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SeaPerch ROV Construction Manual

Remotely operated vehicle
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SeaPerch
Remotely Operated Vehicle (ROV)
Construction Manual
Standard and Selected Optional
Assembly Procedures
January 2011
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
i
Version 2011-01AK
Student Manual
SeaPerch ROV Build v.2011-01AK Student Manual

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  • Page 1 Standard and Selected Optional Assembly Procedures January 2011 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...
  • Page 2 SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 3: Table Of Contents

    Procedure 3.2 – Prepare the Control Box Procedure 3.3 – Assemble the Power Cord Procedure 3.4 – Wire the Vertical Thruster Control Switch Procedure 3.5 – Wire the Horizontal Thruster Control Switches Procedure 3.6 – Finish the Control Box SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 4 Safety Precautions Environments Suitable for Using a SeaPerch ROV Driving the SeaPerch ROV Post-Run Cleaning and Maintenance of the ROV System Appendix I – Troubleshooting Your SeaPerch ROV…………………………..43 Appendix II – How to Solder Like a Pro………………………………………….45 Appendix III – Installing a DB-9 Connector on the Tether Cable……………51 Appendix IV –...

  • Page 5: Protective Eyewear

    Adhesives (if used): Adhesives, particularly two-part epoxy, “super glue” type adhesives, 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 with any adhesives, and hands should always be washed after working with such materials.

  • Page 6: Safety While Using Hand Tools

    Recycling of usable excess materials and disassembled vehicles is encouraged for environmental protection and cost avoidance considerations. Most of the ROV components can be re-used in building future vehicles or as spare parts. Safety While Using Hand Tools...

  • Page 7: Safety While Soldering

    Battery Short-Circuit Hazard: Although the battery can be used quite safely when it is connected properly to the ROV, it can be damaged, cause wires to melt, or even start a fire if its positive and negative terminals are connected directly together. That is called a “short...
  • Page 8 ROV circuitry, through its fused power cord. Be careful to keep the battery terminals covered or away from all wires and metal objects when not in use. Do not connect the ROV circuitry or components to the battery until instructed to do so.
  • Page 9 Version 2011-01AK SeaPerch Remotely Operated Vehicle Assembly of Subsystem One The Vehicle Frame January 2011...

  • Page 10: Tools And Materials Needed

    Two pieces – 4” long Four pieces – 1¾” long One piece – 3½” long Six pieces – 1½” long Write the length on each piece to keep track of cuts and to identify them later. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 11 This line will be used when mounting thruster brackets in Procedure 1.5. Repeat for the other 41/2” piece, and for the two 4” pieces of pipe. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 12: Procedure 1.2 - Drill The Drain Holes

    Always wear safety glasses when building your SeaPerch ROV (and when using any hand or power tool). It is 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 fingers away from the sharp drill bit while drilling.
  • Page 13 Note the PVC “collar” on the front nosepiece. This is added to help in firmly mounting the camera on its shoe during camera installation, if used. It is made by snipping one leg off an elbow as shown, carefully using the PVC pipe cutter. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 14: Procedure1.4 - Assembly And Installation Of The Pvc Tube Floats

    Put the cap back on the adhesive container as soon as possible, to minimize the SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 15 Then frap the zip ties by wrapping an 8” tie around each existing tie between the float and the frame pipe. Tighten as much as possible using pliers, and trim all of the tails using the flush-cut cutters. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 16: Procedure 1.5 - Attach The Thruster Mounts

    This is a good time to think about how the angle of the thrusters affects the performance of 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...

  • Page 17: Procedure 1.6 - Attach The Payload Net

    Make sure the net is tight and flat on the bottom of the ROV, and that the front edge of the net is even with the front vertical pipes, NOT with the front of the PVC Tees.
  • Page 18 8. With a little wiggling and maybe the light tap of a hammer, the upturned ends of the wire stiffener can be inserted and set into the holes, as shown. Turn your ROV back over and attach the payload net to the stiffener with one or two tie wraps. Trim the tails from the ends of the tie wraps.
  • Page 19 Version 2011-01AK SeaPerch Remotely Operated Vehicle Assembly of Subsystem Two The Thrusters January 2011 SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 20: Tools And Materials Needed

    6. Connect the red and black wires to the two terminals on one of the motors (twist them through or around the terminals) and hold them temporarily in place with small pieces of electrical tape. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 21 This is the correct polarity for the SeaPerch ROV thrusters, so mark the motor terminal that is connected to the black wire to show that it is the “negative” terminal by using a black marker pen to color one side of that terminal black.

