Mechanical

Design
Ian Mackenzie
General Principles

Mechanical Design

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .

Ian Mackenzie

Power Transmission
Chains
Motors
CAD

Resources
Questions

November 17, 2007

Exercise

Ian Mackenzie

Mechanical
Design
Ian Mackenzie

Involved in FIRST since 1998

Member of team 188 from 1998-2002

Recruiter/organizer for FIRST Canadian Regional in

2003

Lead mentor for team 1114 in 2004, created SimSwerve

crab drive system

Planning committee member for Waterloo Regional

since 2005

General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .

Head referee at Waterloo Regional, Toronto Regional,

Wonderland

Currently planning committee chair for Waterloo

Regional and mentor for 1114

Scheduling algorithm developer, inspector, game

designer, Lego League referee, webmaster. . .

Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Outline

Mechanical
Design
Ian Mackenzie
General Principles

General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions

How To. . .
Power Transmission
Chains
Motors
CAD

Exercise

Simplicity

Mechanical
Design
Ian Mackenzie
General Principles

Simplicity is the key to

durability
To come up with a complex
solution to a complex
problem is hard; to come up
with a simple solution to a
complex problem is even
harder

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Design for Disassembly

Mechanical
Design
Ian Mackenzie
General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

Access holes

Common tools

Think twice about glue,

welding etc.

Think about how hard it

would be to remove a part
for repair

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Multifunctionality

Mechanical
Design
Ian Mackenzie
General Principles

Figure out where you can use

one part or mechanism for
multiple tasks
I

One arm to pick up a ball

and hang from a bar
One rod as both a pivot
and a structural member
One shaft for both arms
and wheels (OK, maybe not)

Can save weight and

complexity

Careful of conflicting
requirements

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Theory

Mechanical
Design
Ian Mackenzie
General Principles

BREAKING NEWS: Theory

actually works

Calculate gear ratios

Determine whether a motor

has enough torque

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions

Calculate forces and torques

on joints

Swerve drive kinematics

Work-energy arguments

Exercise

Qualitative Theory

Mechanical
Design
Ian Mackenzie
General Principles

Self-locking mechanisms

Directions of forces or
torques

Rate of change of
force/stress/torque etc.

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Iteration

Mechanical
Design
Ian Mackenzie
General Principles

Design is iterative!

Rethink old ideas

Eliminate leftovers

In the early stages, it is often

a good idea to throw out
designs and redo them from
scratch
Every time you restart, you
know the problem a lot
better

As my Grade 9 math
teacher used to say,
Expand, then simplify

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Weight

Mechanical
Design
Ian Mackenzie

FIRST has a weight limit

Very easy to exceed the

weight limit without noticing

Drilling holes can only get

you so far

Think twice before using

steel parts, large bolts, or
thick plate

Lighten parts as you go

Weight is bad; weight up

high is much worse

Consider alternate materials:

Lexan, nylon, HDPE/LDPE,
or wood

General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Outline

Mechanical
Design
Ian Mackenzie
General Principles

General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions

How To. . .
Power Transmission
Chains
Motors
CAD

Exercise

Power Transmission

Mechanical
Design
Ian Mackenzie
General Principles

Common problem: how to transmit power between a

shaft and something attached to it
I
I
I

Gear
Sprocket
Wheel

High stresses, so easy to break

Often hard to fix

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Power Transmission
Set Screws

Mechanical
Design
Ian Mackenzie
General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

Set screws inhale audibly. . .

Weak

Prone to coming loose

Sometimes the only choice for small shafts

Resources

Use a dimple on the shaft

Questions

Use Loctite or similar to slow down loosening

Check/tighten every match

How To. . .
Power Transmission
Chains
Motors
CAD

Exercise

Power Transmission
Pins

Mechanical
Design
Ian Mackenzie
General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

