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Introduction to Mechanical System Design

by: Antonia Quitzon

Introduction to Mechanical System Design MECH 311

Marketplace > Kettering University > Mechanical Engineering > MECH 311 > Introduction to Mechanical System Design
Antonia Quitzon

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Class Notes
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This 9 page Class Notes was uploaded by Antonia Quitzon on Tuesday October 13, 2015. The Class Notes belongs to MECH 311 at Kettering University taught by Staff in Fall. Since its upload, it has received 16 views. For similar materials see /class/222305/mech-311-kettering-university in Mechanical Engineering at Kettering University.


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Date Created: 10/13/15
Kettering University s 1 Ii MECH 311 Introduction to Mechanical Systems Design Spring 2009 Kettering University Kettering s Pluck n Dump MECH 311 Introduction to Mechanical Systems Design Spring 2009 PROJECT PHILOSOPHY The basic goal of the MECH311 nal project is to provide a realistic design experience from concept to completion including signi cant time material and performance speci cations as a means of practicing the steps and using the tools required by a typical design process During the course of this project design teams are expected to follow the various stages of a typical design process Identi cation Ideation Feasibility Analysis and Implementation see Required Reading on Design Processes Concept Tree and Brainstorming methods are to be used throughout this project whenever applicable IT IS EXPECTED THAT YOU WILL RECORD ALL ASPECTS OF YOUR DESIGN EXPERIENCE EG BRAINSTORMING ANALYSIS DETAILED DESIGN CIRCUITS AND PROGRAMMING NOTES IN YOUR STUDENT ENGINEERING PROJECT LOGBOOKS Student Engineering Project Logbooks are a DAILY summary of your design experience and MUST be presented by all team members daily to the laboratory professor Team members will SIGN AND DATE the logbook when presenting it to the professor The logbooks will include a detailed summary of the daily activities in the process of completing your final design beginning with BRAINSTORMING The project will require ingenuity and creativity as well as analytical ability It will illustrate the balance between synthesis analysis experimentation creativity and good judgment A rigorous time schedule and realistic constraints will be coupled with the accountability aspect ofthe engineering design profession Finally the experience will provide you with examples of the need for good communication knowledge of the engineering sciences and the development ofan engineering value system PROBLEM STATEMENT You will design a device to compete in an arena competition Your device will participate in a competition that will pit TEAM AGAINST TEAM The winning team will be the team that outperforms other teams in accordance with the goals constraints and the performance criteria set forth by this document and as interpreted by the Standards Overview Board members henceforth known as the 808 s NOTICE ALL SOB S MUST APPROVE IN WRITING ANY AND ALL DEVIATIONS FROM THE CONTEST RULES AND PROCEDURES IT IS EACH TEAM S RESPONSIBILITY TO OBTAIN DOCUMENTATION OF AUTHORIZED CHANGES AN INDIVIDUAL SOB S OPINION AND PERMISSION ARE M SUFFICIENT FOR CHANGING OR INTERPRETING THE RULES ANY REQUEST FOR CHANGE OR INTERPRETATION MUST BE MADE IN WRITING TO THE EMAIL ADDRESS MECH311KETTERINGEDU NO EXCEPTIONS 2 TIMETABLE There are several important deadlines and deliverables that must be met in accordance with the timetable set forth on the MECH311 website wwwketteringeduacadmechatronics These assignments are explained later in this document COMPETITION DESCRIPTION For a better understanding of these rules refer to the Ketten39ng Pluck n Dump Arena KPDA located in the Hougen Design Studio General Ob39ectives For each competition run two PLUCK N DUMP devices will be placed in one of two 10inch by 12inch start zones on the KPDA At the initiation signal given by one ofthe SOBs both PLUCK N DUMP devices will be activated and a timer is started The devices are to begin driving along a track toward the end ofthe KPDA where a set of ve balls are stored The goal ofthis portion ofthe movement ofyour device is to capture as many of balls as possible and store them on your device Of the five balls at the end two are in your track or zone two are in your opponent s zone and one is up for grabs A mechanism will release this up for grabs ball to the device that arrives at the end rst Along the way two additional balls will be encountered on overpasses for you to attempt to capture NOTE your device should not attempt to capture your opponent s balls or interfere with their operation in any way After capturing as many balls as you can your device is to REVERSE its motion and proceed to the other end of the KPDA where a series of three troughs are placed beyond the end of the KPDA Your objective is to transfer captured balls from