Company Members

Amirali Akhavi ’14 - Electronics

Charles Fries ’14 – Programmer
Tyler Honnold ’14 – Research & Development
Nolan Schneider ’14 – Research & Development
Nicholas Sopwith ’14 – Head of Control Systems

Alexander Aprea ’15 – CEO

Jared Borg ’15 – Mill Operator
James Guidry ’15 – Engineer
Ryan Kenneally ’15 - Engineer
Matthew Woollgar ’15 – Head of Manufacturing

Benjamin Byers ’16 - Electronics

Patrick Horan ’16 – Lathe Operator
Collin Meissner ’16 - CADD
Killian Randle ’16 - CADD
Riley Unter ’16 – Engineer

Carson Black ’17 – Graphic Design

Jake Honnold ’17 – Technical Writer
1 PAGE ’17 - Engineer JESUITROBOTICS.ORG
Mentors
Matthew Kiyama
Sam Kriefels ’17 - Engineer Rolf Konstad – Head Coach
Cassidy Nguyen ’17 - Electronics Jay Isaacs –Senior Assistant Coach
I. Introduction
A. Abstract
Throughout history, humankind has used earth’s waterways for travel and trade. However,
water travel is often perilous, with heavy storms and icy waters overwhelming ships. If
conditions are right, such as those in Thunder Bay, these shipwrecks are remarkably well
preserved with their contents intact. Exploration of these wrecks helps to support ocean
research of the chemical and physical conditions found around the Great Lakes affecting
archaeological sites.

Rovotics has the capability and technology to explore shipwrecks of all types. A twenty person
company, Rovotics has the people, the experience, and the ability to deliver state-of-the-art
customized Remotely Operated Vehicles (ROV), designed to meet the mission requirements.
Efficiently organized into departments, including design, control systems, and manufacturing,
Rovotics utilizes program management methods and source code management systems to
streamline the development cycle. Advanced manufacturing capabilities include precision
machining with a Computer Numerical Control (CNC) mill, design and assembly of custom
printed circuit boards, and composites manufacturing.

For this mission, Rovotics presents its newest ROV, Predator. Predator is designed for
serviceability, safety, and performance including compact and fully accessible electronics, an
active buoyancy heavy lift device, and custom video subsystem.

This technical report details the development process and design details that make Rovotics’
Predator the best ROV for the MATE contract.

Figure 1 Rovotics with Predator

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Table of Contents
I. Introduction ........................................................................................................................... 2
A. Abstract ........................................................................................................................... 2
II. Design Rationale .................................................................................................................. 4
A. Mechanical Design Process ............................................................................................ 4
B. Vehicle Systems…………………………………………………………………………………..4
C. Frame………………………………………………………………………………………………..5
D. Thrusters .......................................................................................................................... 5
E. Buoyancy .......................................................................................................................... 6
F. Housing ............................................................................................................................. 6
G. Electronics ....................................................................................................................... 7
H. Programming.................................................................................................................. 11
I. Mission Specific............................................................................................................... 13
III. Safety ................................................................................................................................. 17
A. Company Safety Philosophy ......................................................................................... 17
B. Lab Protocols ................................................................................................................. 17
C. Training ........................................................................................................................... 17
D. ROV Safety Features ...................................................................................................... 17
E. Safety Checklist.............................................................................................................. 18
IV. Logistics ............................................................................................................................ 18
A. Schedule and Company Structure ................................................................................ 18
B. Source Code Management ............................................................................................ 19
C. Budget…………………………………………………………………………………………….19
V. Conclusion ......................................................................................................................... 19
A. Challenges ...................................................................................................................... 19
B. Troubleshooting Techniques ........................................................................................ 19
C. Lessons Learned and Skills Gained ............................................................................. 20
D. Future Improvements..................................................................................................... 20
E. Senior Reflections .......................................................................................................... 20
F. Acknowledgments .......................................................................................................... 21
G. References ..................................................................................................................... 22
VI. Appendices…………………………………………………………………………………………23
A. Safety Checklist….………………………………………………………………………………23
B. Budget……………..………………………………………………………………………...……24
C. Software Flowchart……………………….…………….………………………………………25

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II. Design Rationale
A. Mechanical Design Process
In order to maximize the efficiency of the design process, we use a multi-step approach, which
allows the team to earlier envision the end result. This reduces the number of design iterations.
The first step is to sketch out the concept on a whiteboard during the brainstorming phase
(Figure 2). For more complicated pieces, where dimensions and shape are significant,
cardboard mock-ups are built to create a physical representation. During this step, various
ideas are shared and discussed while necessary changes are incorporated until the desired
configuration is achieved.

Once the design team has

validated the concepts through
sketches and mock-ups, a
detailed Computer-Aided
Design and Drafting (CADD)
model in either 2D or 3D, based
on need, is fashioned utilizing
Figure 2 Whiteboard Design for
Figure 3 Buoyancy Design Review Draftsight or SolidWorks,
Buoyancy respectively (Figure 3). For
parts targeted for production on the CNC mill, the CADD models are converted in a Computer
Aided Manufacturing (CAM) package, SheetCam. Using SheetCam, engineers generate the “G-
Code” tool path files from the drawings, which are then loaded into the “Mach 3” machine
control software.
For some custom parts, CADD drawings are printed 1:1 as
templates for jigs. For example, the side buoyancy profile
was printed and glued to a piece of plywood which in turn
was used as a hot wire form cutting template (Figure 4).

