FINAL REPORT - MD1

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Dec 6, 2023

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WARMAN DESIGN REPORT ERIC KIOKO - 13555887 UTS – COORDINATOR: Dr. Mickey Clemon MECHANICAL DESIGN 1 – AUTUMN 2020
Warman Design Report Mechanical Design 1 – Autumn 2021 CERTIFICATE I certify that the work in this report has not previously been submitted except as fully acknowledged within the text. I also certify the report has been written by myself. In addition, I certify that all information sources and literature used are indicated in the report. Signature of student: Eric Nzioka Kioko Date: 24/05/2021 Group 02, Monday, 9:00am. 1 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 ABSTRACT This report outlines group Mon_02’s design and the manufacturing process of the whole robot. The report also gives details of the FRDPARRC analysis of the personal artefacts that I was in charge of for this project. The personal artefacts consist of fasteners, mechanical adapters, navigation path and for the electrical artefact; motor driver/motor shield H bridge. The project was to build an autonomous robot according to the Warman competition. The group tried to reach all the required functional requirements and made necessary countermeasures to avoid any risks that might occur. 2 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 Contents CERTIFICATE .......................................................................................................................................... 1 ABSTRACT .............................................................................................................................................. 2 Acronyms and abbreviations ................................................................................................................. 5 INTRODUCTION ..................................................................................................................................... 6 Warman Competition ........................................................................................................................ 6 Objectives/Requirements/Goals ........................................................................................................ 6 Outline of the report ......................................................................................................................... 6 Literature Review ............................................................................................................................... 7 Acknowledgements ........................................................................................................................... 7 RESEARCH AND PLANNING ................................................................................................................... 8 FRDPARRC .......................................................................................................................................... 8 Design and Development ................................................................................................................. 12 Analysis ............................................................................................................................................ 12 Designs and Analysis Criteria ........................................................................................................... 12 Gantt chart ....................................................................................................................................... 13 Risk Assessment ............................................................................................................................... 14 Group Tasks and Performance ......................................................................................................... 14 OVERALL SYSTEM DESIGN .................................................................................................................... 15 Mechanical Components ................................................................................................................. 15 Base/Chassis ................................................................................................................................ 15 Motor and controller Mounts ...................................................................................................... 15 Wheels ......................................................................................................................................... 15 Payload/Collection Basket ........................................................................................................... 15 Electrical Components ..................................................................................................................... 16 Control unit (Arduino) .................................................................................................................. 16 Motors ......................................................................................................................................... 16 Motor Drive ................................................................................................................................. 16 Battery ......................................................................................................................................... 17 Power Regulator .......................................................................................................................... 17 ARTEFACT 1: FASTENERS ..................................................................................................................... 18 Functional Requirements ................................................................................................................. 18 Design Parameters (morphology) .................................................................................................... 19 Analysis ............................................................................................................................................ 19 References ....................................................................................................................................... 19 3 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 Risks ................................................................................................................................................. 