your device to these troughs However your device MUST stop and NOT go past the end of the arena othenNise you are disquali ed and will receive no score A device will be considered past the end of the arena if any aspect ofthe design involved in locomotion goes past the end of the drive surface There are three troughs a closest trough middle trough and farthest trough Points used to determine your competition score will be awarded according to the following schedule One point will be given for each ball captured by your device One additional point will be given for each ball that is successfully transferred to the closest trough Two additional points will be given for each ball that is successfully transferred to the middle trough Four additional points will be given for each ball that is successfully transferred to the farthest trough Zero points will be given if the device goes past the end ofthe arena 3 Thus points are awarded according to the following schedule Balls 1 2 3 4 5 Captured 1 2 3 4 5 Closest Trough 1 2 3 4 5 Middle Trough 2 4 6 8 10 Farthest Trough 4 8 12 16 20 For example let s say you capture four balls transfer one to the farthest trough two to the middle trough and one does not successfully transfer to any trough Your score would be 41X42X212points lfthere is a tie in number of points the team that completes the task first will be declared the winner of that run If a device does not complete the task in less than two 2 minutes then it will be disquali ed forthat run In the initial tournament each team will compete twice and will start on different lanes rightleft ofthe KDPA platform each time The four teams whose device accrues the highest point total on either run will compete in a nal tournament and the one team that accrues the most points in the nal bracket ofthe tournament will be declared the winner of the overall competition In the nal tournament the first seed will compete against the fourth seed initially with lane choice given to the rst seed Similarly the second seed will compete against the third seed with lane choice given to the second seed lf seeds are not clear then lane choice will be determined by coin toss The nal tournament is a single elimination series of heats In the nal run the choice of lane will be determined by coin toss Note that if your device falls offthe edge of the KPDA the run ends immediately and you will receive no points NOTE the 808 s reserve the right to declare a winner or order further competition if no clear winner emerges after all PLUCK N DUMP devices compete BASIC RULES AND CONSTRAINTS The following is a list of constraints under which the PLUCK N DUMP devices must be designed built and operated 1 All PLUCK N DUMP devices may use any form of locomotion such as legs powered wheels propellers etc I All energy used for powering the PLUCK N DUMP device must come from any combination of DC electric motors and any number of coil springs andor rubber bands and gravity No other energy source is admissible If a LEGO RCX controller is used electric motors must be Mabuchi RF500TB12560 and operated by the 4 A A 01 O l G 0 LEGO Brick controllers Each team will be supplied six AA batteries for powering the LEGO Brick controllers andor all other circuits of your device ANY ADDITIONAL batteries required to replace lowpower batteries are to be supplied by the design teams If a LEGO RCX controller is not used a wider variety of DC motors are available including FF130 SH FK280 PA RE26O RA or RE28O RA however whichever motor is chosen must be operated within its designated voltage range Up to three motors can be used for locomotion steering and other functional purposes The PLUCK N DUMP device must be placed in its entirety on the official surface within a starting zone as de ned on the KDPA Furthermore all competition devices must be CAPABLE of tting inside a box with a 6 X 10 footprint and no more than 6 inches high while in the start position Each PLUCK N DUMP device including the LEGO RCX controller if used must have a total operating weight not exceeding 15 pounds 24 02 or 680 gms If used the LEGO RCX controllers must be enclosed and protected from shock and unnecessary contact within a housing mounted on the PLUCK N DUMP device ABSOLUTELY NO MODIFICATION CAN BE MADE to the LEGO RCX controllers such as cutting it down covering it with glue removing the housing or anything else that alters its appearance IF YOU MODIFY THE CONTROLLER YOUR TEAM WILL BE DISQUALIFIED FURTHER THE TEAM WILL BE RESPONSIBLE FOR THE REPLACEMENT COST OF THE CONTROLLER APPROXIMATELY 120 AND EACH MEMBER WILL BE GIVEN AN INCOMPLETE GRADE UNTIL THE COST IS RECOVERED LEGO power cords attached to the motors and switches used in competition can NOT be cut down in any way or coated with hotmelt glue Each team will be supplied with cords as needed for motors and switches and these cords must be returned at the end of the semester by the teams along with tools and the LEGO RCX controller Cords will be checked for length at that time IF A