Robot Design Project Report

Engineering 1282.01H
Spring 2018

Team B4: Smart Machine Command Crew

Michelle Fischer
Connor Redslob
Christina Spanos
Sarah Teater

R. Freuler 8:00 AM

Date of Submission: 04/23/18

 The Formula EH Grand Prix is coming up and team managers and race executives

have decided to employ an automated vehicle to perform pit preparation tasks. They have

asked the Ohio State Research and Development (OSU RED) team to produce prototype

robots to be evaluated. The Smart Machine Command Crew was commissioned by OSU

RED to create one of the prototypes. The pit preparations need to be streamlined, and a

robot will attract media attention to the innovative new cars being revealed on race day.

To solve this problem, the team employed the engineering design process. Work

on the project began on January 26, 2018 when ideas for the robot were brainstormed.

The ideas were evaluated, and a mock-up was built and presented to senior engineers.

Then, construction on the prototype began, and different aspects were added to the robot

each week to prepare for upcoming performance tests. Extensive testing was done in

preparation for performance tests and the final competition. The final design of the robot

had a wood chassis with two wheels and two skids. There was a gear for turning the fuel

crank and prongs for picking up the wrench. A wall was built on the back for toggling the

car jack and pressing the final button, and the QR code was mounted using erector pieces.

Overall, the robot design worked well in the final competition, and the robot

received a high score of 93/100. The robot won three of the five total rounds in the final

competition, doing much better than expected. Moving forward, the robot needs a

sturdier QR code mount to increase precision of Robot Positioning System (RPS) on the

course. Also, the placement of the gear and the fork mechanisms should be switched to

decrease the chance of the robot remaining in the dead zone after depositing the wrench.

Lastly, the code should be rewritten to account for a higher motor speed to decrease the

time that the robot takes to complete the course.

i
 TABLE OF CONTENTS
Executive Summary i
Table of Contents ii
List of Figures iv
List of Tables v
1. Introduction 1
1.1. Meet the Team 1
1.2. Report Outline 2
2. Preliminary Concepts 2
2.1. Constraints 2
2.2. Drivetrain Brainstorming 4
2.3. Car Jack Brainstorming 4
2.4. Fuel Crank Brainstorming 5
2.5. Wrench Brainstorming 5
2.6. Design Concept 1 6
2.7. Design Concept 2 7
2.8. Design Concept 3 8
2.9. Robot Prototype 9
2.10. Strategy 1 10
2.11. Strategy 2 11
2.12. Pseudocode 12
3. Analysis, Testing, and Refinements 14
3.1. Analysis 14
3.1.1 Chassis and Drivetrain 15
3.1.2. Motor Analysis 15
3.1.3. Mechanisms 16
3.2. Testing and Refinements 17
3.2.1. Performance Test 1 17
3.2.2. Performance Test 2 18
3.2.3. Performance Test 3 20
3.2.4. Performance Test 4 21
4. Individual Competition 22
4.1. Run 1 23

ii
4.2. Run 2 23
4.3. Run 3 24
4.4. Modifications 24
5. Final Competition 25
5.1. Round Robin Run 1 25
5.2. Round Robin Run 2 26
5.3. Round Robin Run 3 26
5.4. 1st Round of Tournament 27
nd
5.5. 2 Round of Tournament 27
6. Final Design 27
6.1. Final Robot 28
6.2. Features and Strengths 29
6.3. Final Strategy 30
6.4. Final Code 31
6.5. Schedule and Timesheets 33
6.6. Final Budget 34
7. Summary and Conclusions 34
References 37
Appendices A1
A. Decision Matrices A1
B. Robot Performance Scoring B1
C. Robot Prototype C1
D. Performance Test Results D1
E. Motor Decisions E1
F. Robot Mechanisms F1
G. Individual Test Results G1
H. Final Competition Results H1
I. Working Drawing Set I1
J. Electrical Systems J1
K. Final Code K1
L. Code Representation L1
M. Time Summary M1
N. Design Schedule N1
O. Budget and Parts List O1