19 Countermeasures ............................................................................................................................ 20 CONCLUSION ................................................................................................................................... 20 ARTEFACT 2: MECHANICAL ADAPTERS ............................................................................................... 21 Functional Requirements ................................................................................................................. 21 Design Parameters (morphology) .................................................................................................... 21 Analysis ............................................................................................................................................ 21 References ....................................................................................................................................... 21 Risks ................................................................................................................................................. 21 Countermeasures ............................................................................................................................ 21 ARTEFACT 3; NAVIGATION PATH ......................................................................................................... 22 Functional Requirements ................................................................................................................. 22 Design Parameters (morphology) .................................................................................................... 22 Analysis ............................................................................................................................................ 22 References ....................................................................................................................................... 22 Risks ................................................................................................................................................. 22 Countermeasures ............................................................................................................................ 22 ARTEFACT 4: MOTOR DRIVER .............................................................................................................. 23 Functional Requirements ................................................................................................................. 23 Design Parameters (morphology) .................................................................................................... 23 Analysis ............................................................................................................................................ 23 References ....................................................................................................................................... 24 Risks ................................................................................................................................................. 24 Countermeasures ............................................................................................................................ 24 CONCLUSION ................................................................................................................................... 24 COST ANALYSIS/ECONOMIC FEASIBILITY ............................................................................................ 25 CONCLUSION/DISCUSSION ................................................................................................................. 26 APPENDIX ............................................................................................................................................ 27 REFERENCES ........................................................................................................................................ 43 4 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 Acronyms and abbreviations FRDPARRC – Functional Requirements, Design Parameters, Analysis, References, Risks, Countermeasures SHS – Square Hollow Section MDF – Medium-Density Fibreboard 5 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 INTRODUCTION Warman Competition The Warman competition aims to solve a problem where engineers are meant drop neutralising pellets onto mined ore, this is to separate the mined ore from the metals. Before this, a prototype is made, and the competition is to make a prototype that demonstrates how this can be achieved. The prototype requires the engineers to drop 10 tennis balls that represent the neutralising pellets into 4 different silos, the different amount of tennis balls that are dropped represent the higher quality of neutralising agent required for that specific silo. Objectives/Requirements/Goals To design, build and demonstrate through the prototype, a proof of concept for the robot that will be used as a pellet deployment system. This prototype needs to go from the start/end zone and needs to drop a specific number of the ten balls into one of the 4 silos and then needs to come back to the start/end zone. This needs to be done autonomously and for the most points to be earned, the correct number of pellets need to be dropped into the right silos as demonstrated in Figure 1 below. The system is also required to have the 10 balls pre-loaded onto the robot in the beginning and must complete all operations within 120 seconds. Additionally, the robot must be able to fit in a 500 x 500 x 500 mm box without payload and must not have a mass greater than 6kg. Figure 1. Schematic view of the competition track showing silo tube location and the number of pellets targeted to be in each tube at the competition of the run. Tubes (silos) are shown transparent for clarity. Outline of the report The purpose of this report is to cover the technical and theoretical details of the Warman competition robot. It also includes the design and ideation processes, research stages. The overall system designs and the personal artefacts assigned to me. Additionally, the cost analysis/economic feasibility report is included with reasoning behind each part. Lastly, the conclusion summarises the whole report and the learning experiences from undertaking this project. 