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P09203 – 1kg Robotic Motor Module Gen 2 Platform This project is Sponsored by the Kate Gleason Foundation.  Team Members:  Lauren Farnsworth → Team Lead, DFMA, Process Design Expert  Mike Egan → Chief Engineer  Matt Missel → Design Engineer, Machining & Assembly Expert  Greg Leaper → Systems Analyst and Website Administrator 2

Project Description  Provide a product line of off-the-shelf motor modules and platforms for diverse applications  Scalable, modular, robust wheeled platform to carry payloads of 1kg mass  Module should be fully compatible with team P09204  Open architecture, Open source development  Target audience is educational and outreach programs 3

Customer Needs  Robust  Modular (High-tech Lego)  Infinite effective motion  High overall system efficiency  Open source and open architecture  Thorough documentation 4

Design Rationale  Customer needs Identify what the customer really wants  Specifications Translate customer needs into engineering specifications  Concept generation Sketch approximately 20 concepts which have the potential to meet customer needs and specifications  Concept selection Weight pros, cons, and risks of each concept  Detailed design 5

Design Evolution Initial ConceptFinal Design

Manufacturing Upper Housing Solidworks Model Extruded Form Blueprint Cut “Extrusion” Finished Part CNC Machined

Manufacturing Lower Housing Solidworks ModelBlueprintMastercam Toolpaths 4-Axis Machining Center Part in 4 th Axis Finished Part

Specifications and Testing 9

Cost Breakdown Prototype and Test Total Cost (3 MM, 1 IM) Estimated Idler Unit Cost (Lot of 1 IM) $ $ Estimated Motor Unit Cost (Lot of 1 MM) $ Estimated Motor Cost (Lot of 1000 MM) $ Robotic Platform (2 MM & 2 IM) $ RP1 MM Gen 1 Unit cost $404.70

Estimated Molding Cost (lower Housing) 11 Current Material Unit Cost $8.03 Estimated Molding Material Unit Cost $0.13 Estimated Molding Process Unit Cost $0.47 Estimated Molding Tooling Unit Cost $0.41 Estimated Molding Total Unit Cost $1.01 Lot of 20000, 2 cavities per mold, Nylon

Future Design & Recommendations  Further simplify lower housing  Improve turn table design  Make the lower housing a plastic part  Make the upper housing an extruded part  Order Motors earlier  Verify vendor information 12

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