Final Report on WARMAN Design and Build Project PDF

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Summary

This is the final report of the project for the subject. It comprises of 4 artefacts and compiled together to form the final individual report....

Description

Faculty of Engineering & Information Technology

Warman Design and Build Competition Project – Ball Dispensing Robot

A Report Submitted for Mechanical Design 1 (48600)

Dimitri Albert Graciandi

May 2021

Mechanical Design 1 Manufactured Track Competition Robot for Timed Payload Disposition

School of Mechanical and Mechatronic Engineering (MME) Faculty of Engineering and Information Technology (FEIT)

Manufactured Track Competition Robot for Timed Payload Disposition

Done by:

Dimitri Albert Graciandi

UTS Student Number:

13322831

Supervisor:

Dr. Mickey Clemon

Co-supervisor:

Mohamed Awadallah

Subject Number:

48600

Date:

University of Technology Sydney (UTS) P.O. Box 123, Broadway, Ultimo, NSW 2007 Australia 2

Mechanical Design 1 Manufactured Track Competition Robot for Timed Payload Disposition

Certificate I certify that the work in this report has not been previously submitted except as fully acknowledged within the text. I also certify that the report has been written by myself. In addition, I certify that all information sources and literature used are indicated in the report. Signature of Student: DG

Date: 22 May 2021

Group 5 Thursday 3:00 – 5:00 PM Group Members: Bjarne Ungemach 13217637 Dimitri Albert Gracciandi 13322831 Huynh Thanh Hoang Do 12740662 Jason Ye 12947990 Trang Khanh Dien 13759295

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Mechanical Design 1 Manufactured Track Competition Robot for Timed Payload Disposition

Abstract This report is an overview of the Warman Design and Build competition project and to see and study the processes involved in design and research to manufacture a working robot. For this report, the process of designing the robot will be summarised to five artefacts which includes Base Assembly, Robot Movement Mechanism, Track Width and Wheel Motor. Throughout the artefacts, justification, calculations, and research of the design will be explored to ensure all the design process will produce a product design that works safely and reliably according to its usage purpose which is pointed out in its functional requirements. Each of the functional requirements for the robot will act as the baseline of decision making and to enable each artefact to be verified quantitively. The design decisions made with the basis of the functional requirements will also be backed up with the research and ideation process to give more clarity as to why each decision was made and each option was chosen. With the final results being the robot meeting the functional requirements reasonably well with potential risks identified and countermeasures pointed out.

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Mechanical Design 1 Manufactured Track Competition Robot for Timed Payload Disposition