6 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 Literature Review For this project, we started by thinking about what would be the easiest design to accomplish the projects’ objectives. After consulting and researching previous groups’ ideas as well, we decided to do the telescopic arm which requires less movement of the whole robot and more focus on the arm deployment system. This idea was better to us because it required less movement of the whole robot and rather more focus on the arm and the lifting mechanism. Acknowledgements For this Warman project, it was done in groups and it was only due to the groups collective hard work that the robot was able to work. Each group member contributed to their specific artefacts and the group communicated effectively on a weekly basis to efficiently build the prototype that meets all the required objectives. Many thanks to our subject coordinator Dr. Lee ‘Mickey’ Clemon and to our tutor Dr. Mohammed Adwadallah. Also not forgetting my group members who all put in a lot of effort; our group leader Leon Agalawatta, Toby Marchant as our manufacturing engineer 1, Max Mckern as our manufacturing engineer 2, our mechanical engineer as Sam Lawson and I as the mechatronics engineer. 7 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 RESEARCH AND PLANNING FRDPARRC FUNCTIONAL REQUIREMENT DESIGN PARAMET ERS ANALYSIS REFERENCES RISK COUNTER- MEASURES BASE CHASSIS “Give precise linear motion” to accurately place the payload into the storage area. “Omnidirection al load capability with long life” to be stable enough to place loads on it within a 500x500x500 mm^3 area. “Rapid acceleration” to complete the proposed task in under 120 seconds and subsequently, rapid acceleration must occur to maximise time for other tasks. Accurately place the payload into the storage area. Must be stable enough to place loads on it within a 500x500x50 0mm^3 area. “Rapid acceleration ”. The whole robot needs to complete the proposed task in under 120 seconds. 1. These wheels were considered the most appropriate as they allowed for linear motion and were easy to implement. The addition of pillow bearings (Appendix C.3) for the axle to pass through allowed for little resistance and easy motion. The use of YG2900 Arduino Wheels (appendix 1) to drive the chassis completes the system and should allow for the completion of the task within 120 seconds. The rubber outside of all the wheels also provide enough grip to move the robot so no time will be wasted with slippage. 2. The wheels used also allow for motion in either direction. The use of non- direction specific pillow bearings attached to the underside of the frame allow for easy motion in either direction and don’t require any maintenance due to the closed nature of the bearings used. Similarly, the use of 2 YG2900 Arduino Wheels placed at either end of the robot, control how fast and far the robot travels in either direction. This design was chosen due to the ease of access to the parts and the overall construction Anon, 2021, viewed 15 April 2021, <https://www.bunnings.c om.au/ambassador- 100mm-white-plastic- centre-wheel-and- rubber-tyre_p3942885>. Anon, 2021, viewed 15 April 2021, <https://www.bunnings.c om.au/metal-mate-25-4- x-25-4-x-1-2mm-3m- aluminium-square-box- tube_p1079488>. Datasheets - Aluminium Alloy - Commercial Alloy - 6063 - '0' Extrusions | Dalsteel Metals 2021, Dalsteel.com.au. viewed 15 April 2021, <http://www.dalsteel.co m.au/technical- information/datasheets/ Aluminium-Alloy-6063-0- Extrusion s_ 160.asmx>. Driving wheels not powerful enough/ov er- encumber ed Bolts used to hold parts on loosen with use Bolts used to hold parts on loosen with use Switch out for ones with a higher torque rating. Potentially redesign elements above the base chassis to be lighter. Use locktite to secure bolts on, particularly the ones holding the wheels on Have spare parts or choose plastics with a higher modulus of elasticity, potentially 3d print the parts instead of buying. 8 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 being simple to reduce any chance of faults. LIFTING MECHANISM 1. Supply an upwards force on the loading mechanism 2. Have a large enough effective stroke that's enough so the loading mechanism can reach the shortest and tallest tube 3. Must not exceed size requirements of Warman competition 1. Supply an upwards force of approximate ly 34N to lift the loading mechanism which is expected to weight up to 3.5kg 2. Have an effective stroke of 400mm to to able to reach all the tubes 3. Robot must be to fit into a 500x500x50 0 (mm) box at its smallest state Calculations in Appendix 2. -Collins, D. (2020, February 7). What options are there for integrated motor and screw designs? Linear Motion Tips. https://www.linearmo tiontips.com/what- options-are-there- for-integrated-motor- and-sc rew-designs/ -Instructables, & Ben1998. (2017, December 28). Linear Actuator Stepper Motor. Instructables. https://www.instructa bles.com/Linear- Actuator-Stepper- Motor/ -Instructables, & farmerkeith. (2019, February 25). DIY Linear Actuator. Instructables. https://www.instructa bles.com/DIY-Linear- Actuator/ 1. Insufficient upwards force 2. Insufficient stroke length 3. Too large and fails to meet the maximum size requireme nts -For [1] & [2] ensure that extensive testing is done on the lifting mechanism. - For risk [1] is to put into place a factor of safety (FoS) of 1.5 -For risk [3] the countermeasure put in place is to test fit the linear actuator onto the chassis and measure the height of the system and ensure it is not taller than the 500mm height restriction. PAYLOAD DISPENSER Dispenses payloads smoothly and accurately and complies with weight and Material is lightweight but can withstand a weight of approximate Using PVC piping with diameter of 90mm. Any less and the balls from the top storage part would not be able to roll down the bend connecting to the arm due Bunnings’s warehouse, drawer slides, viewed 2 April 2021, https://www.bunnings.c om.au/our- Balls fall out of the pipe Anything less than 90mm, the balls could possibly fall out. Calculations show that 90mm 9 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 volume restrictions. A number of dispensing options are no longer available. They must comply with the weight and volume requirements outlined in the introduction. ly 4kg. Payload unloading is controlled as we need the system to move before releasing more payloads. The cost of the materials is less than $150, preferably around $100. All components are secure and rigid. The delivery system must be within H340x W450x D500mm at the start and completion of the timed run. to the decrease in internal size