  • Page 22: Procedure 2.3 - Drill Holes In The Thruster Housings

    This can most easily be done with a cable stripping tool designed specifically for CAT 3/5/6 type cable. If using scissors, use extreme care not to SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 23: Procedure 2.5 - Pot (Waterproof) The Motors With Wax

    2. Separate the four wire pairs in the stripped section, (in some tether cables, the wires may not be twisted into pairs). The brown pair is not used in the basic SeaPerch, and can be left hanging for now (do not cut this pair off, as it could be used later for an accessory item, such as a sensor, light, or manipulator).
  • Page 24 14. Carefully fill one thruster housing to the very top with wax, creating a positive meniscus as shown. 15. You may wish to hold a paper towel in your hands, over the cap, as you perform this step, to SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 25 17. On the loose end of the tether cable (that does not have the thrusters installed), strip off about 4” (10 cm) of the outer sheath, being very careful not to nick any of the inner wires. This can SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 26: Procedure 2.5A - An Alternative To Potting Motors With Wax

    Petroleum Jelly or PAM Cooking Spray 2-part Potting Epoxy Note: 2-part Potting Epoxy (AeroMarine Epoxy #300/11 Dielectric Potting Compound, jgreer.com) One set of resin and hardener is enough for nine builds and costs $35 SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 27 Then, fill the vial with hardener, and transfer the hardener to the mixing container. Again, be sure to scrape the sides of the container to get all of the hardener into the mixing cup. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 28 10. Any high points on the motor casing can be carefully trimmed away with a utility knife. Note: During the pouring process, any spilled epoxy can be cleaned up with a little rubbing alcohol. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 29: Procedure 2.6 - Mount The Propellers On The Thruster Motors

    Be sure that the fit is firm and that the propeller will not slip off when lightly pulled. You can use a drop of Super Glue on the shaft to make sure the propeller doesn’t fall off. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 30: Procedure 2.7 - Mount The Thrusters Onto The Vehicle Frame

    What angles will get you the best turning ability? What angles will keep the propellers out of harm’s way as the ROV navigates in narrow or crowded places? What is the best compromise for your mission needs? Procedure 2.8 –...
  • Page 31 ROV, as shown. 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 other, making it more difficult to turn the ROV in one direction compared to the other.
  • Page 32 Coil the brown wire pair out of the way and tie-wrap it to the payload net; it may be needed later for accessories or for a thruster wire repair. This completes assembly of your SeaPerch ROV Thrusters! SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 33 Version 2011-01AK SeaPerch Remotely Operated Vehicle Assembly of Subsystem Three The Control Box January 2011 SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 34: Tools And Materials Needed

     Gather the other parts required for the control box assembly, as shown. The tether (umbilical) cable shown is the one that is already attached to the thrusters on the ROV frame assembly, completed in Unit 2. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 35: Procedure 3.2 - Prepare The Control Box

    Plan the layout carefully so that the switches (and their wires) don’t interfere with each other or with internal parts of the box. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 36: Procedure 3.3 - Assemble The Power Cord

    This is best done by snipping the thin web of plastic between the wires with a small pair of scissors or a small pair of wire cutters. Be careful not to nick the insulation on either of the individual conductors. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 37 Procedure 3.3 are optional, but they will help you to complete the wiring quickly and easily and help to keep the wiring well organized, which will simplify any later repair work, if needed. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 38: Procedure 3.4 - Wire The Vertical Thruster Control Switch

    Make a good mechanical connection before you solder. Use just a little solder. Using too much solder can cause the excess to stick out and touch other connections. Always wear safety glasses when soldering! SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 39 Separate the orange crisscross wire pair and strip 1/8” to 1/4" (3-6 mm) of insulation off of each end of both wires. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 40 Bend and squeeze the wire to the terminal as before. Make sure that no other terminal is touched by the orange wires. When you have the SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 41: Procedure 3.5 - Wire The Horizontal Thruster Control Switches

    Procedure 3.5 – Wire the Horizontal Thruster Control Switches Tools: Materials: Soldering Iron and Solder (Rosin Core) Control Box with Assembled Tether Cable Small Needle-Nose Pliers 2 DPDT Switches Flush-cut Wire Cutters Wire Stripper SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 42 7. Connect one end of the 2” (5 cm) green & white striped crisscross wire to the top left 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 the connections yet. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 43 22. 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 between soldering operations. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 44: Procedure 3.6 - Finish The Control Box

    Control Box with All Switches Installed and Wires Routed Neatly SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 45 6. If desired, make some labels from adhesive-backed paper sheets to mark starboard, port, and vertical thrusters. A completed ROV system is shown below. Completed SeaPerch ROV System, Ready for Testing and Ballasting CONGRATULATIONS, you have finished construction of your SeaPerch ROV! Now it’s time to get it ballasted and tested!