Table of Contents CERTIFICATE .................................................................................................................................................. 3 ABSTRACT ..................................................................................................................................................... 4 CONTRIBUTION OF WORK STATEMENT ......................................................................................................... 7 INTRODUCTION............................................................................................................................................. 8 WARMAN COMPETITION ......................................................................................................................................... 8 OBJECTIVES, GOALS, REQUIREMENTS ......................................................................................................................... 8 Objectives/Goals .......................................................................................................................................... 8 Requirements ............................................................................................................................................... 9 OUTLINE OF THE REPORT ......................................................................................................................................... 9 ACKNOWLEDGEMENTS .......................................................................................................................................... 10 RESEARCH AND PLANNING...........................................................................................................................11 FRDPARRC ....................................................................................................................................................... 11 DESIGN AND ANALYSIS .......................................................................................................................................... 15 Prototype 1 ................................................................................................................................................. 16 Prototype 2 ................................................................................................................................................. 16 Prototype 3 ................................................................................................................................................. 17 Prototype Analysis ...................................................................................................................................... 17 FINAL PROTOTYPE ................................................................................................................................................ 18 GANTT CHART ..................................................................................................................................................... 19 RISK ASSESSMENT ................................................................................................................................................ 19 GROUP TASKS AND PERFORMANCE .......................................................................................................................... 20 Performance ............................................................................................................................................... 20 OVERALL SYSTEM DESIGN ............................................................................................................................20 WHEEL SHAFT – NEMA 23 MOTOR ....................................................................................................................... 20 SCISSOR LIFT – NEMA 17 MOTOR ......................................................................................................................... 20 BALL DISPENSER .................................................................................................................................................. 20 INDIVIDUAL ELECTRICAL COMPONENTS ..................................................................................................................... 20 ARTEFACT 1 – BASE ASSEMBLY .....................................................................................................................21 INTRODUCTION AND RELEVANT SLOS ...................................................................................................................... 21 FUNCTIONAL REQUIREMENTS ................................................................................................................................. 21 IDEATION AND SELECTION ...................................................................................................................................... 21 DESIGN PARAMETERS ........................................................................................................................................... 21 ANALYSIS ............................................................................................................................................................ 22 RESEARCH AND REFERENCE .................................................................................................................................... 22 RISKS AND COUNTERMEASURES .............................................................................................................................. 22 ARTEFACT 2 – ROBOT MOVEMENT MECHANISM (WHEELS)..........................................................................23 INTRODUCTION AND RELEVANT SLOS ...................................................................................................................... 23 FUNCTIONAL REQUIREMENTS ................................................................................................................................. 23 IDEATION AND SELECTION ...................................................................................................................................... 23 DESIGN PARAMETERS ........................................................................................................................................... 23 ANALYSIS ............................................................................................................................................................ 23 RESEARCH AND REFERENCE .................................................................................................................................... 24 RISK AND COUNTERMEASURES ................................................................................................................................ 24 ARTEFACT 3 – TRACK WIDTH ........................................................................................................................25 INTRODUCTION AND RELEVANT SLOS ...................................................................................................................... 25 FUNCTIONAL REQUIREMENTS ................................................................................................................................. 25 IDEATION AND SELECTION ...................................................................................................................................... 25 DESIGN PARAMETERS ........................................................................................................................................... 25

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Mechanical Design 1 Manufactured Track Competition Robot for Timed Payload Disposition ANALYSIS ............................................................................................................................................................ 25 RESEARCH AND REFERENCE .................................................................................................................................... 26 RISKS AND COUNTERMEASURES .............................................................................................................................. 26 ARTEFACT 4 – ROBOT WHEEL MOTOR ..........................................................................................................27 INTRODUCTION AND RELEVANT SLOS ...................................................................................................................... 27 FUNCTIONAL REQUIREMENTS ................................................................................................................................. 27 IDEATION AND SELECTION ...................................................................................................................................... 27 DESIGN PARAMETERS ........................................................................................................................................... 27 ANALYSIS ............................................................................................................................................................ 27 RESEARCH AND REFERENCE .................................................................................................................................... 27 RISKS AND COUNTERMEASURES .............................................................................................................................. 27 COST ANALYSIS AND ECONOMIC FEASIBILITY ...............................................................................................29 ECONOMIC FEASIBILITY ......................................................................................................................................... 29 CONCLUSION AND DISCUSSION....................................................................................................................30 CONTRIBUTIONS .................................................................................................................................................. 30 Bjarne Ungemach ....................................................................................................................................... 30 Huynh Thanh Hoang Do ............................................................................................................................. 30 Jason Ye ...................................................................................................................................................... 30 REFERENCE...................................................................................................................................................31 APPENDIX ....................................................................................................................................................32