B. Vehicle Systems
Predator is a completely new ROV and an original design.
Our experience told us that producing our own thrusters and

Figure 4 Cutting Buoyancy with hotconnectors would divert us from the primary purpose of
wire building the ROV and its mission accessories. Therefore,
Rovotics has carefully balanced the use of original and commercially sourced components in
Predator. Details of each subsystem will be discussed in the document.

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C. Frame
Based upon multiple years of design
experience, Rovotics understands the value of
a sturdy and versatile frame. This year’s design
focuses on safety, serviceability and
functionality.

The frame (Figure 5) is constructed from a

combination of aluminum, high density
polyethylene (HDPE) and clear polycarbonate.
The design calls for an open frame which
provides reduced drag and minimal

obstructions to thrust. Two flat working areas Figure 5 Predator Open Frame Design

provide easy access to accessories and

electronics. The bottom and top sections of the frame are capable of being separated for easy
serviceability during testing, practice, and competition.

The bottom half of the frame is clear to enable unimpeded visibility for the pilot through
downward looking cameras during the mission. Accessories are positioned on the lower frame
for functionality and easy access for serviceability.

A dramatic new feature is that the electronics can, positioned on top of the ROV, is completely
detachable without having to disconnect any of the electronics or tether. This feature allows the
electronics to be tested and observed with full visibility while the ROV is powered on in mission
configuration. See section F, for more details.

D. Thrusters
Predator operates with six reliable SeaBotix BTD150 thrusters,
with one horizontally mounted thruster on each of the four
corners of the frame to allow more space for accessories and
minimize thruster wash interference and two vertically mounted
thrusters at approximately the center of the buoyancy. Each
thruster provides a maximum of 28.4 Newtons (6.38 lbf) of
thrust with a sustainable thrust of 20 Newtons (4.49 lbf) (Figure
6). With an operating voltage of 19V DC and a maximum
operating current of 4.2AMPS, each thruster fits well within
Figure 6 Forward and Reverse Thrust
Predator’s power budget (Figure 11). For safety and
equipment protection, grates mounted in front of each thruster’s intake prevent cabling, foreign
objects and appendages from getting sucked into the thrusters.

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E. Buoyancy
Predator is outfitted with a buoyancy float system
specifically designed to neutralize the ROV
buoyancy. The weight in water of the ROV, before
the addition of the float, was 42.6 Newtons (9.58
lbf). The float, made of Styrofoam® coated by a
durable fiberglass shell, provides 44.1 Newtons
(9.91 lbf) of buoyancy, compensating for the
vehicle wet weight and adjusted so the vehicle
floats in a level attitude. Figure 7 Three Part Buoyancy

The three piece design (Figure 7) provides a sleek, lofted curve, with rounded corners to
prevent snags on cabling, and raised sections around the thrusters to provide a safe zone to
prevent injuries or thruster damage during operation. The two side pieces on the ROV provide
primary buoyancy while the third removable front piece can be filled with air to lift the Danforth
anchor from the seafloor (See Danforth Anchor Recovery for more information).

Final dimensions were adjusted in SolidWorks to achieve the appropriate amount of buoyancy.
To fabricate, our engineers made simple wooden guides with the contour profile, then carefully
cut the Styrofoam® block with an electrically heated wire guided by the jig. The foam block was
then fiberglassed using an epoxy resin, sanded smooth and painted bright yellow for safety.
Once mounted, the buoyancy float was fine-tuned with small weights where necessary to
achieve neutral buoyancy and level attitude.

For the tether, adjustable floats were fitted at regular intervals to insure it maintains proper
buoyancy, providing easy tether management and increasing operational stability. The section
of tether closest to the ROV was made neutrally buoyant in order to avoid snagging on the ship
and threatening the success of the mission.

F. Housing
Predator's innovative cuboid welded aluminum pressure housing was specifically designed to
allow for better volumetric efficiency, a more compact ROV for maneuvering in shipwrecks, and
to allow unimpeded access to vehicle electronics for excellent serviceability. Electronic
components tend to be cuboid therefore they can be more densely packed into a cuboid
enclosure than a typical cylindrical enclosure, minimizing the size of the housing. In previous
year models, the electronics were removable from a fixed housing but could not be tested while
installed in the vehicle. To address this limitation, our electronics are now fixed to the vehicle
while the upper housing is removable to allow full access for testing (Figure 8).

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The bottom pressure vessel serves as a hub for all vehicle connectors. Its cuboid shape allows
for many connectors and its position below the main electronics can provides addition reliability
in case of a leak from a connector penetration. The under-vehicle location eliminates any
cabling from the top of the vehicle that could impede access to the electronics during servicing.

The two pressure vessels are connected via an interconnect tube and all sections are sealed
using a 3.175mm (0.125 in) O-ring in a face seal configuration. Welding was outsourced to a
commercial service as we do not have the capability or equipment in-house.

