E T H A N B L A N K E N S H I PP E T E R B U R K E

S C OT T C A R P E N T E RJ I M C A R RO L L

C A R LO S C A S A SE T H A N C O O P E R

JA C O B C R A C E

M EG R 3 1 5 6 – S P R I N G 2 0 1 5 2 - 2 4 - 1 5

TEAM 22

INTRODUCTION

Our vehicle is a Robot designed to transport a 1.5lb pallet, securely engaged, from one place to another.

Our vehicle is designed to be lightweight, cost efficient, well balanced, user friendly and intuitively remotely controlled.

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OVERALL SYSTEM2

Our design consists of a 4 wheel direct drive robot with a vertical lift system. Both the robot and the lift system are controlled with

an X-box controller and Arduino Uno.

FORKLIFT SYSTEM

ENGAGING AND SECURING MECHANISM

ACTUATION: securing arm is actuated using a HS55 Hitec servomotor. Torque to actuate securing arm is .011 in lbf and the Power is 7.445 mWatts

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FORKLIFT SYSTEM

SAFETY FACTORS: • S.F. for the two forklift rods is 491.• S.F. for the forklift base RP is 165.• The maximum deflection of the two forklift rods is 0.009 in2.

ADDITIONAL COMPONENTS:• A linear bearing is used to reduce vertical lift coefficient of friction to 0.002 • A pulley system is used to provide lift to the load.• The max tension in the cable is 1.73lb when lifting the load.

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VERTICAL LIFT

ACTUATION: the vertical lift is performed using a Pollou-994 DC motor.

RANGE OF MOTION: 4.58in vertically• The rotating speed of the motor while raising the lift is 70 rpm• The lift raises at 0.9 in/s

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VERTICAL LIFT

SAFETY FACTOR: • S.F. of the sliding mechanism RP is 26

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VERTICAL LIFT

MANUFACTURING: • The vertical lift rod and tube will be cut to length and ends will be

tapped for required screw size.• The top, sliding system, and bottom will be RP.

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CHASSIS

CONFIGURATION: Aluminum sheet with cut outs and bent up edges is designed to provide easy mounting areas.• All items are mounted directly onto the chassis. • Material used is Aluminum 6061 T6 0.040in sheet.

MANUFACTURING: Raw sheet-metal is cutout and then the edges are bent up. All labor is performed by team members.

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CHASSIS

DEFLECTIONS: max deflection is 3.97x10-6 in

SAFETY FACTORS: 370

CHASSIS WEIGHT: 0.145lb

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DRIVETRAIN AND STEERING

CONFIGUTATION: 4 direct drive servo motors

FUNCTION: Propulsion

TURNING AND STEERING: Tank style. Max Turning Torque is 2.2inlbf

WHEELS: Custom Rapid Prototyped. S.F. is 462

CONFIGURATION: All wheel drive

GRIP TYPE: Mouse-pad

SAFETY FACTOR: coefficient of friction is 0.9 and our safety factor while starting the incline is 1.07 from rest

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DRIVETRAIN AND STEERING

AXLES AND BEARINGS: • servo motor shaft and arm are directly attached to wheel.

ASCEND THE INCLINE TORQUE: 3.365 inlbf

COEFFICIENT OF FRICTION: 0.9

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DRIVETRAIN AND STEEERING

DRIVETRAIN:• Total servo motor Torque on the incline: 3.365 inlbf• Power required to go up the incline: 1.34 Watts• Rotational speed of each servo motor: 33.63 RPM

• Turning torque: moment of friction created from turning is 2.867 inlbf

• The drive moment is 4.554 inlbf. Therefore the driver moment is greater than 10% of the turning torque which means the robot is able to turn.

