MAE156A: Fundamental Principles of Mechanical Design I

Instructors:Dr. Nathan DelsonDr. Jerry Tustaniwskyj

Lecture Overview

Machine Shop Course Intro. Motivation for Interdisciplinary Design Robot Project Course Logistics Turntable Analysis Pre-quiz to assess prerequisite knowledge Also as take home assignment due at beginning

the next lecture

Machine Shop Course The machine shop course provides critical skills for fabrication, and developing Design For Manufacturability (DFM) skills. Shop skills will be used for 156B prototype fabrication Four-week course in 156A (weeks 3-6),with option 2-week extension in 156B

Mechanical Design is Dominated by Two Factors

The rapid pace of technology development in ALL areas

Electronics Sensors Motors Mechanical Components

Intense worldwide competition in most fields

You will continually need to learn new technology and optimize performance

Interdisciplinary Design has Risen to the Forefront of Technological

Breakthroughs

Effective design of a single product often requires close integration of a wide range of disciplines

Mechanical, Optical, Fluids, Materials Electronics: Microprocessor and Sensors Control, Software

Examples: Ink jet printing Motion based gaming (accelerometers and soon magnetics) Gene sequencing

Interdisciplinary Design is: A required element of an Accredited ME degree A stated priority of UCSD’s Chancellor

Mechatronics

A Mechatronic Device has close integration of Mechanical and Electronics

High performance requires consideration of both mechanical design, electronics, and control.

http://video_demos.colostate.edu/mechatronics/inkjet_printer_components.wmv

Sensors: The Fastest Changing

Technology

About the Instructors

Jerry Tustaniwskyj

Nate Delson

Objectives & Methods of MAE156A&B

Provide a real world design experience in a supportive environmentLearning from the iterative nature of the design process through two design projects 7 week Robotic/Mechatronics design project 15 week sponsored design project

Self Guided Learning to develop life-long learning skills

156A Robot Project for Winter 2011:Plugging Oil Leaks with a customized Top

Hat

 

• At the peak of the Deepwater Horizon oil spill the public was asked to submit design solutions.

• There are over 3000 oil rigs in the gulf

• UCSD Mechanical Engineering students will help develop robotic methods for simulating capping of multiple oil leaks with a Top Hat

Leaking Oil and Top Hat Simulators

To stop the “oil” the top hat must press down the oil stream under pressure and keep it compressed so that no oil escapes. Less than 1 mm gap between top hat base and oil plume is necessary to stop leak.

Handling Multiple Oil Leaks

 

Complete Contest Rules on-line

Top Hat Magazine Oil Wells

Accelerated Life Testing (ALT) in form a shake table will be performed before and after final test. Robust design will rewarded!

• Between 1-3 top hats will be located arbitrarily in a magazine by an instructor

• Oil leaks will occur at corresponding well sites on the Oil Well turntable

• Each robot will be required to pick up the Top Hats, place them on the leaking wells, and hold down the top hats.

• Robot score will be based upon the speed at which all leaks are stopped.

Differences from Prior Quarter:Customized Top Hats!

 

Based upon oil well research it is now believed that capping can be better implemented with a Top Hat that has been designed for a specific well.

Therefore, the rules for this quarter:

•Each Top Hat must be placed on a corresponding well based upon the number on the turntable.

•The Top Hats will start with an inverted vertical orientation.

•The maximum weight of the complete machine cannot exceed twice the weight of the base plate plus two unmodified turntables.

•At the start of the contest the instructor must be able to place the Top Hats and Oil Wells in any location on the turntables without obstructions. For placement purposes it is allowed to manually rotate the turntables.

During Weeks 1-3 Students will work in Pairs on Optimizing A Turntable Platform

 

Performance Measurements:• Open-loop speed from 0 to 270 degrees• Part of grade will be based 100% on speed of turntable • Other grade component will depend on report and justification of optimization efforts.

Thousands of friction drives have been built in MAE3, but few have been optimized. It is your chance to change Design Studio history!

Robot Pair/Team Formation

In weeks 1-3 students work in pairs Choose a partner from your section time

slot from either Axx or Bxx section

In week 3-7 pairs are combined to teams of 4 to build a complete robot.