at the bend. This could have been counteracted by cutting the pipe however this would mean the balls were more likely to fall out. The PVC on the telescopic arm was cut in half as the ball would easily stay inside the pvc. The bottom of the telescopic arm will point towards the middle guiding the ball out in the exact spot we would like it to go. The drawer slides are steel and zinc plated. This will be the heaviest part of the robot weighing 3kg for 4 sets of drawer slides. Each drawer slide extends 40mm and will be connected to the top and bottom of each piece of PVC. The cuts of pvc will be raised using another piece of MDF, they will be cut to the shape of the pvc and glued to both the MDF plate and the pvc pipe. Calculations have shown that the balls will easily go through the system and into the track pipes totalling 30seconds. This leaves 1 minute 30 seconds for the robot to move down the track, extend and retract the arm and allow the rack and pinion to move the MDF. range/building- hardware/door- window-gate- hardware/cabinet/draw er-slides? page=1&facets=Categ oryIdPath %3D8dedf25d-58b7- 430e-a87c- e889b570bc90%2CSu bCategoryIdPath %3Dc175764f-6e57- 4bcd-a7a8- d0627a89047b&sort=B oostOrder&pageSize= 60 MDF properties, viewed 10 April 2021, https://civiltoday.com/ci vil-engineering- materials/timber/166- mdf-definition-types- properties-manufacture Rack and Pinion, viewed 7 April 2021, https://www.britannica. com/technology/rack- and-pinion MDF can’t hold the weight Rack and Pinion too slow will stop the balls from going out the sides. The only problem would be bouncing but at the angle and speed, it will not bounce enough to fall out. The MDF has a density of 600kg/m^3 making it extremely strong. It is also stiff and rigid which is needed for this task. The rack and pinion can be going while the robot is moving in any direction. Telescopic Arm The furthest tube is 1.8 metres, and as - To reach 1.8 metres, we will have - As the arm is going to be heavy, we will have to make sure that the robot will be Anon, 2021, viewed 15 April 2021< https://www.bunnin - If the telescopic arm is too If the arm is too heavy and we cannot put 10 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 such the deposit system will have to bridge that distance without failing. The other tubes, which are closer are all different lengths away thus needing a way to control the length of the tube. As per the design requirements, the robot must fit into a 50x50x50cm box, thus it needs a way to extend out. drawn sliders connected to PVC pipes in order to reach the distance. We need a lightweight material due to the draws sliders weighing a net total of 3 kg. - To control the length of the deposit system, we will have a string connected to the bottom of the system, this string will be reeled in. In order to reel it in and out we will connect a motor to the reel. Thus, will help us reel it in. able to support the weight without tipping over or the arm falling off the robot. we will have to find the force and moments acting on the robot when the arm is fully extended. - The calculations around the arm will focus on how strong the motor needs to be to reel in the arm when at its furthest point. We will also need to find the tension in the string to see the force acting on it. Once we find this, we will be able to choose a string that will be appropriate. - The calculations for the arm will reveal the angle which the system has to be at. Once we find the angle that the telescopic arm sits at, we will be able to use this information to find the length that the robot will be lifted up. gs.com.au/holman- 100mm-x-6m-pvc- dwv-pipe_p4770346 > Anon, 2021, viewed 15 April 2021< https://www.bunnin gs.com.au/goliath- standard-drawer- slide-pair- 400mm_p4020969? gclid=Cj0KCQjw6- SDBhCMARIsAGbI 7Ui4cD49Wk0ajiug PcCEdC10XU77Up wpxKdkODvmqWrb MzSvRVVVdzoaAh GxEALw_wcB&gcl src=aw.ds > Anon, 2021, viewed 15 April 2021< https://www.jaycar. com.au/standard- high-power-d-c- motors-20000- rpm/p/YM2772 > heavy, we may not be able to add enough counterwei ghts while staying under the 6kg limit. enough counterweights on the vehicle without exceeding the 6kg limit we will have to try and find lighter draw sliders, or a different method to extend the telescopic arm, but as we do not have it built at this stage, we won’t be able to test if it is too heavy. FASTENERS -Affix two or more components of the robot together for a smooth and firm robot -Withstand the load when the -Joiners to affix the chassis and the screws to fasten them together. -Wheels held down - We have wood screws which we could have used, however, since our base was metallic, we decided to use the machine screws since the wood screws work better with wood or softer materials. - Used the Phillips and •CUBII Industrial Solutions. (2020, May). Fasteners and its importance in industry. https://cubii.co/en/fas teners-and-its- importance-in- industry/ -Nuts might not be tight enough since they’re pressing onto the bearing which is a moving To mitigate this risk is by using washers together with the nuts to allow for the nuts not to be loosely held. 11 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 robot is in application. -Allow for the different components to be easily removed/dism antled when necessary, without damaging the joining components. by the 8 machine screws 4 which are slotted drive types and 4 which are Phillips’ drive types. -M6 nuts to hold the bearing in wheels at the end of the rod. slotted drives since they are the most common and easily available. •Bolt Depot. (2018). Fastener Basics. https://www.boltdepo t.com/fastener- information/printable- tools/Fastener- Basics.pdf part. However, the likelihood of this happening is small since there were 3 nuts used. Design and Development 12 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 Analysis The group discussed about different pros and cons of the different prototypes we had and decided to analyse using the PUGH evaluation as well as a Gantt chart and by the provided data we made some minor changes to our prototype. Designs and Analysis Criteria PUGH EVALUATION Excavator Arm Swiveling Arm Telescopic Arm COG/Stability 7 9 5 Mechanical Complexity 2 8 3 Software Complexity 1 8 2 Manufacturing Complexity 2 8 3 Payload Accuracy/Delivery 8 4 10 Cost 6 8 7 Size 7 7 7 Range of Motion 10 5 5 13 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 SCORE 43 57 49 Table 1 – PUGH evaluation Gantt chart Table 2. Gantt Chart Risk Assessment The risks