iii
 LIST OF FIGURES
FIGURE NUMBER DESCRIPTION PAGE NUMBER
2.1 Robot Design 1 Sketch 6
2.2 Robot Design 2 Sketch 7
2.3 Robot Design 3 Sketch 8
2.4 Robot Mockup Front View 10
2.5 Strategy 1 Diagram 11
2.6 Strategy 2 Diagram 12
3.1 Path for Performance Test 1 18
3.2 Path for Performance Test 2 19
3.3 Path for Performance Test 3 21
3.4 Path for Performance Test 4 22
6.1 Final Robot Picture 29
6.2 Final Competition Strategy 31
6.3 Budget Pie Chart 34
C1 Robot Mockup Back View C2
E1 Torque vs. Speed Diagram E2
E2 Distance Traveled Diagram E3
F1 Wrench Mechanism F2
F2 Gear Mechanism F2
I1 Robot Assembly I2
I2 Robot Exploded Assembly I3
I3 MDF Base Subassembly I4
I4 Main Base Bottom Drawing I5
I5 Main Base Top Drawing I6
I6 Miscellaneous Parts for MDF Base Drawing I7
I7 Drivetrain Exploded Subassembly I8
I8 QR Code Stand Exploded Subassembly I9
I9 QR Code Holder Drawing I10
I10 Fuel Crank Gear Drawing I11
I11 Wrench Prongs Drawing I12
I12 Proteus Back Guard Drawing I13
I13 Modified Parts Drawing I14
J1 Electrical Systems Diagram J2
M1 Time Spent Pie Chart M2

iv
 LIST OF TABLES
TABLE NUMBER DESCRIPTION PAGE NUMBER
A1 Drivetrain Matrix A2
A2 Car Jack Mechanism Matrix A2
A3 Fuel Crank Mechanism Matrix A3
A4 Wrench Mechanism Matrix A3
A5 Decision Matrix A4
B1 Score Breakdown B2
D1 Performance Test 1 Results D2
D2 Performance Test 2 Results D2
D3 Performance Test 3 Results D3
D4 Performance Test 4 Results D3
E1 Motor Descriptions E2
E2 Time to Complete Tasks E3
E3 Robot Component Masses E4
E4 Ramp Measurements E4
G1 Individual Results 1 G2
G2 Individual Results 2 G2
G3 Individual Results 3 G3
H1 Round Robin 1 Results H2
H2 Round Robin 2 Results H2
H3 Round Robin 3 Results H3
H4 Tournament Results 1 H3
H5 Tournament Results 2 H4
N1 Design Schedule N2
N2 Design Schedule Continued N3
N3 Design Schedule Continued N4
O1 Budget Breakdown O2
O2 Budget Breakdown Continued O3

v
 Table H3: Results from final competition round robin run 3.
Primary Tasks Points Possible Points Earned
Initiate on start light 9 9
Touch wrench 8 8
Control wrench 12 12
Toggle jack lever 10 10
Rotate fuel pump crank 8 8
Press an electrical test button 7 7
Press correct electrical test button 12 12
Press final charging button 9 9
Possible Primary Task Points 75 75
Secondary Tasks
Deposit wrench 8 -
Rotate fuel pump crank in correct direction 10 10
Rotate fuel pump crank 180° 7 7
Possible Secondary Task Points 25 17
Total Possible Task Points 100 92

Table H4: Results from final competition tournament round 1 of 64 teams.

Primary Tasks Points Possible Points Earned
Initiate on start light 9 9
Touch wrench 8 8
Control wrench 12 12
Toggle jack lever 10 10
Rotate fuel pump crank 8 8
Press an electrical test button 7 7
Press correct electrical test button 12 12
Press final charging button 9 9
Possible Primary Task Points 75 75
Secondary Tasks
Deposit wrench 8 -
Rotate fuel pump crank in correct direction 10 10
Rotate fuel pump crank 180° 7 -
Possible Secondary Task Points 25 10
Total Possible Task Points 100 85

H3
 APPENDIX I
Working Drawing Set
I2
Figure I1: Smart Machine Command Crew robot assembly [6].
I3
Figure I2: Smart Machine Command Crew exploded assembly [6].
I4
Figure I3: Robot base subassembly [6].
I5
Figure I4: Sketch of bottom of main base [6].
I6
Figure I5: Sketch of top of main base [6].
I7
Figure I6: Sketches of miscellaneous parts of MDF base [6].
I8
Figure I7: Exploded subassembly of drivetrain [6].
I9
Figure I8: Exploded subassembly of QR code stand [6].
I10
Figure I9: Sketch of QR code holder [6].
I11
Figure I10: Sketch of fuel crank gear [6].
I12
Figure I11: Sketch of prongs for carrying the wrench [6].
I13
Figure I12: Sketch of Proteus back guard [6].
I14
Figure I13: Modified parts drawing [6].