03c_FabricationMechatronicsTrainingV2

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Georgia Institute Of Technology *

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2110

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Mechanical Engineering

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Dec 6, 2023

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pdf

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1 G EORGIA I NSTITUTE OF T ECHNOLOGY George W. Woodruff School of Mechanical Engineering ME 2110 - Creative Decisions and Design, Fall 2023 Studio #3 and #4 –Fabrication and Mechatronics Studio Description: This studio contains two parts: IDEA laboratory fabrication training and mechatronics training. Each of these and the associated deliverables are described in the following. Members of your team will be divided into groups. In the first week, Group A will work on mechatronics and Group B will work on fabrication. In the next week, groups will change places. IDEA Laboratory Safety: It is critical that you follow safe practices in the use of the IDEA laboratory and other physical fabrication facilities. The fabrication equipment in the IDEA laboratory involves many hazards. If used improperly or negligently, the studio tools and equipment can cause severe injury and bodily harm. Soldering stations also can cause burns if used improperly. The instructional team will brief you on laboratory safety practices and you will be required to sign a user agreement form regarding safe use of the laboratory space before you can use equipment. Training Schedule: This assignment will occur from Week 3 to Week 4, as noted on the course calendar. Table 1 shows the training schedule. All elements will be turned in on Canvas and will be due at the start of studio Week 6. Table 1. Training schedule for fabrication and mechatronics during Weeks 3 & 4. Training Schedule Group A Group B Week 3 Mechatronics Training and Task Sheet (group) Fabrication Training and Gear Train Assembly (individual) Week 4 Fabrication Training and Gear Train Assembly (individual) Mechatronics Training and Task Sheet (group)

2 PART 1. MECHATRONICS TRAINING AND TASK SHEET. Studio Description: This assignment is designed to give students the skills and experience to program the Arduino Uno microcontroller and to utilize the mechatronics kit, which integrates electrical, mechanical, and pneumatic systems. Students must program the Arduino to accomplish various tasks involving mechatronics components. The lab has two sections performed over two weeks. During the first week, Group A will complete one part of the lab, labeled “Mechatronics Lab Tasks: Group A;” during the second week, Group B will complete “Mechatronics Lab Tasks: Group B.” Although the programming style will not be graded, the programs should be helpful for the final project. Therefore, it is important to program using standard structure and commenting so that the program will be easy to follow for reference. Studio Tasks and Deliverables: 1. Complete mechatronics training. The student must attend the briefing given by the studio GTA. 2. Complete mechatronics task sheet. The student must finish the required mechatronics task sheet for their group. To complete the task, the student must demonstrate completion of the required task and provide a brief oral explanation of how the code accomplishes the required task. The student group will upload a video of each task completed with an oral explanation of how the code works and a contribution statement pdf to Canvas. Each student within a group must participate in coding one task and presenting another teammate's task in the video. This is a pass/fail requirement for this class. A group that receives an incomplete or “fail” grade must correct any feedback and present their corrections in-person to their studio TA for regrading. Mechatronics Kit: The mechatronics kit contains sensors, actuators, boards, power supplies and other components that will be used in this studio assignment and in the final project. Please note that your team will check out a mechatronics kit during studio. This kit is for your team to share and use over the studio assignment. All team members are responsible for the complete return of this kit and all its components in working condition. If your team is missing any components or have damaged components due to negligence, then you must replace these components immediately following the BOM links on the website. Students will not be given a final grade for this course until all kit materials have been returned. General Instructions: Before attempting to perform these programming tasks, read the Arduino Mechatronics Manual on the course website. The manual provides background on the layout of the Arduino Uno controller and explains how to implement the mechatronics components in a design. The tasks for Group A and Group B , and the checklists, are provided on subsequent pages. Canvas Submission Instructions: Mechatronics task completion will be verified by a video upload to Canvas, a PDF contribution statement upload, and submission of the final code. A single video demonstrating all tasks is expected. Separate videos demonstrating each task are also acceptable. The final video(s) should clearly show the Arduino working on each task, then show the code that was used to execute it with an oral description of how it works. Every student within Group A (or B) should be involved in the video for another teammate’s task. To accommodate