associated with the robot are assessed to ensure that the requirements are not compromised. Therefore, to solve any of these risks, countermeasures are put in place. The risks are as stated in the FRDPARRC table as well as the countermeasures. The following table would look in more detail about how risks on parameters such as safety, functionality, cost and time. Type of risk Risk rating Likelihood of occurrence Cause Consequence Safety Medium Medium An error in the coding which would make the heavy arm swing rapidly. Temporary injury to a person, probably to the lower body, might also cause the robot break. Functionality High Medium Not knowing clearly about the design parameters as well as, low analysis in design stages The robot isn’t able to reach all the PVC pipe and thus doesn’t meet the specified requirements. Cost Low Low Low future thinking when in design stages as well as Due to too high costs, it becomes hard to finish the 14 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 overengineering of functional issues that may be faced. robot and thus may cause the group to have an unfinished final robot. Time Medium Medium Lack of group meetings and group communication and allocation of tasks Due to lack of good planning, building the robot will become a heavy task due to undone tasks. Group Tasks and Performance Leon – creating the Gantt chart, create a final sketch, analysis of system containers, FEA analysis of materials, cost analysis and finalise CAD parts and assembly. Max – Draw CAD models, analysis of system wheels, create CAD of base, finalise system hardware. Eric – create presentation 1, analysis of System Motors, analysis of Software, finalise System software. Sam – Create Presentation 1, analysis of System Arms, create CAD of Arms, Finalise & Edit Presentation 2, Finalise System Design. Toby - create presentation 1, Draw CAD models, Analysis of System Base, Create CAD of Wheels w/ motor, Finalise System Hardware. Everyone contributed to; Identify Functional Requirements, Individual Idea Generation, Identify Design Parameters, Analyse & Research/References, Group Discussion, Reach Design Decision, Finalise & Edit Presentation 1, Presentation of Presentation 1, Create Presentation 2, Finalise & Edit Presentation 2, Create Final Presentation, Finalise System Requirements, CAD drawings, Testing and Validation, Finalise & Edit final Presentation, Present Final Presentations. The group worked together communicating and solving the issues as a group. OVERALL SYSTEM DESIGN Below are the mechanical and electronic components which work in conjunction to make the whole robot work. Mechanical Components Base/Chassis The base is made up of 4 steel bars joined together with tubing joiners and a MDF base on top of it which allows for a housing for the electronic components and other components. 15 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 Motor and controller Mounts The motors and controllers will be mounted with 3D printed bases and stuck onto the base/chassis. Wheels We used 4 100cm diameter wheels however, these were used only as a guide and support but two DC powered wheels were used to move the robot. Payload/Collection Basket The robot will have an MDF at the top and using PVC tubes as the storage system and will use gravity to allow the balls to drop into the silos. Electrical Components Control unit (Arduino) The controller used was the Arduino Uno which is used to allow for the mechatronic components of the whole robot. The Arduino is what allows us to move the arm back after it has been extended and released the balls into the silos. Additionally, it is used to control the L298 motor drivers which allow the linear actuator to move to the desired height and the desired distance for the DC powered wheels. Motors DC - The Robot is 2 using DC powered wheels to move the robot and both wheels will be placed at the front to allow for the robot to move. 16 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 Stepper - The robot uses a servo motor for the lifting mechanism to allow for the robot to be able to reach the height of the high silos. Motor Drive An L298N stepper motor module was used to control the height of the stepper motor powered linear actuator as well as the length for the wheels to move the robot. Battery The group used a small 9V battery to power the Arduino Uno. However, a LIPO battery from an RC car is used to power the L298N stepper motor controller. The LIPO battery has 7.2V and 6800mAh. 17 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 Power Regulator The L298N stepper motor controller has its own 5V power regulator in-built. This is to allow for the Arduino and controller not to overheat. 18 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 ARTEFACT 1: FASTENERS Functional Requirements The function of these fasteners is; To be able to affix two or more components of the robot together for a smooth and firm robot Must be able to withstand the load when the robot is in application. Allow for the different components to be easily removed/dismantled, when necessary, without damaging the joining components. Keep all the components safe from damage 19 | P a g e
Warman Design Report Mechanical Design 1 – Autumn 2021 Design Parameters (morphology) The design has multiple components. Each component used as a fastener is specifically chosen with the fitting dimensions. The fasteners consist of; o M6 nuts – 4 used for each of the wheels o 8 Machine screws 4 slotted drive type and 4 Phillips drive type o 6mm miniature ball bearing – 4 used for the 4 wheels o 4 box tubing joiners For the wheels, connected to the wheel axle we used a bracket that was held down by the 8 machine screws 4 which are slotted drive types and 4 which are Phillips’ drive types. The bracket is screwed down to the base chassis of the robot to hold down the box tubing joiners as well as the wheel axle in order for the base to be firmly connected and for the wheel axle to be held in an unmoving position to allow for the wheels to move around the bearing that is held down by the bracket. Additionally, we used m6 nuts for the wheels 3 each to hold the bearing in and an extra one for each wheel to hold out the outside of the wheels at the end of the rod. We will also use 8 more screws and nuts to hold together our arm that will be able to go in and out. These will allow them to be connected to each other and also for the storage system above which will be made of PVC we have 4 screws and nuts to hold them to the top base. Analysis