MAE156A: Fundamental Principles of Mechanical Design I

1. MAE156A: Fundamental Principles of Mechanical Design I Instructors: Dr. Nathan Delson Dr. Jerry Tustaniwskyj

2. 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

3. 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

4. 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

5. 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

6. 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

7. Sensors: The Fastest Changing Technology

8. About the Instructors • Jerry Tustaniwskyj • Nate Delson

9. 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 • 7 week Robotic/Mechatronics design project • 15 week sponsored design project • Self Guided Learning to develop life-long learning skills

10. 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

11. 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.

12. 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!

13. 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.

14. 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!

15. 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.

16. Prior Year Robot

17. Emphasis on Analysis, Optimization, and the Design Process • In the real-world trial and error is expensive • Good 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.

18. Mechanical Interdisciplinary Areas of Optimization of Turntable?

19. Mechanical Gear ratio Friction reduction Inertia Spring design Interdisciplinary Control algorithm Real-time software Sensor and motor driver electronics Other? Areas of Optimization of Turntable

20. 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

21. 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

22. 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 grade • Course 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.

23. 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)

24. 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

25. Engineering Staff Chris Cassidy David Lischer Tom Chalfant Steve Roberts Instructors Mark Anderson Nathan Delson Mechatronics TAs David Adams Ritwik Ghosh Tsukasa Takahashi (Lead) Yoshio Tsuruta Machine Shop Tutors Christopher Guevara Ky Woodard Myles Syverud Instructional Team

26. 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 code • Computer Lab door code • CAD Software is in EBU2-203,205, 239, as well as Geisel Library

27. Demo of Turntable

28. Prerequisite Quiz • After quiz • Pick up extra copy of quiz to complete at home and bring at beginning of next lecture • Stand by your section time sign and choose a partner. • Partners can register with the TAs and pick up a turntable kit. Check webpage for office hours.