Introduction to Mechatronics - MAELabs UCSD

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					MAE156A: Fundamental Principles
    of Mechanical Design I

Dr. Nathan Delson
Dr. Jerry Tustaniwskyj
Lecture Overview
  Machine Shop Course Intro.
  Motivation for Interdisciplinary Design
  Robot Project
  Course Logistics
  Turntable Analysis
  Pre-quiz to assess prerequisite knowledge
  n   Also as take home assignment due at beginning the next
         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
       w Electronics
       w Sensors
       w Motors
       w 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
      w Mechanical, Optical, Fluids, Materials
      w Electronics: Microprocessor and Sensors
      w Control, Software
 n   Ink jet printing
 n   Motion based gaming (accelerometers and soon magnetics)
 n   Gene sequencing
 Interdisciplinary Design is:
 n   A required element of an Accredited ME degree
 n   A stated priority of UCSD’s Chancellor

A Mechatronic Device has
close integration of
Mechanical and

 High performance
requires consideration of
both mechanical design,
electronics, and control.
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 environment
  Learning from the iterative nature of the design
  process through two design projects
  n   7 week Robotic/Mechatronics design project
  n   15 week sponsored design project
  Self Guided Learning to develop life-long learning
    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

•   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.

                      Complete Contest Rules on-line

Accelerated Life Testing (ALT) in form a shake table will be
performed before and after final test. Robust design will rewarded!
          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
n    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 expensive
 Good engineering decisions require both:
  n   Solid theoretical analysis
  n   Good use of experimental results
 All teams will start with a working turntable
  n   Challenge is optimizing speed
 Cargo Transfer Mechanism design requires effective:
  n   Concept Generation, Project Management, and Risk Reduction
 Individual reports will require justification of design decisions
 and demonstration of how these increased robot
Areas of Optimization of Turntable?
Mechanical         Interdisciplinary
 Areas of Optimization of Turntable
Mechanical             Interdisciplinary
  Gear ratio              Control algorithm
  Friction reduction      Real-time software
  Inertia                 Sensor and motor
  Spring design          driver electronics
         Engineering Confidence
comes from Understanding a Complete System
            from Top to Bottom
In MAE156A you will:
•Design and build the mechanical system
•Write the software
•Wire and debug the electronics
•Analyze and optimize dynamics and control
In 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:
                Homework and Grading
 Keep copies of all assignments turned in
 n You will need results for robot project

Review on-line calendar carefully!
 n   Late assignments -20% (none accepted more than 2 business days late)
Grading guidelines will be the same for both sections
 n   Robot project grading will be split between Tustaniwskyj and Delson
On-time attendance to Mechatronic Workshops and Machine Shop
Course is essential, and a portion of the grade
Course packets and on-line resources will be required for assignments.
Any grade disputes should be raised within one week of posting on
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
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)

  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

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

                                            Finals: Risk Reduction Presentation
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
 n   MAE150 and MAE101C should be taken concurrently or prior to
 Tuesday and Thursday afternoon sections conflict with
 n   If you have this conflict see the student affairs office, and they will
     create a spot for you in another section.
Instructional Team
Engineering Staff      Mechatronics TAs
  Chris Cassidy          Yoshio Tsuruta (Lead)
  Isaiah Freerksen       David Adams
  David Lischer          Ritwik Ghosh
  Tom Chalfant           Josh Wu
  Steve Roberts          Mark Jones
                         Colin Benson
  Nathan Delson
  Jerry Tustaniwskyj   Machine Shop Tutors
 Lab Office Hours start           Mechatronics Lab door
 this evening!                    code
 Sign out from TA in lab          Computer Lab door
  n   CD with PIC compiler – to   code
      be returned in same OH.      CAD Software is in
  n   Turntable parts per pair.   EBU2-203,205, 239, as
                                  well as Geisel Library
Demo of Turntable
Prerequisite Quiz
  After quiz
  1.   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
  3.   Partners can register with the TAs and pick up a
       turntable kit. Check webpage for office hours.

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