MAE156A: Fundamental Principles of Mechanical Design Instructors: Dr. Nathan Delson Dr. Mostafa (Matthew) Hedayat

Section Logistics 156A Schedule and Logistics Section Logistics Machine Shop Signup Course Objectives Project Description Intro to Mechatronics Initial Assignments Instructional Team Introductions

MAE 156A Schedule First 7 Weeks Microprocessor Robot Project Week 1: Basic Stamp Workshop 65% of grade Machine Shop Course Weeks % of grade (high pass/pass/no pass) Last 3 Weeks Begin real-world, sponsored design projects, to be completed in 156B Individual Mechanical Components research and risk reduction 25% of grade

Section Logistics Both Sections A00 and B00 will meet together for lectures which will alternate between Dr. Delson and Dr. Hedayat. Robot Project teams will be assigned by instructors, and will primarily be based upon machine shop schedule (posted Wed) Sponsored project teams will be based highly on student preference Half the teams will present to and be graded by Dr. Delson, and the other half by Dr. Hedayat. The website schedule will indicate if we meet in the large lecture room, Design Studio, or smaller lecture rooms for student presentations.

Machine Shop Signup The machine shop course provides critical skills for fabrication, and developing Design For Manufacturability (DFM) skills. As per the schedule of class, each student needs to sign up for a 3 hour period. Machine shop space is the most limited lab in MAE. Please help us with fitting everyone in.

Basic Stamp Workshop: Week 1 Chris Cassidy will be running hands-on Basic Stamp workshops during week 1 in the Design Studio! In your scheduled 3hr lab period: Go to the Design Studio during week 1 Go to the machine shop during weeks 2-7 If you missed your workshop, you MUST attend another workshop during week 1.

Course Objectives

Educational Objectives of MAE156A Design today is dominated by: Rapid changes in technology Worldwide competition Therefore good engineers need: Lifelong learning skills Experience with multidisciplinary projects Use of worldclass design and project management practices used by top companies

The Design Process is as Important as your Ideas and Analysis Iteration Concept Generation Problem Definition Concept Selection Embodiment Design Detail Design Fabrication Evaluation Design Education

Why a Mechatronics Design Project? Mechatronics Word developed in Japan to describe products where there is close integration between mechanical and electrical components Microprocessors controlled robot High level of performance requires integration of:  Mechanical structure  Electronics  Software

Table at Beginning of ContestYour Drawing, copying the shape of blocks Winter 2008 Robot Project: The Artist in Color

Design Competition The robot that completes the drawing in the fastest time without going outside the line wins! Emphasis will be placed on: Application of theory to improve performance Optimization of robot performance Justification of design decisions

Learning from Prior Designs Good designers always use proven designs With justifications regarding choices With proper reference to source material Prior designs Robot 1 Fastest robot

Intro to Mechatronics

Mechatronics Components Sensors Actuators Microprocessor & Control Electronics Mechanical Structure

Good Electronics Design Practices Verify performance of each component independently before integration Use specification (spec.) sheets for reliable performance Measure circuit extensively with voltmeter and oscilloscope Design for robustness, so circuit works even under variations in temperature and component performance. Understand the underlying physics of each component, to best understand their advantages and limitations.

Categories of Electronic Components Passive and Active components Analog and Digital High and Low power Standard (conductive) and Optical circuits

Good Electronics Design Practices Verify performance of each component independently before integration Use specification (spec.) sheets for reliable performance USE V = IR Measure circuit extensively with voltmeter and oscilloscope Design for robustness, so circuit works even under variations in temperature and component performance. Understand the underlying physics of each component, to best understand their advantages and limitations.

Categories of Electronic Components Passive and Active components Analog and Digital Microprocessors and I/O High and Low power

Active Components: What is the Big Deal about Transistors and Semiconductors? Semiconductor Sometimes conducts and sometimes does not Foundation of electronic logic and amplification “Transistor Man” When the voltage in the base become higher than the emitter, a small current into the base can control a much larger current from the collector out through the emitter.