Figure 8 Two Part Pressure Hull

G. Electronics
This section describes Rovotics’ Predator overall electrical design including a Tether Control
Unit (TCU) on deck, tether connecting to the ROV, and onboard electronics.

Tether Control Unit

The Tether Control Unit (TCU) controls power, communications,
pneumatics and video distribution for the entire ROV system and is a
key element of our overall system safety (Figure 9).

To activate the ROV, the 30A circuit breaker on the TCU must be closed
and the main power switch, turned on. The power switch is a safety
feature insuring no accidental operation of the ROV. In addition to the
circuit breaker and the main power switch, there is a power toggle Figure 9 Tether Control Unit
button for all major networking components inside the TCU. One high
capacity step down power regulator (48VDC to 12VDC) is used to power the embedded

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 Figure 10 TCU Electrical Schematic

electrical components (Figure 10). Voltage and current meters allow the co-pilot to monitor for
power issues, such as discharged batteries and short circuits.

Of the two video signals from Predator, one goes to an internet protocol (IP) video server (AXIS
241S) and the other goes to an integrated monitor. Two video signals allow for multiple camera
feeds to be displayed at once and increased situational awareness. The IP video feed is
displayed on the control laptop so pixel measurement software image analysis can be
performed on the shipwreck.
The TCU’s integrated monitor allows the co-pilot to view video without looking away from critical
safety components. This video feed may also be viewed on a secondary monitor if necessary.

All networking with the ROV is handled by a Netgear router and switch, providing Ethernet ports
for the ROV’s tether and command laptop.

Our pneumatics are operated by a simple push button on the TCU which activates a solenoid
connected to a pneumatics line. This design allows for easy use during the mission.

Our TCU is built in a convenient robust carrying case for portability. The top lid opens exposing
the integrated monitor and the controls described. All electronics are housed in a pull out
drawer for easy servicing.

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 Tether
Our tether connects the ROV and TCU together, carrying all power, data, video signals and
pneumatics. The tether consists of a single CAT5e Ethernet cable for data, dual 12 AWG
conductors for power and ground, two Belden 735A coaxial cables for video and a 6.35mm
pneumatics line for certain accessories. All lines are wrapped in a polyethene sheath for
safety, abrasion resistance and ease of handling. The tether is connected to the ROV via
Subconn waterproof connectors and is strain relieved to allow unpowered vehicle recovery.

The Ethernet cable was selected due to the ability to carry signals more than 90m. The Belden
video cables were selected due to their 75 ohm impedance for video quality, reduced
interference, flexibility and small diameter (3.5 mm). The pneumatics tubing is rated at 1379
kPa, well above the operational pressure of 275 kPa, and has proven to provide sufficient
airflow by in water testing.

To ensure robust power delivery, our tether conductors were sized using an online calculator4,
to ensure we maintained sufficient voltage at the ROV power converters during maximum
power operation to avoid brown outs. The calculations predicted a total resistance of 0.16
Ohm, which would result in a minor 4.8V voltage drop at the maximum circuit breaker rating of
our system of 30A per Ohm’s Law. This would result in a supply voltage of approximately 43V
at the ROV power converters, well above the minimum 36V input voltage required6.

Electronics:

When Rovotics designed the electronics

system, the main goals were safety,
functionality, serviceability, compactness,
video quality, and robust power. Safety is
always our first priority in all of our systems at
Rovotics to insure employee and work
environment safety. We used CADD to
Figure 11 Predator Power Budget
optimize wire layout, routing, and to efficiently
utilize stacking volume. Video quality was enhanced by utilizing shielded coaxial cable to match
impedance and reduce interference. This year we added a third power convertor to
accommodate our six thrusters and numerous accessories.

The main vehicle electronics assembly has three stages of power conversion. The primary 48
volt to 19 volt power conversion is done by three 280 watt Zahn DC to DC power converters
(Zahn Model DCDC48/24/280). Each power converter supplies one of the three dual channel
Sabertooth speed controllers that control the six Seabotix thrusters. Each Zahn power converter
also provides a power source for a portion of the secondary control systems. The secondary

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power conversion of 19 volt supply from the Zahn is dropped down again to 12v, which is our
standard supply voltage for our logic control system (Figure 15).

Our primary control electronics consists of three Arduino microcontrollers (designated ROV1,
ROV2, and ROV3) and a Netgear Ethernet switch. The Arduinos each controls certain aspects
of our communications, sensors, and control systems. The 5 port
Netgear switch provides Ethernet ports to ROV1, ROV2, and the
topside system via the tether.

ROV1, an Arduino Ethernet, controls the motors and video

switchers and communicates with the topside software via
Ethernet. It also acts to relay commands to ROV3 via a serial bus
link.
Figure 12 ROV2 Custom Shield

ROV2, another Arduino Ethernet, gathers all the sensor data,

including voltage, current, salinity, and leak detection. Two dual
Phidgets SSR relays are used to control our accessories.
Figure 13 Etched Lead
Detection Board
ROV3, an Arduino Mini Pro, controls all mission
accessories through packets sent from the topside
through a serial bus link with ROV1.