CORD HAS BEEN CUT AND SHORTENED THE TEAM WILL BE RESPONSIBLE FOR THE REPLACEMENT COST OF THE CORD AND EACH MEMBER WILL BE GIVEN AN INCOMPLETE GRADE UNTIL THE COST IS RECOVERED All commercially manufactured components such as motors springs sprockets etc must be used for their intended function ie do not use them as ballast spacers etc 10 Usage of plastic sprockets is limited to a selection of 8 FROM A KIT that will be provided to EACH TEAM by the SOB s 11 Ifthe PLUCK N DUMP device uses a projectile it must be tethered when red A projectile by de nition is any object leaving the of cial surface and weighing less than 20 of starting weight 12 No device or portion thereof may leave the KPDA surface by a distance of more than 6 inches 13The PLUCK N DUMP device must move as a unit where no parts are either left behind or thrown about The only exception to this is an obvious accidental part failure 14 Balls are considered transferred when they are of oaded from the PLUCK N DUMP device that is they no longer are touching the device 5 15 Balls are considered in a trough as long as they are held within the structure of that trough 16At the start ofa competition the device must be placed in a start zone and not held in any way Any motion andor expansion must be initiated by pressing a single switch by a single operator in a single attempt that does not assist the locomotion of the device in any way Once a device has started a competition run any further contact from a team member will result in that device being disquali ed forthat run 17Each PLUCK N DUMP device must be constructed from approved materials which are noted in Table I THERE ARE NO EXCEPTIONS TO THIS NO REQUESTS FOR MATERIALS DEVIATIONS OR SUBSTITUTIONS WILL BE CONSIDERED Some materials will be provided in a KIT form Materials provided in kits are generally not replaceable 18Manufacturing and construction methods will be limited to those available in the E Douglas Hougen Design Laboratory and Student Model Shop No one is allowed to manufacture anv parts outside of the model shop 19Adhesives may be used only as adhesives that is for adhering one component to another No adhesive is allowed to touch any object other than the PLUCK N DUMP device itself at any time 20 Friction reducing or enhancing agents are allowed but they must not drip onto the of cial surface nor come in contact with said surface at any time NOTE that sandpaper is NOT an H 39 construction material 21At qualification all designs and prototypes will be subject to review by the SOB s Modi cations may be ordered designs declared unsafe un t or disquali ed for violation of the rules ofthe project All decisions of SOB s are final SOB s also reserve the rigm to resolve m guestions regarding rule interpretation in accordance with the intended spirit of this project NOTE Any charges of rule violations MUST BE brought on or before the gualification date Under NO CIRCUMSTANCES will anybody be allowed to charge rule violations against another team s vehicle AFTER gualification 22AII PLUCK N DUMP devices must be returned to the ME Department Teams must check the LEGO RCX controllers and cords back in with their tools 23 If you wish to keep copies of ANY written material from the course INCLUDING Student Engineering Project Logbooks either obtain or make them prior to their submission Materials will not be available for return in subsequent semesters 24AII devices vehicles must feature the team name and names of team members written legibly on it 25A signi cant grading penalty will be assessed at the end of the semester if rule violations are discovered after qualification THE SPIRIT OF THE COMPETITION It is very common for students to try to find that perfect design concept to provide the competitive edge over everybody else Unfortunately this often means creating a design that uses a loophole in the rules or circumvents the intended spirit of the competition The 808 s will not entertain or encourage designs that utilize loopholes or gray areas of rules for design intent This paragraph is meant to state in plain language our vision for how competitive devices will work and how the competition will be executed Our vision is that competition devices will move from the start zone capture and hold balls available to them on the KPDA and then move to the trough end of the arena Upon reaching the trough end ofthe arena our vision is that a mechanism designed for the purpose of transferring held balls to the troughs will operate We do not envision devices where balls are simply bulldozed from one end to another Stopping for strategic reasons is acceptable but stopping for other reasons is not encouraged We envision that the devices will move at a speed that suggests an aggressive attempt to complete the competition In other words devices should move faster than a lackluster crawl CERTIFICATION The Certi cation Session is a mandatory session when the teams must show that their PLUCK N DUMP device is functional in the following ways 1 The device must