List of Figures Figure 1: Schematic view of the competition track showing silo tube location and number of pellets targeted to be in each tube. (Warman 2021) ............................................................... 9 Figure 2: Prototype 1 mechanism design. .............................................................................. 16 Figure 3: Prototype 2 mechanism design. .............................................................................. 16 Figure 4: Prototype 3 mechanism design. .............................................................................. 17 Figure 5: Final prototype design. ............................................................................................ 18 Figure 6: Transverse Front Wheel Drive engine diagram. (Penrite Oil 2020) ......................... 24 Figure 7: Track width. (Xray 2018) .......................................................................................... 26 Figure 8: Artefact 3 Risks and Countermeasures. .................................................................. 26 List of Tables Table 1: Table of team contribution. ........................................................................................ 7 Table 2: FRDPARRC table. ....................................................................................................... 15 Table 3: PUGH Evaluation table. ............................................................................................. 17 Table 4: Pros and Cons table. ................................................................................................. 18 Table 5: Gantt Chart. .............................................................................................................. 19 Table 6: Risks and Countermeasures table............................................................................. 19 Table 7: Artefact 1 Risks and Countermeasures. .................................................................... 22 Table 8: Artefact 2 Risks and Countermeasures. .................................................................... 24 Table 9: Artefact 4 Risks and Countermeasures. .................................................................... 28 Table 10: Cost breakdown. ..................................................................................................... 29

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Mechanical Design 1 Manufactured Track Competition Robot for Timed Payload Disposition

Contribution of Work Statement For this project, I have done several tasks that were decided as a group on which each member is responsible for. Mainly, I am in charge of designing the robot frame. I have decided to make the frame in a form of a chassis which will hold all components of the robot together. Furthermore, I am responsible for making the CAD for the robot design. And in doing so, I also have to decide on the wheels and the movement mechanism for the robot. When combining all my respective parts it makes the base of the robot on which the other group members will build upon to enable the robot to fully function in accordance with the functional requirements of the robot. Although, under the unfortunate situation that the world is currently facing which in the coronavirus pandemic, I was only able to do my part and responsibility to the group remotely as I am located in my home country, Indonesia. However, I still managed to do and give my contribution to the group in order to get the robot working and functioning. Group Member Dimitri Albert Graciandi Bjarne Ungemach Huynh Thanh Hoang Do Jason Ye Trang Khanh Dien

Contribution/Responsibility Mechatronic designs Base assembly design and vehicle movement Ball dispensing system Scissor lift mechanism Calculations and mechatronic design Table 1: Table of team contribution.

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Contribution % 20% 20% 20% 20% 20%

Mechanical Design 1 Manufactured Track Competition Robot for Timed Payload Disposition

Introduction The sections mentioned below in this part of the report will outline the details of the competition and the report to give context on what this project and in turn the report is about and what information and/or guidelines are used as the basis of the commencement of the project design and build.

Warman Competition The Warman Competition is a design and build competition that is run by Engineers Australia and participated by universities across Australia and New Zealand. This competition was designed an initiated to increase students’ experience in creative thinking, practical engineering design and hands-on construction (Warman 2019). The competition’s challenge had usually always been on constructing a vehicle or robot to transport goods in one form or another with varying condition and specific objectives and requirements that differs in every competition annually. For this year’s competition which is the 34th Warman Design and Build competition, the specific details and context of the theoretical situation in which students need to design upon is summarised as follows. A system for deployment of chemical agents that works autonomously is needed. The system will deploy ten pallets of chemically neutralising agents to four silos located in the refining plant. The four silos require different numbers of pallets due to the varying chemical depth. The system needs to deploy the pallets rapidly and must not contact the chemical surface within the bunded area, and also rapid return of the system is necessary to avoid irreparable damage to the system.

Objectives, Goals, Requirements Objectives/Goals • Design, build and demonstrate a proof-of-concept scaled prototype of pallet deployment system in a laboratory environment. • Points will be earned when autonomous system starts entirely within the Start/End zone and delivers pellets to each of the four tubes. • The number of pellets to be deposited at each silo is 3 for Silo A, 1 for Silo B, 4 for Silo C and 2 for Silo D as can be seen on figure 1 below. • Further points will be scored when the entire system returns to being fully to the Start/End zone side of the vivid black line in under 120 seconds with faster systems preferred.

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Mechanical Design 1 Manufactured Track Competition Robot for Timed Payload Disposition

Figure 1: Schematic view of the competition track showing silo tube location and number of pellets targeted to be in each tube. (Warman 2021)

Requirements The specific requirements to meet for the competit...