We also had wood screws which we could have used, however, since our base was metallic, we decided to use the machine screws since the wood screws work better with wood or softer materials. Furthermore, we used the Phillips and slotted drives since they are the most common and easily available. For the box tubing joiners, we decided to use these since they had good grip together with the metallic base. We used ball bearings for the wheels however to improve it we could use washers to help prevent loosening by spreading the load over a great surface area. References Through some research I got to see some advantages and disadvantages of fasteners which helped the group decide which fasteners to use. CUBII Industrial Solutions. (2020, May). Fasteners and its importance in industry . < https://cubii.co/en/fasteners-and-its-importance-in-industry/ > Bolt Depot. (2018). Fastener Basics . https://www.boltdepot.com/fastener- information/printable-tools/Fastener-Basics.pdf Risks For risks that might happen is that the nuts might not be tight enough since they’re pressing onto the bearing which is a moving part. This could lead to the wheels not working due to the nuts not being tight enough, however the likelihood of this happening is small since there was 3 nuts used. 20 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 Countermeasures The plan to mitigate this risk is by using washers together with the nuts to allow for the nuts not to be loosely held. So, what we will do is just add washers and may also get rid of the extra nut if not necessary. CONCLUSION Through the choices made we were able to apply the SLOs below; 4. Apply the principles of mechanism analysis and design. 5. Apply good mechanical design practice to design and build a mechanical device. 21 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 ARTEFACT 2: MECHANICAL ADAPTERS Functional Requirements The mechanical adapters’ functional requirements include; Transforming rotational to linear motion for the threaded rod in the linear actuator Transforming linear to rotational motion for the rack and pinion used for the telescopic arm Design Parameters (morphology) The design parameters met through this is that through the threaded rod in the linear actuator, the robot is able to reach the tall silos and thus drop all the balls into the silos as required for this Warman competition. Furthermore, the rack and pinion also make the robot able to reach the silos and thus able to meet the requirement of dropping the balls in each of the pellets. Analysis The rack and pinion were a good choice for the telescopic arm, however, the arms we used were the drawer ones, and they were the heaviest components, weighing up to 3kgs which is half of the maximum weight allowed for the whole robot. Furthermore, the threaded rod and lead screw was a good choice as it lifted the robot well, however, it was an expensive choice. References Macsim. 2021. Threaded Rod . https://www.macsim.com.au/category/1854-threaded-rod Risks If the threaded rod breaks, then it would be dangerous since it would be holding the top part of the robot where the tennis balls will be stored. Countermeasures As a countermeasure, the top part of the arm will be held by string in order for it not to fall on someone’s foot CONCLUSION Through the choices made we were able to apply the SLOs below; 4. Apply the principles of mechanism analysis and design. 5. Apply good mechanical design practice to design and build a mechanical device. 22 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 ARTEFACT 3; NAVIGATION PATH Functional Requirements The navigation path needs to allow for the robot to complete the task in the fastest time as possible. Design Parameters (morphology) The navigation path needs to allow for the required 2mins time therefore it should be the shortest distance to allow time for the other tasks such as extending of the arm and dropping of the balls in the silos. As calculated, the best path for our robot is only sideways along the start/end zone line. This allows for the best time compared to moving the robot along the line. Analysis By doing this the robot is estimated to take approximately 1min 35 seconds at max. compared to going through the track, this would make the robot take longer due to our arm taking time to drop the balls. References Weir. 2021. Advice from a Warman Winner . https://www.global.weir/brands/warman/warman- design-and-build-campaign/advice-from-a-warman-d-and-b-winner/ Risks The robot could fail to move which would make the robot fail since the arm cannot rotate and the wheels therefore need to move to the precise line of the silos in order for the telescopic arm to drop the balls. Countermeasures As a backup, we could use the weight of the arm to make the arm to move in one direction and drop a counterweight on the other side of the robot in order to stop the robot. CONCLUSION Through the choices made we were able to apply the SLOs below; 4. Apply the principles of mechanism analysis and design. 5. Apply good mechanical design practice to design and build a mechanical device. 23 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 ARTEFACT 4: MOTOR DRIVER Functional Requirements The motor drivers we used is the L298N Dual Motor Driver which; Interface between the stepper motor and the Arduino for our lifting mechanism which allows the robot to reach the taller silos (delivery tubes) in order to drop the tennis balls. This is also used for the DC motor wheels and allows for the robot to move from side to side autonomously. Design Parameters (morphology) To meet the requirement for the vehicle to be autonomous Allow for the robot to be able to reach all the balls To be able to reach move to the different locations for the arm to drop the balls. Analysis Component Specifications Image Motor driver module; L298N dual motor driver Type: module Logic voltage: 5V Operating voltage: 3-30V Max current: 4A Power: 25W Cost: $11.95 Dimensions: 69 x 56 x 36 mm 24 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 References Jaycar, 2021, ‘Dual/stepper motor controller module’. Viewed 23/05/2021 <https://www.jaycar.com.au/medias/sys_master/images/images/9526468673566/XC4492- dataSheetMain.pdf> Risks The heat sink of the L298N motor driver heats up really quickly especially with the stepper motor thus, it dangerous if someone touches it while in operation or soon after operation ends. This could cause serious burns to the person’s hand. Using the weak type of wiring to connect the Arduino to the motor drivers could also cause the wires to burn quickly. Countermeasures Only one person will be operating the L298N and the heat sink will not be touched until it cools off. Furthermore, the group members and others will be informed of the risk in order to avoid anyone touching it. By using thicker wires that can withstand high amps of current, this avoids the risk of the wires getting hot and degrading CONCLUSION Through the choices made we were able to apply the SLOs below; 4. Apply the principles of mechanism analysis and design. 