Prior Year Robot

Emphasis on Analysis, Optimization, and the Design Process

In the real-world trial and error is expensiveGood engineering decisions require both:

Solid theoretical analysis Good use of experimental results

All teams will start with a working turntable Challenge is optimizing speed

Cargo Transfer Mechanism design requires effective: Concept Generation, Project Management, and Risk Reduction

Individual reports will require justification of design decisions and demonstration of how these increased robot performance.

Areas of Optimization of Turntable?

Mechanical Interdisciplinary

Areas of Optimization of Turntable

Mechanical Gear ratio Friction reduction Inertia Spring design

Interdisciplinary Control algorithm Real-time software Sensor and motor driver electronicsOther?

Engineering Confidence comes from Understanding a Complete

System from Top to BottomIn MAE156A you will:•Design and build the mechanical system•Write the software•Wire and debug the electronics•Analyze and optimize dynamics and controlIn MAE156B and Real-World Projects, you will:•Purchase and integrate many components, but understanding the underlying operation will help you do this with confidence

MAE156B Sponsored Projects

• Real world industry and research projects

• Topics range from medical, defense, environmental, automation, product design, and many more

• Students are responsible for the budget, major design decisions, and getting the hardware to work

• Student preference is considered in project choice.

• Check out prior projects at:• http://www.maelabs.ucsd.edu/mae156/student_projects.

htm

Homework and Grading

Keep copies of all assignments turned in You will need results for robot project

Review on-line calendar carefully! Late assignments -20% (none accepted more than 2 business days late)

Grading guidelines will be the same for both sections Robot project grading will be split between Anderson and Delson

On-time attendance to Mechatronic Workshops and Machine Shop Course is essential, and a portion of the gradeCourse packets and on-line resources will be required for assignments.Any grade disputes should be raised within one week of posting on webct. In any assignment, credit to teammate and outside contributions should be noted.Peer Review, like in MAE3, will be implemented for the robot and sponsored projects.

Schedule Overview

Week 0-1: Microprocessor workshop Week 6: Slow Speed Robot Demo

Week 1-2: Motor Driver Workshop Week 7: Robot Contest

Week 3: Turntable speed performance Week 8: Robot Oral Presentations and Meet with 156B Sponsors

Week 4: Concepts for transfer mechanism Week 9: Problem Definition of Sponsored Projects

Week 5: Meet with Instructors Week 10: Risk Reduction meetings

Finals: Risk Reduction Presentation

The 156A three projects:•A Mechatronics Robot Project (weeks 1-7) . Meet in EBU2-311•A four-week Machine Shop Course (weeks 3-6). Meet in EBU2-B35•Beginning of the Sponsored Project (weeks 8-10)

Prerequisites and “Corequisites”

MAE156B is meant to be taken in the quarter immediately following MAE156A. Accordingly, prerequisites to 156B should be taken before or concurrently with 156A. This means:

MAE150 and MAE101C should be taken concurrently or prior to 156A.

Want to add MAE156A? If you have pre and co requisites

New sections Monday and Friday 8am-10:50am

Instructional Team

Engineering StaffChris CassidyDavid LischerTom ChalfantSteve Roberts

InstructorsMark AndersonNathan Delson

Mechatronics TAsDavid AdamsRitwik GhoshTsukasa Takahashi (Lead)Yoshio Tsuruta

Machine Shop Tutors Christopher Guevara Ky WoodardMyles Syverud

Logistics

Lab Office Hours start this evening!Extended office hours this weekend. Start on the turntable early to beat the MAE3 rush. Sign out from TA in lab CD with PIC compiler – to

be returned in same OH. Turntable parts per pair.

Mechatronics Lab door codeComputer Lab door code CAD Software is in EBU2-203,205, 239, as well as Geisel Library

Demo of Turntable

Prerequisite Quiz

After quiz1. Pick up extra copy of quiz to complete at

home and bring at beginning of next lecture

2. Stand by your section time sign and choose a partner.

3. Partners can register with the TAs and pick up a turntable kit. Check webpage for office hours.