  • Page 46: Testing And Ballasting The Rov

    ROV. Testing for Proper Thruster Operation: After passing the tests above, it is time to connect the ROV to its battery. Connect the two power leads (the alligator clips or the quick-disconnect terminals) to the appropriate positive and negative terminals of the battery.
  • Page 47 (making sure to get all of the air out of the pipes) and letting go. A properly ballasted ROV should very slowly rise to the surface. Most initially pop up like a cork. If it just sits on the bottom, it’s time to re-evaluate ballast already installed and/or check the floats to make sure that they have not...
  • Page 48 This can be accomplished in a swimming pool, a small water tank, such as a water trough, or even in a bathtub. By placing the ROV on the surface at one end of the tank or tub, there should be enough running distance to observe whether it will run in a generally straight line when both horizontal thrusters are switched on in the forward direction at the same time.

  • Page 49: Using The Seaperch Rov

    Should the tether cable be tending far to the right or left, due to the position of the ROV relative to the operator, it may seem to move better in one direction than the other.
  • Page 50 ROV. In addition to rinsing the vehicle and cleaning off any debris, it is helpful to submerge it in a tub of fresh water and run the thrusters for a few moments, to better clear corrosive materials from the motor shafts.

  • Page 51: Appendix I - Troubleshooting Your Seaperch 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 rear of the vehicle, and that the crossed tie wraps are in place to keep the vehicle-end of the tether cable pointing straight back from the ROV.
  • Page 52 ROV use. Note: If you modify the ROV's wiring or the placement or orientation of switches within the control box to achieve proper operation, you should put a note inside the control box to leave a record of the change or non-standard configuration, to minimize confusion should you or others need to repair or modify the ROV in the future.

  • Page 53: Appendix Ii - How To Solder Like A Pro

    Some of these simply have a boost button on the handle, which is useful with larger joints, others have a thermostatic control SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 54 Try to use the right size tip whenever you can. Smaller wires and circuit boards require small fine tips, and mic cable onto an XLR would need a larger tip. You can get pointed SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 55 Fume Extractors Solder fumes are poisonous. A fume extractor will suck the fumes (smoke) into itself and filter it. An absolute must for your health if you are setting up a soldering bench. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 56 Do this by putting the tip of your soldering iron into the hole and flicking the solder out when it has melted. Common Sense Alert! Please be careful when you flick melted solder...flick it away from you. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 57 When the solder in the contact melts, slide the wire into the contact. Remove the iron and hold the wire still while the solder solidifies again. You will see the solder 'set' as it goes hard. SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 58 If the joint has been moved during soldering, it may look grainy or dull. It may also look like this if the joint was not heated properly while soldering. If the joint was overheated the solder will have formed a spike and there will be burnt flux residue. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 59: Appendix Iii - Installing A Db-9 Connector On The Tether Cable

    3. The DB-9 plug is an electrical connection, not a mechanical one. If the connection comes apart while in use, there is a chance that the operator may lose their SeaPerch. This can easily be prevented. Tools:...
  • Page 60 2. Place a female DB-9 connector (the connector without the pins on the front side) in a vice with the solder pins pointing towards you, five-row on top. The ROV end of the tether will be attached to the female plug.
  • Page 61 If all looks good, install the plugs into the hoods, which are universal (one hood fits all). SeaPerch ROV Build v.2011-01AK Student Manual...
  • Page 62 6. From this point, proceed with the assembly of the control box as described in Procedure 3.4 of the Basic Build Manual. Note: to ensure a good mechanical connection for the tether, plug the connectors together and wrap the plugs with a piece of electrical tape. SeaPerch ROV Build v.2011-01AK Student Manual...

  • Page 63: Appendix Iv - Installation Of An Underwater Video Camera

    Optional installation of an underwater video camera Background: Addition of an underwater video monitor to the SeaPerch ROV helps to make the platform a true research tool, enhances student excitement and inquiry in the entire ROV exploration process, and is just downright fun.
  • Page 64 #8 x ½” self-tapping machine screw to hold the camera in place. Collar 4. Uncoil the video cable and the ROV tether and align side-by-side. Tape or tie wrap the two cables together at intervals of 12”-18” to prevent tangling of the two wires. You may need to add buoyancy to the cable –...

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