ROV1 and ROV2 are each fitted with Rovotics

custom designed and built breakout shields, which
streamlines the wiring of the control system
Figure 14 Rovotics Designed Custom 8 Channel (Figure 12).
Video Board2

The leak detector connected to ROV2 was fabricated in-house using CADD and a laser printer
pattern which was then transferred to a copper clad board, etched, and cleaned (Figure 13).
The etched copper fingers act as a variable resistor in a voltage divider with a 10M pullup
resistor to 5V. ROV2 can sense the voltage in the middle of the divider which will vary if the
copper finger are wet or dry. ROV2 sends the voltage reading to Torpedo which will alert the
co-pilot to a leak if the value is outside of a certain range. For example, if the detector is dry the
voltage reading sent to the topside would be 5V. If moisture results in a 10M resistance
across the copper fingers, then the voltage reading sent to the topside is 2.5V.

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 The two 8 channel Rovotics custom video switch boards controlled by ROV1 change the
camera feed sent to the topside to allow for multiple views of mission specific accessories. On
Predator three cameras are attached to each board. Each board utilizes shielded coaxial cable
connections to match impedance and reduce interference as well as power filtering in order to
protect sensitive video electronics (Figure 14).

Figure 15 Main ROV System Interconnect Diagram

Internally all components are wired with silicon coated wire for its current carrying capability and
its flexibility, making it easy to route through the chassis. This year all of our video lines are RG
179 Coaxial to provide noise immunity from the speed controllers in the ROV.

H. Programming
Rovotics uses a dedicated topside laptop for joystick and co-pilot inputs, embedded controller
on board the ROV, and User Datagram Protocol (UDP) packets for communication. UDP
broadcasting keeps the control system simple and robust with no end point IP address, so any
team device can view the status of the ROV’s main systems as listeners on the network.

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Top-Side Code
Predator is controlled via a laptop running a C++ application, “Torpedo,” written in Qt Creator.
Torpedo is controlled through a Graphical User Interface (GUI) and a joystick (Figure 16). The
goal during development was to give the pilot and co-pilot complete and intuitive control over
Predator. This freedom of movement was accomplished by a unique vector drive algorithm and
state-of-the-art control system. Torpedo has a
GUI to display information from the ROV's
communication network and to accept
commands from the co-pilot. Torpedo was
developed from the ground up to be user
friendly and easy to debug, reducing required
training time and expediting the development
cycle. In the case of a communication loss or
joystick disconnect, Torpedo promptly alerts
the co-pilot with an alert message, so the co-
pilot always knows the status of the entire
Figure 16 Command Program GUI control system.

Vector Thrust Control

Predator's motor layout, with four horizontal thrusters mounted at 45 degree angles on each
corner, lends itself to using vector thrust control. The joystick's x, y and z axes are read and
then mathematically rotated 45 degrees to match the layout of the motors. By using vectored
thrust, Predator has an incredible amount of maneuverability as it can rotate in place, strafe in
all directions, and reliably execute complex combinations of rotational and lateral shifts. A user
adjustable dead zone prevents the analog joysticks from allowing the ROV to wander when the
joystick is near neutral. The joystick utilizes a bilinear reading scale, allowing for gradual,
precise motions when docking, with an intuitive progression to full speed sprints when moving
to the worksite.

Bottom-Side Code
The processing of the bottom-side code is completed by three Arduino microcontrollers: ROV1,
ROV2, and ROV3. The firmware is written in the Arduino variant of C++.

ROV1 controls the thruster speed controllers, relays commands to and from ROV3, and
controls the video switching circuit boards. ROV1 receives the UDP packet with the motor
values for the six thrusters, the desired video channels for each board, and the accessory
values. Before outputting the thruster values received from the topside, the ROV1 software first
checks those values to make sure they are within the safety parameters of the thrusters, then
outputs them as PWM (Pulse Width Modulation) signals. To switch video channels, the ROV1
software first takes the desired video channel it receives from the topside, and determines

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which board the desired channel is on. A three bit binary pattern is decoded to determine which
of the 8 channels to enable.

ROV2 is the primary telemetry system on the ROV, and reads and returns the data from the
onboard sensors. ROV2 is capable of taking data from an inertial measurement unit reporting in
real time the ROV's attitude in the X, Y or Z direction. Additionally Predator has the capability to
measure internal temperature and humidity, detect leaks, and take current readings from each
of the main power converters.

ROV3 is a serial bus slave off of ROV1 and controls Predator’s existing mission specific tools
with room to grow. All commands are originally sent to ROV1 and then transmitted via a serial
link to ROV3. ROV3 has the capability to trigger two 12V 9A relays, two 19V 9A relays, and one
5A dual channel bidirectional Sabertooth motor controller.

For safety, ROV1, ROV2, and ROV3 disable all thrusters and accessories if communications
are lost with the topside, but resume operation if communications are restored. Another safety
feature includes, our leak detector indicator, which can alert the co pilot to the presence of
moisture in the electronics can.