move at least 12 inches horizontally in less than four seconds via its own locomotion 2 The device must demonstrate a planned mechanism fortransferring one or more balls Designs will be judged for tness and safety as per rule 21 Furthermore at the time of certi cation all teams must provide a name fortheirvehiclel QUALIFICATION The quali cation is mandatory before a team will be allowed to compete in the nal competition To qualify each team must show that their PLUCK N DUMP device is functional as shown during certi cation also size and weight design requirements must be met Again designs will be judged for tness and safety as per rule 21 Failure to pass either inspection Certi cation or Quali cation based on the SOB s judgment results in loss of up to 5 points off of the nal proiect grade During this session all classes are invited to send spies to each othel s sections for determining patent infringements and rule violations AgainI any charges of rule violations MUST BE brought on or before the gualification date Under NO CIRCUMSTANCES will anybody be allowed to charge rule violations against another team s vehicle AFTER gualification COMPETITION UPDATES You are advised to visit the website s QampA Bulletin link on a daily basis for rules updates and other information httpwwwketterinqeduacadmechatronicsdnahtm Table I Sanctioned Materials MATERAL SPECIFICATIONS Motors Mabuchi see literature Springs purchase your own if you choose Rubber Bands AA Batteries Sprockets Chain Fishing Line or other cord provided in lab 1inch or 15inch dowel 3 in long 225 gr Switches to work with the LEGO system only 09 gr Toothpicks Sheet Metal 1quot x 4quot x 0023quot 8 grcm3 14in wood dowel 6 in long 235 gr 532 amp 14in metal dowel 1420 UNC AllThread 1A20 UNC Nut Pine Wood 1quotX 4quotX 12quot 043 grcm3 14quot x 12quot x 12quot wood panel whatever is available in lab only Nails and Screws Tape provided in lab Paper clips Craft Sticks 15 gr Wire Coat Hanger Paint or any aesthetic coloring you provide Washers Bushings and Hooks Adhesives for fastening only Pop rivets Lead weight for ballast only Tygon tubing for motor shaft only 8 PROJECT DELIVERABLES There are a total of six deliverables during the course ofthis project as described below Please note that the documentation process builds upon itself until it culminates in the form ofthe Final Project Report It is strongly recommended that each report be viewed as a part of the Final Proiect Report as it is being prepared This will signi cantly relieve the burden of the nal documentation DELIVERABLE I Conceptual Design Following the rst three stages of a typical design process Identi cation ldeation and Feasibility each design team must prepare a conceptual proposal for a device in accordance with the objectives stated in the problem statement The quotConcept Treequot and quotBrainstormingquot methods must be used to break down the overall design problem into subproblems and then generate a conceptual design for a device As Deliverable I each team is expected to prepare A patent which follows the format ofa typical patent see class notes including 0 Title and abstract 0 A set of technical drawings and a detailed technical description of how the conceptual design works 0 At least two claims which represents the quotbackbonequot idea of the design V thin the limits of this project the claimed concept should be novel and essential to the whole design Obvious methods like using pulleys to increase torque are not considered novel Avoid generality in claims Claims will be judged by the 808 s and they will be partially or totally accepted or rejected A copy of all the patents for all class sections will be placed in a binder in the lab DELIVERABLE DETAILED DESIGN AND ANALYSIS Following the fourth step of a typical design process Analysis each team of design engineers must analyze re ne reanalyze nalize and fully document the design of the device As Deliverable ll each team is expected to prepare a report of a professional quality which includes 0 description of how the device works as adapted from Deliverable I o a wellexplained set of engineering analyses including necessary diagrams which prove the feasibility of the design in theory NOTE it is KEY that you estimate the WEIGHT OF YOUR DEVICE AND JUSTIFY that it is possible for it to move at the speed required Clearly lighter weight devices have a better chance of achieving the required speedll o a complete set of CAD generated engineering drawings fully dimensioned are required for prototype manufacturing including an assembly drawing 0 a bill of materials parts list including weight analysis NOTE Deliverable II will be used to iudqe readiness for manufacturing All components of the device must have dimensions which are based on sound engineering analysis andor judgment If this determination cannot be drawn from the report the team will be asked to revise their report In this case valuable manufacturing time will be lost 9


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