I
I

Stronger than set screws

Fairly easy to use
I

I
I

Can be tricky to get hole

centred

Weakens shaft
Hard to remove
I

Tapered pins can be used,

but theyre hard to find
and tricky to use

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Power Transmission
Keys

Mechanical
Design
Ian Mackenzie
General Principles

Very strong

Does not significantly

weaken shaft
Keying shaft requires special
cutter

Can buy standard

pre-keyed shaft

Still need some way to hold

gear and key from sliding
along shaft

Often a good idea to have

set screw hold key in place

Can have some backlash if

not done properly

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Power Transmission
Bolts

Mechanical
Design
Ian Mackenzie
General Principles

Often underrated

Very simple and easy to build

Very strong

Easily disassembled

Most often used to attach

sprocket/gear to wheel

Can also be used between

sprockets/gears

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Chains

Mechanical
Design
Ian Mackenzie
General Principles

Strength
I
I

I
I

Switch to 3/8?
Power argument: P = F v
(power = force velocity)
Power P is a constant
We want to reduce the
tensile force F
So. . . ?

Tensioning
I

I
I

Sprung tensioner or simple

block/roller
Reduce backlash
Reduce probability of
chain becoming derailed

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Motors

Mechanical
Design

Motor Curves

Ian Mackenzie
General Principles

Current (amps)

Efficiency (%)

400

100

100

4000

360

90

90

3600

320

80

80

3200

Speed (rpm)

Power Out (watts)

FP801-005 Motor

Constant Voltage: 12.0 V

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

MOTOR PERFORMANCE

How To. . .

Current (a)

Power Transmission
Chains
Motors
CAD

Efficiency
280

70

70

2800

240

60

60

2400

Power Out (watts)

Resources

Speed (rpm)

Questions
200

50

50

2000

160

40

40

1600

120

30

30

1200

80

20

20

800

40

10

10

400

Exercise

50

100

150

200

250

300

350

Torque (oz-in)

400

450

500

550

600

Motors
Multiple Motors

Mechanical
Design
Ian Mackenzie
General Principles

Only way to increase actual

power in drivetrain
But wont the motors fight
each other?
I

As long as each motor is

not running faster than
free speed, it is
contributing power
Some motors might
contribute more power
than others
Need to (roughly) match
motor speeds if using
different motors

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Computer Aided Design

Mechanical
Design
Ian Mackenzie
General Principles

Usually used for complex

and/or high-precision parts
Not just a drafting tool use
for design as well!
I
I

See how parts go together

Check clearances between
components
Calculate mass of
subassemblies
Visualize mechanism
motion
Edit, restructure, and
redesign parts and
assemblies

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Computer Aided Design

Mechanical
Design
Ian Mackenzie

Get familiar with a CAD

program before the build
season
I
I
I

Think about design intent

I

Inventor
SolidWorks
Pro/ENGINEER
Make sure you can modify
the design easily (because
you will)

Use version control for CAD

files
I
I
I

Peace of mind
Allow sharing of data
Subversion, Autodesk
Vault

General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Resources

Mechanical
Design
Ian Mackenzie
General Principles

Mechanism Galleries, workshop presentations

http:
//www.firstroboticscanada.org/site/resources

White Papers, image galleries, discussion boards

http://www.chiefdelphi.com

Subversion (free, high-quality version control system)

http://subversion.tigris.org
http://tortoisesvn.tigris.org

SDP/SI
http://www.sdp-si.com

McMaster-Carr
http://www.mcmaster.com

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Resources (cont.)

Mechanical
Design
Ian Mackenzie
General Principles

Boston Gear
http://www.bostongear.com
I

Use BostSpec 2 to search for gears (need to create free

account)

Canadian Bearings (find local store)

http://www.canadianbearings.com
Metal Supermarkets (find local store)
http://www.metalsupermarkets.com

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Questions?

Mechanical
Design
Ian Mackenzie
General Principles
Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .

ian.e.mackenzie@gmail.com

Power Transmission
Chains
Motors
CAD

Resources
Questions
Exercise

Exercise
Some ideas of things to look for:

Mechanical
Design
Ian Mackenzie
General Principles

Simple solutions to complex problems

Disassembly

Multifunctionality

Theoretical calculations required

Physical principles

Why a certain method of power transmission was used

Resources

Chain design

Questions

Why a certain material was used

Exercise

Why a certain type of component was used

Why a certain type of structure was used

Design tradeoffs (usually weight and something else)

Why pneumatics used instead of motors, or vice versa

BONUS: Design leftovers

Simplicity
Disassembly
Multifunctionality
Theory
Iteration
Weight

How To. . .
Power Transmission
Chains
Motors
CAD