I. Mission Specific
Rovotics’ Predator is a custom-built ROV uniquely suited for the exploration of shipwrecks,
scientific analysis of the surroundings and site conservation jobs. Predator’s mission will be
divided into three separate tasks. Task 1: Measure the length, width, and height of the
shipwreck; correctly scan the shipwreck at three target locations; create a photomosaic from
five locations; determine the type of ship; determine shipwreck’s cargo; enter the shipwreck;
locate and determine the ship’s build date; recover a dinner plate with port of call; and
ultimately, identify the ship using Predator’s vision, sonar, and remote sensing systems. Task 2:
Measure the conductivity of the ground water, retrieve a microbial mat sample, recover and
replace a sensor string, and estimate the number of zebra mussels on the wreck. Task 3:
Remove two bottles, an anchor line, and the Danforth anchor from the seafloor. Details of
Predator’s mission specific tools, set forth below, describe how each of these tasks will be
completed.

Measuring the Length, Width, and Height of Ship

Underwater measurements will be determined by scaling screen shots of the underwater
shipwreck. On the screen shot, a pixel dimension will be taken of a known object, followed by a
pixel measurement of an unknown object using a software package called “PixelStick”5 (Figure
17). By using a known dimension, the unknown dimension can be solved quickly using an
algebraic formula. To calculate the length and height of the ship we are using the 75cm by 75
cm hole on the side of the ship as the known measurement. For the width, we are using our
custom zebra mussel grid for the known measurement.

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For example, calculating the ship width by using the known size
of the hole in the side of the ship.

325 𝑝𝑖𝑥𝑒𝑙𝑠 (𝑝𝑜𝑟𝑡ℎ𝑜𝑙𝑒) 1275 𝑝𝑖𝑥𝑒𝑙𝑠 (𝑠ℎ𝑖𝑝 𝑤𝑖𝑑𝑡ℎ)

=
75 𝑐𝑚 (𝑝𝑜𝑟𝑡ℎ𝑜𝑙𝑒 𝑘𝑛𝑜𝑤𝑛) 𝑥 𝑐𝑚 (𝑢𝑛𝑘𝑛𝑜𝑤𝑛 𝑠ℎ𝑖𝑝 𝑤𝑖𝑑𝑡ℎ)
1275 𝑝𝑖𝑥𝑒𝑙𝑠 𝑥 75 𝑐𝑚
= 294.23 𝑐𝑚 𝑠ℎ𝑖𝑝 𝑤𝑖𝑑𝑡ℎ Figure 17 Measuring Pixels
325 𝑝𝑖𝑥𝑒𝑙𝑠

Scanning Ship Target Locations

To complete the scanning of the ship target locations the ROV will traverse the ship from the aft
to the bow. To insure a uniform visual of the black rings at each of the target locations, via the
onboard cameras, the pilot will maintain a constant depth while traversing the ship. This will
also position the ROV to take the five pictures needed to create a photomosaic of the ship.
Predator is equipped with a light bar for better picture quality.

Estimation of Number of Zebra Mussels on Shipwreck

By counting the number of mussels present in the area encompassed by a premeasured grid
that we will place on the shipwreck, we are able to estimate the total number zebra mussels on
the entire ship using mathematical ratios.

Plate Recovery
To retrieve the plate on the seafloor, a gear-rotating motor spins a
rod towards the ROV. This rod is comprised of spokes made from
plastic tipped springs which move the plate toward and into the
basket. When the motor is off, these fingers prevent the plate from
falling out of the basket. Through testing we discovered that, by
using an opposing spiral pattern of fingers instead of a continuous
Figure 18 Plate Pickup
spiral, we greatly improved the speed and reliability of the plate
acquisition (Figure 18). The co-pilot activates the motor through Torpedo.

Measuring Groundwater Conductivity

A salinity sensor is mounted on a cone made of clear
polycarbonate for pilot visibility and easy alignment (Figure 19).
The salinity sensor uses two prongs on the end of the probe
which send electrical signals to each other to measure the
conductivity of the water. A voltage divider circuit which includes
the conductivity sensor and a 10kΩ resistor is energized by
setting a digital output to HIGH. The voltage from the divide is
Figure 19 Conductivity Sensor
sensed by ROV2 and transmitted to Torpedo for display on the

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GUI. A portion of the 5V from the digital output is dropped across the conductivity sensor, and
the remainder is dropped across the 10kΩ resistor:

Microbial Mat Sampling

Using a cylindrical tube with a wire across the opening to cut and retain the sample from the
cup, we land on top of the microbial mat sample and rotate the ROV. This rotation allows the
wire to cut the base of the sample which is then retained in the tube for transportation to the
surface.
Sensor Line Recovery
To recover the sensor line, our ROV features a hook with a tapered
notch for ease of retrieval (Figure 20). This simple attachment is
made from smoked polycarbonate to allow for pilot visibility in clear
water. This device is attached to the Danforth anchor recovery
assembly to utilize active buoyancy for assistance in lifting the sensor
from the seafloor. Figure 20 Sensor Line Recovery