3 this, for example, each group could teleconference (e.g., Zoom, MS Teams, etc.) to record the video. The video should have the following sequence: § Student 1 with the mechatronics kit would use their laptop camera to record the Arduino kit working on Task 1. § Student 2 then shares their screen and talks through the code for Task 1 and how it works. § Student 2 then turns off screen sharing. § Student 1 then demonstrates Task 2 on the Arduino kit on camera. § Student 2 (or Student 3) then shares their screen and talks through code for Task 2. § Then they turn off screen sharing. This is repeated until all tasks are done. On Canvas, upload the video(s) to the submission site and your code in a .pdf file.

4 Mechatronics Lab Tasks: Group A (Week 3) 1. Test that your mechatronics components are all in working order. Using the Github directory (in the Arduino Mechatronics Manual) where you downloaded the myDuino library, download and run BOTH Actuator_Test.ino and MyDuino_Test.ino . Check and understand the code to know which components are being used and verify that they are operating correctly. Reference the mechatronics manual when connecting the pneumatic components. 2. Connect one momentary switch (long-arm or roller) and one solenoid (large or small) to the Arduino board. Use the switch to control the state of the solenoid. When the switch is pressed and released, the state of the solenoid should change; i.e., if the solenoid is inactive, pressing and releasing the switch once will cause it to activate. The solenoid should then remain active until the switch is pressed and released again. Hint: remember the lesson about switch debouncing! 3. Connect the rotary encoder, a DC motor and two momentary switches (long-arm or roller) to the Arduino development board. Use the readings from the encoder to control the duty cycle of the PWM signal to the DC motor. Each full rotation of the encoder should correspond to a 10% change in duty cycle (0-100). In other words, if the program is started and then the encoder is turned one full rotation, the motor should be running at 10% duty cycle; after 10 rotations, the motor should be running at full speed. While one switch is held down, the motor should spin clockwise. While the other is held down, the motor should spin counterclockwise. When both or neither switches are held, the motor should not turn at all. Also, use the LEDs on the development board to indicate the motor's direction of travel. One LED should illuminate when the motor is traveling CW and the other when the motor is traveling CCW. 4. Connect the IR sensor, banana plugs, and a motor to the Arduino development board. Rotate the motor in one direction for 10 seconds when the IR sensor detects an object within 6 – 10 cm from its lens. You will need to calibrate the IR sensor to determine the relationship between its voltage outputs and distance. The banana plugs should function as a “kill” switch, stopping the motion of the motor regardless if 10 seconds have elapsed or if there is an object within the 6-10 cm range of the IR sensor. 5. Swap the IR sensor for the ultrasonic sensor. No calibration should be necessary. Place an object 10cm away from the face of the speakers (the two cylinders protruding from the sensor case). How accurate is the reading? How does this compare to the IR sensor, and why might there be a difference?