Digital Electronics: 1s and 0s Digital Input is read high if V > 2 Digital Input is read low if V < 0.8 If a digital input is “floating” or between 0.8 and 2, the input maybe ambiguous BS2 Digital Input uses TTL Thresholds

Basic Stamp II Microprocessor 16 digital Input/Output I/O pins

Digital Output If specifications are not exceeded: A digital pin set to output a high level will be at 4.7V or higher A digital pin set to output a low level will be at 0.2V or lower Digital Output Specifications: Pin set high Each pin can source 20mA max Each group (P0-P7 and P8-P15) can source 40 mA max Pin set low Each pin can sink 25mA max Each group (P0-P7 and P8-P15) can sink 50 mA max Note: Other microprocessors typically sink current, but require a pull-up resistor to source current

High and Low Power Electronics Every electrical component (like mechanical components) have power limitations Typically Low Power Microprocessors, sensors Watch that runs for 10 years on one battery Typically High Power Motors, solenoids, and other Actuators Large heat sinks, thick wires, etc..

Optical Sensor Light activates base of transistor

Sensors: The Fastest Changing Technology

Sensors for 156A Robot Project Contact switch (digital: on/off) Optical Infrared (IR) sensor Used primarily as digital but could be analog Integrated transmitter and receiver for reflective Separate components for beam interruption Potentiometer (analog) Optical vs Contact Switch?

Sensor Physics: The Key to Good Design Infrared detector measures light in 940 nm Visible light response to light:

Robot Project Milestone Week 1: Basic Stamp Workshop Week 2: Concept Generation Week 3: Electromechanical Familiarization device Problem definition questions Week 4: Preliminary Design Review Week 5: Refinement & Analytical Modeling Week 6: Optimization & Measurement Week 7: Contest

MAE156 vs MAE3 Robot Project Microprocessor Engineering Components (and spec sheets) Higher level of analysis Optimization Design drive trains so gear ratios can be adjusted! Higher level of design process Justify decisions Project management

Documentation Assignment Keep a Design Notebook where all your ideas and doodles are recorded Keep a 3-Ring Binder with dividers to organize important material Reports will require use of notebook.

Shop & Design Studio Facilities The Shop and Design Studio are your area for creativity and productivity Guidelines are based upon assumptions of responsibility and mutual respect We are constantly trying to improve the facilities and create a world class educational environment. Please let staff and faculty know about ideas for improvements.

Initial Assignments

Individual Assignments 1: Due Tuesday at beginning of lecture Week 2 Reading: Handout: Introduction to Mechatronics and Measurement Systems, Chapter 1 (also take a look at the video demonstrations for Chapter 1 at: Identifying the need for life-long learning. Eg. Dot Matrix vs Ink Jet Printer Review last quarter's hardware and binders Develop 3 design concepts for the robot Keep originals for team meeting, but turn in photocopies

Team Assignment for Week 2 Establish weekly meeting time Characterize Ambient Light Sensor’s ability to distinguish between red and blue blocks under different lighting conditions. Develop design for familiarization project

Familiarization Project: Due Tuesday of Week 3 Build device that can detect the presence and color of a single row of blocks. You can use: A single ambient light sensor Other kit parts The objective of the familiarization project is to become familiar with the key components in your robot kit, and to get you part of the way towards the final goal of having a completed robot. To successfully complete the familiarization project, you must build a device that at the push of a button can sense the Number and Color of blocks in a single row of blocks. You must also prove to us somehow that this has been accomplished (LED’s or Debug command)

Instructional Team Engineering Staff Chris Cassidy Tom Chalfant David Lischer Steve Roberts Instructors Nathan Delson Matthew Hedayat Teaching Assistants James Gray Tutors Mark Heise (156A alum) Daniel Bedenko (lab)