6. Apply good mechatronics principles to develop a mechatronic system to control a mechanical device. 25 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 COST ANALYSIS/ECONOMIC FEASIBILITY For the completion of the Warman competition robot, the group had to source parts to construct the robot. The materials that were used were all sourced locally from stores such as Bunnings, core electronics and Jaycar. Below are the parts, the store sourced from and their costs. Part Store Cost 65mm 1m PVC Bunnings $13 32mm 1m PVC Bunnings $8 20mm 1m PVC Bunnings $4.35 90mm 1m PVC Bunnings $9.85 MDF 900x600 Bunnings $4.50 Nylon Line Bunnings $5 Linear Actuator (stepper motor and lead screw) Core Electronics $87.95 L298N dual/stepper motor driver Jaycar $14.95 Multipin Nylon 2Pin Jaycar $3.25 12VDC Motor Jaycar $18.95 Stepper Motor Jaycar $9.95 5-10V DC Wheel Jaycar $9.95 5-10V DC Wheel Jaycar $9.95 Total cost $214.14 26 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 CONCLUSION/DISCUSSION This report analyses the 2 mechanical artefacts and 2 electrical artefacts for group 2 Monday class for the Warman competition. Each components used is explained and the process through which the robot was made is explained. The report also justifies the choices made. However, since we have not completed the robot yet, some content may change and but the overall design of the robot will remain the same. The project overall has helped me understand more about how to work as a team as well as how to improve through research and constant review in order to increase the likelihood of success in a project. It is very useful and will be able to help me transfer this in the workplace. 27 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 APPENDIX Appendix Appendix A: Internet multimedia - ? links of all Videos - Link to video of robot’s mechanism https://teams.microsoft.com/_?culture=en- au&country=AU&lm=deeplink&lmsrc=NeutralHomePageWeb&cmpid= WebSignIn#/mp4/viewer/teams/https:~2F~2Fstudentutsedu.sha repoint.com~2Fsites~2F48600MechanicalDesign1-MD1Monday- MohamedAwadallah~2FShared%20Documents~2FMD1%20Monday%20- %20Mohamed%20Awadallah~2FVideos~2FMonday%20Group%202.mp4? threadId=19:0dc9381176bb4539b7efad50241deed0@thread.tacv2 &baseUrl=https:~2F~2Fstudentutsedu.sharepoint.com~2Fsites ~2F48600MechanicalDesign1-MD1Monday- MohamedAwadallah&fileId=681f0bc9-b887-49cd-b5b1- 7f524bd58ca3&ctx=files&rootContext=items_view&viewerActio n=view Appendix B: Calculations 28 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 Appendix C: CAD 29 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 Made by group leader - Leon 33 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 Appendix D: Team Meetings, data sheet of motor drive and code CODE: FOR THE WHEELS: // connect motor controller pins to Arduino digital pins // motor one int enA = 10; int in1 = 9; int in2 = 8; // motor two int enB = 5; int in3 = 7; int in4 = 6; void setup() { // set all the motor control pins to outputs pinMode(enA, OUTPUT); pinMode(enB, OUTPUT); pinMode(in1, OUTPUT); pinMode(in2, OUTPUT); pinMode(in3, OUTPUT); pinMode(in4, OUTPUT); } void demoOne() { // this function will run the motors in both directions at a fixed speed // turn on motor A digitalWrite(in1, HIGH); digitalWrite(in2, LOW); // set speed to 200 out of possible range 0~255 analogWrite(enA, 200); // turn on motor B digitalWrite(in3, HIGH); digitalWrite(in4, LOW); 34 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 // set speed to 200 out of possible range 0~255 analogWrite(enB, 200); delay(2000); // now change motor directions digitalWrite(in1, LOW); digitalWrite(in2, HIGH); digitalWrite(in3, LOW); digitalWrite(in4, HIGH); delay(2000); // now turn off motors digitalWrite(in1, LOW); digitalWrite(in2, LOW); digitalWrite(in3, LOW); digitalWrite(in4, LOW); } void demoTwo() { // this function will run the motors across the range of possible speeds // note that maximum speed is determined by the motor itself and the operating voltage // the PWM values sent by analogWrite() are fractions of the maximum speed possible // by your hardware // turn on motors digitalWrite(in1, LOW); digitalWrite(in2, HIGH); digitalWrite(in3, LOW); digitalWrite(in4, HIGH); // accelerate from zero to maximum speed for (int i = 0; i < 256; i++) { analogWrite(enA, i); analogWrite(enB, i); delay(20); } // decelerate from maximum speed to zero for (int i = 255; i >= 0; --i) { analogWrite(enA, i); analogWrite(enB, i); delay(20); } // now turn off motors digitalWrite(in1, LOW); digitalWrite(in2, LOW); digitalWrite(in3, LOW); digitalWrite(in4, LOW); } void loop() { demoOne(); delay(1000); demoTwo(); 35 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 delay(1000); } FOR THE STEPPER MOTOR /* Stepper Motor Control - one revolution This program drives a unipolar or bipolar stepper motor. The motor is attached to digital pins 8 - 11 of the Arduino. The motor should revolve one revolution in one direction, then one revolution in the other direction. Created 11 Mar. 2007 Modified 30 Nov. 2009 by Tom Igoe */ #include <Stepper.h> const int stepsPerRevolution = 200; // change this to fit the number of steps per revolution // for your motor // initialize the stepper library on pins 8 through 11: Stepper myStepper(stepsPerRevolution, 8, 9, 10, 11); void setup() { // set the speed at 60 rpm: myStepper.setSpeed(60); // initialize the serial port: Serial.begin(9600); } void loop() { // step one revolution in one direction: Serial.println("clockwise"); myStepper.step(stepsPerRevolution); delay(500); // step one revolution in the other direction: Serial.println("counterclockwise"); myStepper.step(-stepsPerRevolution); delay(500); } 36 | P a g e