5 Mechatronics Lab Tasks: Group B (Week 4) 1. Test that your mechatronics components are all in working order. Using the Github directory (in the Arduino Mechatronics Manual) where you downloaded the myDuino library, download and run BOTH Actuator_Test.ino and MyDuino_Test.ino . Check and understand the code to know which components are being used and verify that they are operating correctly. Reference the mechatronics manual when connecting the pneumatic components. 2. Connect the ultrasonic sensor and one momentary switch (long-arm or roller) to the driver board. Instead of using a digital input port, connect the switch to the encoder port as demonstrated in Figure 17 of the Mechatronics Manual. Use the switch to control the state of the LED. When the switch is pressed and released, the state of the LED should change; i.e., if the LED is off, pressing and releasing the switch once will cause it to turn on. The LED should not turn off until the switch is pressed and released again. Use the ultrasonic sensor as a kill switch that can turn off the LED. If an object is within 10cm, the LED should remain off, independent of the switch state. Hint: remember the lesson about switch debouncing! 3. Connect the rotary encoder, a DC motor and two momentary switches (long-arm or roller) to the Arduino development board. Use the readings from the encoder to control the duty cycle of the PWM signal to the DC motor. Each full rotation of the encoder should correspond to a 10% change in duty cycle (0-100). In other words, if the program is started and then the encoder is turned one full rotation, the motor should be running at 10% duty cycle; after 10 rotations, the motor should be running at full speed. While one switch is held down, the motor should spin clockwise. While the other is held down, the motor should spin counterclockwise. When both or neither switches are held, the motor should not turn at all. Additionally, use the LEDs on the development board to indicate the direction of travel of the motor. One LED should illuminate when the motor is traveling CW and the other when the motor is traveling CCW. 4.Connect a potentiometer and banana plugs to the Arduino development board, then connect both solenoids and both pneumatic valves to the digital output ports of the Arduino board. Using the knob on the potentiometer, have it incrementally activate the digital output ports as you turn the knob, starting with DI1 and continuing until all 4 components are activated. The banana plugs should function as a temporary kill switch that deactivates the digital outputs for the next 10 seconds. After 10 seconds have elapsed, the components should return to their previous state.

6 PART 2. FABRICATION TRAINING AND TASK SHEET Studio Description: This assignment is designed to teach students how to use the laser cutter, 3D printing, power tools and the bandsaw to create parts and assemblies. The final product will be a gear train assembly. The lab consists of three training modules, where small groups of students will rotate between laser cutting, 3D printing, power tools and bandsaw. During the first week, Group B will be trained. During the second week, Group A will be trained. Studio Tasks and Deliverables: 1. Complete training. The student must attend the IDEA laboratory safety overview and training on the laser cutter, 3D printer, power tools, and bandsaw given by the studio GTA. The GTA will record the student’s attendance and completion of training in Canvas. This is a pass/fail requirement for this class. This training MUST be completed before the student can begin using IDEA lab equipment. During training, you will fabricate parts of the assembly shown at the end of this document individually. A Bill of Materials (BOM) is included in the drawing on Page 9. Referenced CAD files are loaded to Canvas, linked within the project descriptions page. These provided .sldprt CAD models from the assembly will be used to create .dxf, .svg, and .pjx files. 2. Complete fabrication and assembly of the required components. Individually, students will produce one assembled Planetary Gear Train according to the drawings in this document. A recommended process plan is provided that can be followed as a step-by-step process. Each student should upload a video of their completed assembly to Canvas showing its functionality (gears turning). 3. Complete Fabrication Tasks and File Creation. Each student must individually complete the tasks below, including the creation of .dxf, .svg, .pjx, and .stl files as well as a series of images (e.g. .png, .jpg). The files created will be uploaded to the Canvas submission. a. Laser cutting training assignment: Your assignment is to generate a file for laser cutting in Inkscape. Download the .zip file that contains CAD assembly files from the main course Canvas page. Select the “Ring Gear”, “Sun Gear”, “Planet Gear”, “Front”, and “Back” .sldprt files and generate .dxf files from the relevant component faces. Generate a valid Inkscape .svg file for laser cutting in Trotec Job Control, it should be modified such that an appropriate color palette is used. Modify the cut settings such that Power = 100, Speed = 0.3, PPI/Hz: 1000, Passes = 1 and perform a vector ordering operation with ‘quick ordering’. Record the time estimate for cutting. You will need to save a .pjx Job Control file with appropriate cut settings. Take a screenshot of the final build plate layout (e.g., .png, .bmp, .jpg, .jpeg). Upload the .dxf, .svg and .pjx files and the screenshot file to Canvas. b. 3D printing training assignment: Your assignment in this studio is to download the “Planet Carrier” .sldprt file, generate a .stl file, and create a build plate layout in Cura that includes the part properly oriented on the build plate (no support structures, no adhesion, 5% infill (grid type), material PLA-Generic, 0.4 mm nozzle, 0.15 mm layer height) appropriately spaced such that it does not overlap with the edge of the build plate. Remember to change the 3D printer model (Ultimaker 2+, 3, or 3S) based on

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