconds(2);
digitalWrite(trigPin1, HIGH);
delayMicroseconds(10);
digitalWrite(trigPin1, LOW);
durationF = pulseIn(echoPin1, HIGH);
distanceF = durationF * 0.034/2;

digitalWrite(trigPin2, LOW);
delayMicroseconds(2);
digitalWrite(trigPin2 , HIGH);
delayMicroseconds(10);
 digitalWrite(trigPin2, LOW);
durationL = pulseIn(echoPin2, HIGH);
distanceL = durationL * 0.034/2;

digitalWrite(trigPin3, LOW);
delayMicroseconds(2);
digitalWrite(trigPin3, HIGH);
delayMicroseconds(10);
digitalWrite(trigPin3, LOW);
durationR = pulseIn(echoPin3, HIGH);
distanceR = durationR * 0.034/2;

Serial.println("distanceF =");
Serial.println(distanceF);
Serial.println("distanceL =");
Serial.println(distanceR);
Serial.println("distanceR =");
Serial.println(distanceL);

////////// IR SENSOR////////
Sensorvalue1 = analogRead(irSensorFront);
Serial.print("FrontSensor:");
Serial.println(Sensorvalue1);

//////////COMMAND/////
if ((distanceF >= 15) && (distanceR >= 5) && (distanceL >= 5)) {
///FORWARD///
Serial.println("W");
digitalWrite(M1, LOW);
digitalWrite(M2, LOW);
analogWrite(E1, 75);
analogWrite(E2, 75);
}

else if ((distanceL >= 25) && (distanceF <= 25))

//left//
{
Serial.println("A");
digitalWrite(M1, LOW);
digitalWrite(M2, HIGH);
analogWrite(E1, 200);
analogWrite(E2, 200);
delay(300);

}
else if ((distanceL >= 13) && (distanceF >= 20)&& (distanceR <= 13))
/////////SLIGHT left/
{ digitalWrite(M1, LOW);
digitalWrite(M2, HIGH);
analogWrite(E1, 100);
analogWrite(E2, 100);
delay(180);
}
else if ((distanceF >= 20) && (distanceR >= 13) && (distanceL <= 13))
{ //SLIGHT right//
digitalWrite(M1, HIGH);
digitalWrite(M2, LOW);
analogWrite(E1, 100);
analogWrite(E2, 100);
delay(180);
}

else if ((distanceR >= 25) && (distanceF <= 25))

{////RIGHT////
digitalWrite(M1, HIGH);
digitalWrite(M2, LOW);
analogWrite(E1, 200);
analogWrite(E2, 200);
delay(300);

else if (distanceF <= 20)

{
digitalWrite(M1, LOW);
digitalWrite(M2, LOW);
analogWrite(E1, 0);
analogWrite(E2, 0);
delay(500);

if((Sensorvalue1>450))
{
digitalWrite(M1, LOW);
digitalWrite(M2, LOW);
analogWrite(E1, 0);
analogWrite(E2, 0);
delay(5000);

} }
[21:26, 21/11/2019] Mazin Taylors: int E1 = 10;
int M1 = 12;
int E2 = 11; ///////////////low/high(right)////high/low(left)
int M2 = 13;
char incoming_byte = 0;
int value = 0;
int irSensorFront = A0;
int Sensorvalue1 = 1;
#define echoPin1 2 // Echo Pin Front
#define trigPin1 3 // Trigger Pin Front
#define echoPin2 7 // Echo Pin Left
#define trigPin2 6 // Trigger Pin Left
#define echoPin3 8 // Echo Pin Right
#define trigPin3 9// Trigger Pin Right
long durationF, distanceF;// Duration used to calculate
long durationL, distanceL;
long durationR, distanceR;

void setup() {
Serial.begin (9600);
pinMode(trigPin1, OUTPUT);
pinMode(echoPin1, INPUT);
pinMode(trigPin2, OUTPUT);
pinMode(echoPin2, INPUT);
pinMode(trigPin3, OUTPUT);
pinMode(echoPin3, INPUT);
pinMode(irSensorFront, INPUT);
}

void loop() {
digitalWrite(trigPin1, LOW);
delayMicroseconds(2);
digitalWrite(trigPin1, HIGH);
delayMicroseconds(10);
digitalWrite(trigPin1, LOW);
durationF = pulseIn(echoPin1, HIGH);
distanceF = durationF * 0.034/2;

digitalWrite(trigPin2, LOW);
delayMicroseconds(2);
digitalWrite(trigPin2 , HIGH);
delayMicroseconds(10);
digitalWrite(trigPin2, LOW);
durationL = pulseIn(echoPin2, HIGH);
distanceL = durationL * 0.034/2;
 digitalWrite(trigPin3, LOW);
delayMicroseconds(2);
digitalWrite(trigPin3, HIGH);
delayMicroseconds(10);
digitalWrite(trigPin3, LOW);
durationR = pulseIn(echoPin3, HIGH);
distanceR = durationR * 0.034/2;

Serial.println("distanceF =");
Serial.println(distanceF);
Serial.println("distanceL =");
Serial.println(distanceR);
Serial.println("distanceR =");
Serial.println(distanceL);

////////// IR SENSOR////////
Sensorvalue1 = analogRead(irSensorFront);
Serial.print("FrontSensor:");
Serial.println(Sensorvalue1);

//////////COMMAND////
///FORWARD///
{
digitalWrite(M1, LOW);
digitalWrite(M2, LOW);
analogWrite(E1, 75);
analogWrite(E2, 75);
delay(2000);
digitalWrite(M1, HIGH);
digitalWrite(M2, HIGH);
analogWrite(E1, 0);
analogWrite(E2, 0);
delay(2000);
digitalWrite(M1, HIGH);
digitalWrite(M2, HIGH);
analogWrite(E1, 75);
analogWrite(E2, 75);
delay(1300);
digitalWrite(M1, HIGH);
digitalWrite(M2, LOW);
analogWrite(E1, 75 );
analogWrite(E2, 75);
delay(2000); }