Bottle Recovery
Our bottle retrieval device is located on the bottom of our ROV. This
tool features a mechanical design comprised of a spring loaded
bottom side gate, which opens from pressure caused by the ROV
landing on the bottle, without the need for electrical or pneumatic
actuators (Figure 21).
Figure 21 Bottle Recovery Device
Danforth Anchor Recovery
In assessing the mission requirements, we determined that the retrieval
and recovery of the Danforth anchor was going to be one of the most
difficult tasks. In order to accomplish this, we designed a fully
removable module with active buoyancy to neutralize the weight of the
3.6 kg anchor. This module consists of a custom, rigid "lift bag"
matching the volume required to lift the anchor, which is attached to the
top of a removable frame on the face of the ROV (Figure 22). Two
carabineers are located on the bottom of the frame which lock securely
to the main support of the anchor. Once the anchor is acquired, the Figure 22 Danforth Anchor
Recovery Accessory
"lift bag", which is centered over the lift points to avoid destabilizing the
ROV, is then inflated with compressed air from the surface. Small holes in the top of the "lift
bag" allow for venting of excess air. When the ROV returns to the surface, the entire module,
including the anchor, can be quickly removed so that the ROV can immediately return to the
work site. This design was chosen over a traditional lift bag to simplify vehicle operation and
poolside retrieval.

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Anchor Line Recovery
Predator has multiple capture devices and, depending on the orientation of the debris and ROV,
the pilot can select the best tool to retrieve the anchor line and return it to the surface. Predator
is also capable of handling multiple retrieval tasks at once thereby minimizing the number of
surface trips required. For example, the sensor line retrieval
can be completed in conjunction with the anchor line recovery.

Ship Identification
Predator utilizes a high beam light bar and a wide angle,
pannable camera, which allow the pilot to identify the
manufacture date inside the hull, determine the nature of the
cargo, and thoroughly scan the debris field for additional
identifying artifacts.
Figure 23 Forward Pannable Camera
Mission Specific Cameras and Vision System Pod

Predator is equipped with multiple camera and vision systems making it uniquely fitted for
recording and analyzing archaeological sites. The front main 140 degree wide angle camera is
mounted on a digital servo making the camera vertically pannable 180 degrees (Figure 23).
The servo responds to either joystick hat buttons or preset values depending on mission tasks
selected from the command software. The benefit of a
pannable camera is that it provides the same
functionality of 4 static cameras. The camera modules
are sealed with clear acrylic housings with bayonet O-
ring seals for easy accessibility. The main camera is
linked to an IP video server streaming real time video.
This video stream can be picked up by any standard
web browser, allowing the mission specialist to take
screenshots and generate the printed mosaic of the
shipwreck. Along with pixel analysis software, ship
dimensions can be determined easily.
Figure 24 Potted Camera CADD

Our static system is comprised of four wide angle, 120 degree cameras, each contained within
a custom aluminum housing with a polycarbonate front panel and a strain relief back, and
potted with a clear compound to prevent leakage (Figure 24). The four cameras are
strategically placed on the ROV to provide the maximum amount of visibility. NTSC cables link
the cameras to the video display system. An additional advantage of our custom system is its
cost benefit to the customer, as our system is less expensive than commercially-produced
cameras.

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III. Safety
A. Safety Philosophy
Safety is the highest priority for Rovotics. Through our rigorous safety
procedures and requirements, we were able to remain accident free this
year.

B. Lab Protocols
To insure the utmost safety while operating in the lab and on the ROV,
specific safety procedures were implemented. Safety glasses and closed
toe shoes must be worn at all times in the lab. Cords are kept out of
aisles and walkways to keep the area neat and prevent tripping. When
operating machinery, especially the belt sander, where hands could be
Figure 25 Cutting Bulk
caught in dangerous rapidly moving parts, team members are prohibited Aluminum
from wearing gloves. Proper shields and enclosures are in place around allUnderUSupervision
machines that could
throw chips during operation. Our new lab facilities include a chemical vent hood, so all
soldering can be completed with minimal fume exposure.

C. Training
Rovotics trains through a peer-to-peer system. New employees are required to spend their first
meetings observing veteran members operate the machines. Thereafter, they are able to start
operating the machines under the supervision of senior members who will guide them and
assure that they comply with safety procedures (Figure 25). This culmination of observation,
training, and practice has proven to be an effective method in teaching new employees proper
adherence to safety protocols.

In addition all members are responsible for policing each other to make sure everyone is
complying with company standards. An example of an incident this year was when a member
neglected to wear safety glasses while soldering a wire connection. Company members who
observed this breach jointly agreed to make him write, “I will not take off my safety glasses” 50
times on the whiteboard insuring the mistake was never made again.

D. ROV Safety Features

With soft skids and smooth edges, Predator contains numerous safety features designed to
keep the crew, ROV, and work environment safe during operation. In addition to electrical
protection and software safe modes discussed in previous sections, mesh netting and motor
shrouds cover the thrusters. The buoyancy float which was formed to protect the vertical
thrusters from impact further protects people near the ROV from the spinning blades. The four
aluminum supports for the unique frame act as handles for ease of moving the ROV and to
prevent injury to company members during ROV transportation. Various waterproofing
techniques insure all electronics remain dry, keeping them operational and protecting both

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personnel and equipment from short circuits. In the event of leakage, a leak detector monitored
by one of our Arduinos detects moisture in the main electronics can and alerts the pilot to shut
down and return to the surface.