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DRIVETRAIN AND STEEERING2

SAFETY FACTOR: 462

POWER AND CONTROL

MAIN POWER CONTROL AND ITS ELEMENTS:

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POWER AND CONTROL

REMOTE CONTROL CIRCUIT:

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POWER AND CONTROL

REMOTE CONTROL USABILITY AND ERGONOMICS:

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POWER AND CONTROL

ON / OFF POWER SWITCHES:

OVERALL POWER USAGE FOR ONE LAP: 70.8 JDEMONSTRATE THE USE OF STORED BATTERY ENERGY FOR TWO RUNS: Using 4 AA Maxwell Batteries we have a total of 447 J to power the robot. Safety factor for the first run is 6.37 and for the second its 5.57

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OVERALL SYSTEM

TOTAL WEIGHT OF ROBOT: 1.96lb• Vertical Lift: .454lb• Chassis: .571lb• Drivetrain: .468lb• Electronics: .467lb

ESTIMATED TOTAL TIME TO TRAVERSE THE COURSE: 2.33 min

STABILITY ON THE INCLINE: while on the incline 84% of the weight is on the front axle of the robot, with the load.

ALL SUBSYSTEMS FIT TOGETHER IN THE SPECIFIED VOLUME: Yes

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OVERALL SYSTEM

CLEARANCE FOR BOTTOM AND TOP OF RAMP: minimum clearance on top of the ramp is 0.673 in.

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USE OF RAPID PROTOTYPING

CATALYST INFO AND BREAKDOWN:PARTS DETAILS: see appendix

Volume• 1 x Securing clamp arm 0.234 in3

• 1 x pulley 0.693 in3

• 4 x wheels 6.2 in3

• 1 x top lift assembly 0.27 in3

• 1 x sliding assembly 0.932 in3

• 1 x bottom lift assembly 2.107 in3

Total Volume 10.436 in3

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MANUFACTURABILITY OF THE VEHICLE

PARTS TO BE MANUFACTURED: • 1 x Chassis 6 hrs• 2 x 1/8” forklift rods 1 hrs• 2 x vertical lift rods 4 hrs• 1 x Drum support bracket 3 hrs• 1 x motor mounting spacer 1 hrs• 1 x counterweight 1 hrs

• Total manufacturing/machining16 hrs

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MANUFACTURABILITY OF THE VEHICLE

MATERIALS TO BE USED:• Aluminum 6061 T6 sheet 12in x 12in, 0.040 in thick• Aluminum 6061 Rod 0.125 in dia• Aluminum 6061 Tube 0.25 in dia• Hardened steel Rod 8mm dia• Steel Bar Stock .5in x 1in

HOW WE PLAN TO MAKE THE PARTS: Team members will be using the schools machine shop to manufacture and machine parts.

Specific tools include: vertical band saw, drill, tap and die set, grinding wheel, bending brake.

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Team 2 BUDGET

MATERIALS: • Vertical lift $65.86• Chassis $15.04• Drivetrain $68.95• Electronics $29.12• Total Materials cost $178.97

SUPPLIES:• 24Ga wires $5.49• Solder $5.99• Mouse-pad $4.99• Total Supplies cost $16.47

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Team 2 BUDGET

RAPID PROTOTYPING:

• Total Volume 10.436 in3 at $5.00/in3 $52.18

• Total Rapid Prototyping cost $52.18

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Team 2 BUDGET

LABOR: hrs x cost = subtotal• Machining 16 $30.00 $480.00

• Ordering parts 6 $10.00 $60.00• Assembling 8 $10.00 $80.00• Troubleshooting 20 $10.00 $200.00• Repairing 15 $10.00 $150.00• Soldering 7 $10.00 $70.00• RP Set Up 1 $15.00 $15.00

• Total labor cost $1055.00

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Team 2 BUDGET

Materials; $178.98

Supplies; $16.47

Labor; $1,055.00

Rapid Prototyping; $52.18

Budget Breakdown

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SUMMARY AND FUTURE PLAN

By meeting all the requirements set forth by the competition rules, we are ready to begin manufacturing, machining, rapid prototyping and building the entire robot.

Our calculation indicate that the robot is capable of completing the obstacle course with outstanding performance

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