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Warman Design Report Mechanical Design 1 – Autumn 2021 REFERENCES Anon, 2021, viewed 15 April 2021, <https://www.bunnings.com.au/ambassador-100mm- white-plastic-centre-wheel-and-rubber-tyre_p3942885>. Anon, 2021, viewed 15 April 2021, <https://www.bunnings.com.au/metal-mate-25-4-x-25-4- x-1-2mm-3m-aluminium-square-box-tube_p1079488>. Supplies, S. 2021, Square Tube Joiner Two Way Corner , Shapealuminium.net.au. viewed 15 April 2021, <https://www.shapealuminium.net.au/square-box-tube-joiners/square-tube- joiner-two-way-corner>. Collins, D. (2020, February 7). What options are there for integrated motor and screw designs? Linear Motion Tips. <https://www.linearmotiontips.com/what-options-are- there-for-integrated-motor-and-screw-designs/> Instructables, & Ben1998. (2017, December 28). Linear Actuator Stepper Motor. Instructables. <https://www.instructables.com/Linear-Actuator-Stepper-Motor/> Bunnings’s warehouse, drawer slides, viewed 2 April 2021, < https://www.bunnings.com.au/our-range/building-hardware/door-window-gate- hardware/cabinet/drawer-slides?page=1&facets=CategoryIdPath%3D8dedf25d-58b7-430e- a87c-e889b570bc90%2CSubCategoryIdPath%3Dc175764f-6e57-4bcd-a7a8- d0627a89047b&sort=BoostOrder&pageSize=60 > MDF properties, viewed 10 April 2021, < https://civiltoday.com/civil-engineering- materials/timber/166-mdf-definition-types-properties-manufacture > CUBII Industrial Solutions. (2020, May). Fasteners and its importance in industry. <https://cubii.co/en/fasteners-and-its-importance-in-industry/> 45 | P a g e
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Question 2 You are a biomedical engineer working for a small orthopaedic firm that fabricates rectangular shaped fracture fixation plates from titanium alloy (model = "Ti Fix-It") materials. A recent clinical report documents some problems with the plates implanted into fractured limbs. Specifically, some plates have become permanently bent while patients are in rehab and doing partial weight bearing activities. Your boss asks you to review the technical report that was generated by the previous test engineer (whose job you now have!) and used to verify the design. The brief report states the following... "Ti Fix-It plates were manufactured from Ti-6Al-4V (grade 5) and machined into solid 150 mm long beams with a 4 mm thick and 15 mm wide cross section. Each Ti Fix-It plate was loaded in equilibrium in a 4-point bending test (set-up configuration is provided in drawing below), with an applied load of 1000N. The maximum stress in this set-up was less than the yield stress for the…
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You are a biomedical engineer working for a small orthopaedic firm that fabricates rectangular shaped fracture fixation plates from titanium alloy (model = "Ti Fix-It") materials. A recent clinical report documents some problems with the plates implanted into fractured limbs. Specifically, some plates have become permanently bent while patients are in rehab and doing partial weight bearing activities. Your boss asks you to review the technical report that was generated by the previous test engineer (whose job you now have!) and used to verify the design. The brief report states the following... "Ti Fix-It plates were manufactured from Ti-6Al-4V (grade 5) and machined into solid 150 mm long beams with a 4 mm thick and 15 mm wide cross section. Each Ti Fix-It plate was loaded in equilibrium in a 4-point bending test (set-up configuration is provided in drawing below), with an applied load of 1000N. The maximum stress in this set-up was less than the yield stress for the Ti-6Al-4V…
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Please give a complete solution in Handwritten format. Strictly don't use chatgpt,I need correct answer. Engineering dynamics
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I need parts 1, 2, and 3 answered pertaining to the print provided. NOTE: If you refuse to answers all 3 parts and insist on wasting my question, then just leave it for someone else to answer. I've never had an issue until recently one single tutor just refuses to even read the instructions of the question and just denies it for a false reasons or drags on 1 part into multiple parts for no reason.
I need parts 4, 5, and 6 answered pertaining to the print provided.
I need answers to questions 4, 5, and 6 pertaining to the print provided.
est 2 (copy) (page 4 of 9) A wiseup.wsu.acza/mod/quiz/attempt.php7attempt=610918cmid 148960&page=3 ops O YouTube M Gmail Maps O GENERAL MATHEM. O New Tab :WSU WiSeUp 1 MONLO GOA ashboard / My courses / FLM15B2_KF_WS6222 2021 / Tests / Test 2 (copy) uestion 4 Quz navigation Gate AB in Figure below is 1.0 m long and 0.9 wide. Calculate force F on the gate and position X of its centre of Not yet answered pressure. Marked out of Finish attempt 10,000 Rag question 3m Oil, s.g.=Q81 7m 1.0m B 50 Answer
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Chrome File Edit View History Bookmarks People Tab Window Help McGraw-Hill Campus - ALEKS Science - CHM1045 GEN CHEM 1 BLENDED 669113 A bconline.broward.edu/d21/le/content/466883/fullscreen/12868783/View McGraw-Hill Campus - ALEKS Science O GASES Interconverting pressure and force A chemistry graduate student is designing a pressure vessel for an experiment. The vessel will contain gases at pressures up to 470.0 MPa. The student's design calls for an observation port on the side of the vessel (see diagram below). The bolts that hold the cover of this port onto the vessel can safely withstand a force of 2.80 MN. pressure vessel bolts side View port Calculate the maximum safe diameter w of the port. Round your answer to the nearest 0.1 cm. O cm Explanation Check O2021 McGraw-Hill Education. All Rights Reserved. Terms of Use FEB
I need answers to questions 13, 14, and 15 pertaining to the print provided. Note: A tutor keeps putting 1 question into 3 parts and wasted so many of my questions. Never had a issue before until now, please allow a different tutor to answer because I was told I am allowed 3 of these questions.
I Blackboard @ Texas Tech Uni x Bb MasteringEngineering - Spri x E MasteringEngineering Maste X C Suppose That H = 3.8 M . (Fi x X Mathway | Calculus Problem x y! how to take a full page scree A session.masteringengineering.com/myct/itemView?assignmentProblemID=12360392&offset=next ABP O Tp E G KAssignment #3 Fundamental Problem 2.29 5 of 6 > I Review Part A Find the magnitude of the projected component of the force along the pipe AO. (Figure 1) Express your answer to three significant figures and include the appropriate units. µA FAO = Value Units Submit Request Answer Figure 4 m F = 400 N 6 m 5 m B 4 m 10:31 PM O Type here to search 2/7/2021
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