E. Safety Checklist
Predator must pass a company-drafted safety inspection protocol before the crew may attempt
to operate the ROV. The safety inspection involves insuring that the electronics and thrusters
function properly, that Predator is leak-free, and that all Rovotics employees and the working
environments are free from potential harm. The safety checklist is located in the Appendices
section (VI-A).

IV. Logistics
A. Schedule and Company Structure
To insure that Predator was fully prepared for the MATE competition, the Rovotics leadership
used a Gantt chart (Figure 26) to guide their decisions regarding allocation of resources and
time. The CEO delegated responsibility for the construction of specific components, such as
custom video boards and software, to the heads of each department who, in turn, led new
members in the development of each part. Leads were also chosen to oversee the completion
of the technical report and poster who, in turn, delegated specific sections to members in the

Figure 26 Gantt Chart

respective departments. Every workday began with a kickoff meeting during which we went
over the tasks scheduled for completion that day. Midday progress reports were given from
each department to track task completion. Closing meetings identified the tasks that had been
completed and those that would be carried over to the next week. If parts were not completed
on time, company members would work throughout the week to complete the parts. As our
company meets only once a week, we viewed weeks as days to insure that all departments
remain productive all year. While mentors were present for technical guidance along the way,
they did not work on the vehicle or its components.

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B. Source Code Management
To better manage concurrent development of software, CADD models and other computer files,
Git is used as the company’s Version Control System (VCS). By using a VCS, the company can
keep track of every change made to every file, from Predator’s source code to Predator’s CADD
files. Git was chosen because it is a well-supported and highly polished Distributed VCS
(DVCS), meaning there is no central repository and each client has a local copy of the full
repository. Git has proven especially useful when multiple people are working on the same
document and allows us to revert to the last working copy in the event an error is made in a
flowchart or CADD. Detailed commit messages help us to insure that all departments are
making progress. By using Git, we have been able to simplify file management and version
control this year.

C. Budget
As a high school company, Rovotics must operate on a limited budget. The majority of our
funding comes from Jesuit High School, school-run fundraisers, and the donations of services
or equipment. Including the value of reused parts and resources used in research and
development, Predator came to a total of $7,485. The six SeaBotix thrusters themselves
account for almost half of the overall expenditures. In addition to the money we spent
developing Predator, Rovotics’ budget is required to provide for travel, tool purchases and
replacements, and general maintenance of the workshop. The full budget is located in the
Appendices section (VI-B).

V. Conclusion
A. Challenges
One of Rovotics’ main challenges this year was relocating to a new lab facility during the peak
of our build season. The decision was made to completely shut down for a three day period and
devote our energy to the move. The goal was to do a major house cleaning, move and
reorganize our equipment, and be fully operational for the following weekend.

A second challenge Rovotics faced was improving our video quality. In the past, we have
always been plagued with a high degree of video interference from electronics components,
particularly the electronic speed controllers. Our video signal would have ghosting, reflections
or interference lines from noise. This year we completely rebuilt our video systems with a new
video board and ground shielding, and all coaxial cable from camera to monitor. Early
production testing has resulted in excellent video quality this year.

B. Troubleshooting Techniques
For Predator to remain operational, its electronics must be kept dry. Previously we would leak
check by dropping the ROV, unpowered, to the bottom of the pool and inspect for water once it
was retrieved. Now, Rovotics’ engineers have developed an innovative and efficient technique.

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After sealing all openings, the ROV’s containers are pressurized to double the operational
depth’s pressure and then sprayed with soapy water, which produces bubbles at leak points.
We do this in the workshop during each pre-mission ROV test, thereby reducing the overall time
needed to waterproof the housing. This check is performed using a special sealing window
fitted with a Schrader valve. If leaks are discovered, Rovotics’ engineers quickly fix them and
identify any manufacturing issues.

C. Lessons Learned and Skills Gained

Rovotics always strives to learn from its failures and improve on its successes. A critical
component of the company’s consistent success is actively applying lessons learned in
previous years and adding them to a continuously growing knowledge base.
Each year we start with a preseason project that addresses a deficiency that we select from the
previous year. This year, we chose to upgrade our video transmission system. We consulted
with a professional video engineer who demonstrated the benefits of using shielded cable to
protect video signals and made a number of recommendations for cabling and connectors that
we integrated into this year’s design process.

In the days leading up to the competition, we learned that no one person can complete all
mission preparations, so we relied on each other to make the vehicle ready for competition.

D. Future Improvements
Rovotics will continue to reduce the complexity of interconnections between electronic devices.
This year, Rovotics developed two Arduino daughter boards and a custom video board. Next
year, Rovotics plans on developing and manufacturing a single board containing bi-directional
motor controllers and solid state relays for accessory control. With the successful integration of
an IP video server with very low frame latency, Rovotics plans to continue researching and
implementing IP Video to reduce video hardware components.

E. Senior Reflections
I would like to thank MATE for allowing us to compete in their ROV competition. I would also
like to thank Jesuit High School for the opportunity to join a team where I can participate in such
a prestigious event. This experience on the robotics team has taught me many technical skills
such as machining, public speaking, CADD, and programming along with meeting some great
people, so I would like thank the coaches and fellow teammates I have met over the years.
Through my experience here, I have decided to major in mechanical engineering. In a sense,
my high school experience has been partially defined by my presence in the robotics program. I
will take all the skills that I have learned and apply them to college and my future.
-Amirali Akhavi

Looking back on my experience, I would like to thank Jesuit Robotics for giving me the
opportunity to participate in this amazing program. It is not customary for a high school junior to

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join the team, and I am incredibly appreciative for the chance to prove my skills. Starting on the
team as a junior, I learned the intricacies of CNC milling, working on large software
applications, and the careful process of creation and revision while learning to be a computer
scientist. Managing the topside software aspect of the team, I learned valuable efficiency skills
and code management. Beyond just the technical skills, I have gained many cherished
memories as a part of this team. I especially want to thank the coaches and the members of the
Jesuit Robotics Team.
-Charles Fries

I would like to thank the MATE Center and all those who dedicate their time to this competition.
The environment and experience that has been created and cared for by the MATE Center has
provided me with rewarding experiences that challenged me and gave me some of the most
rewarding memories of my life. Since I started with the team sophomore year, I have learned
many skills involved in producing a complex ROV in a team environment. Leaving the team, I
realize that I have learned more than just the physical engineering lessons. I have gained many
great memories working with my team members and interacting with the other teams at the
MATE competition.
-Ty Honnold

Thanks to all my teammates, coaches, parents, and MATE. My time on the Jesuit Robotics
Team has been great. I have gained many skills and experiences and my participation has
been one of the most educational and rewarding experiences of my life. This involvement has
influenced me and pushed me in a certain direction for my career. With all these skills and
lessons learned in the last three years, I will continue to learn and be interested in robotics and
engineering.
-Nolan Schneider

Thanks to all the students, parents, coaches, and especially MATE for making the robotics
program at Jesuit possible. As a fourth year member, I've been given the opportunity and
motivation to further a dream into something that will remain a lifelong passion. With the skills
that have developed in me, I have insured a successful future in the electronics industry, and I
plan to stay within the robotics field as well. I plan to major in electrical engineering as a result
of the interest that I have further worked on in MATE competitions.
-Nick Sopwith

F. Acknowledgments
Rovotics’ would like to thank the following benefactors:

 MATE and Marine Technology Society’s  Jesuit High School - For the generous
ROV Committee - For sponsoring this donation of a new lab space and
year’s ROV competition support

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  Rolf Konstad, Head Coach - For his  Justin Hall - Jesuit High School
countless hours of wisdom, time, and Activities Coordinator
patience for the past four years
 Jim Claybrook, “Weldmasters” - For
 Jay Isaacs, Senior Asst. Coach - For welding our electronics pressure vessel
the time, creativity, and knowledge he
has shared with the team for the past  Laurie and Jim Sopwith – For donating
nine years our 48V power supply

 In-lab mentors: Brian Honnold, Steve  Fish Eye Scuba - For providing SCUBA
Kayama, and David Unter tanks for in-pool sessions at a reduced
rate
 Marc Aprea - Presentation Coach and
Team Lobbyist  TAP Plastics, Sacramento – For
donated stock plastic
 Sharon Aprea – Administrative support
 Zahn Electronics, Inc. – For providing
 Andrea Konstad- Administrative support power converters at a discounted rate

 Lisa Schneider - For organizing team  Byers Family – For providing a TCU
lunches and presentation coaching monitor and video board
 Christina Woollgar – For managing our  MacArtney Underwater Technology
finances Group - For providing SubConn
connectors at a discounted rate.
 Meissner Sewing Machine Company,
Inc.- For donating team shirts to give to
 FedEx - For assistance in shipping our
fellow competitors
crate to competition
 Cindy Meissner - For managing our
company clothing  Jamey Sanger - For providing expert
consulting with our video systems
 Tim Kenneally – For organizing our
complicated team travel logistics  All My Best – For providing shirts at a
reduced rate
G. References
1. "Mission & Specs." ROV Education and Resources. MATE Center, 2014. Web. 28
Apr. 2014. < http://www.marinetech.org/missions-specs--scoring/>.
2. Maxim Integrated Circuit Application note for MAX4312:
http://www.maximintegrated.com/datasheet/index.mvp/id/1892
3. Moore, Steven W. Underwater Robotics: Science, Design & Fabrication. Monterey,
CA: Marine Advanced Technology Education (MATE) Center, 2010.
4. The Engineers Toolbox website: http://www.engineeringtoolbox.com/
5. PixelStick: http://plumamazing.com/mac/pixelstick
6. Zahn DCDC48/24/280 Data Sheet: http://www.zahninc.com/sd1xspec4824280.html

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VI. Appendices
A. Safety Checklist

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B. Budget

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C. Software Flowcharts

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