Project Reports

Product Design (MCT-302L)

Lab Manuals and Assignments

Submitted By: 2019-MC-77 (Areeba Azhar)

Submitted To: Dr. Ali Raza

DEPARTMENT OF MECHATRONICS AND CONTROL ENGINEERING

University of Engineering and Technology, Lahore

May 31, 2022

 ASSIGNMENT (MAKE A TOY):
DESIGN:
Following is the attached sketch of the Wire Loop Game:

BILL OF MATERIALS:

Component Cost (Rupees)

9V Battery 60

Buzzer 20

Switch 10

Steel Wire Already available at home

Wood Already available at home

Jumper Wires Already available at home

Total 90
CIRCUIT DIAGRAM:
Following is the attached circuit diagram:

IMPROVEMENTS:
Following are the two improvements that can be made in my toy:
1. Use an adapter instead of a battery so that the issue of drainage of the battery can be overcome.
2. Make the wire loop in a more complex fashion.
 LAB SESSION 1 (DESIGN A SEEDING TOOL):
PROBLEMS FACED BY THE FARMER:
This step involves divergence to myriads of problems faced by the farmer. These problems are taken into account
after understanding the pains and gains of the farmer, and observing his daily life activities surrounding farming.
Following are the problems faced by the farmers:
1. Unequal distribution of seeds
2. Unequal distribution of fertilizers
3. Chances of wastage of expensive seeds
4. Steps performed by human labor repetitively, for instance tillage and seeding
CRITERION-1:
After stating the problems faced by an average farmer in daily routine, the next step is to crisply define Criteria-1.
This is done by converging to some point. Criteria-1 is “the farmer’s feedback”, regarding the problems we have
stated. This is a vital step since it is very important to know what the farmer feels about the aforementioned
problems. There might be a chance that we have missed any problem or written down a problem which is trivial
to the farmer. So it is important for us to be on the same page as that of the farmer in order to facilitate him
properly.
PROBLEM STATEMENT:
Following is the problem statement of our design challenge:
“To design a multipurpose technical tool performing seeding, tilling, and fertilization in one
single step/cycle.”
In this way, we have covered all of the problems faced by the farmer in one single sentence.
SKETCHES FOR SUPPORTING PROPOSED SOLUTION:
Following are the snapshots of the sketches, for supporting our proposed solution to the problem:
CRITERION-2:
Criteria-2 is our final selected solution we have proposed to our design challenge. This step occurs after we have
proposed multiple solutions and their features. After this step, we have to converge to one final selected solution
which succeeds in meeting all of the demands put forth by the farmer. In other words, this final solution should
facilitate the farmer in overcoming the problems he faces while farming, on a daily basis. Our list of solutions are
different hand-held tools for easy function, 4-point row seeder (motor controlled), multi-line pushway tool,
tractor attachment tool, quadral agricultural tool. Our final selected solution is “Quadral Custom Agricultural
Tool”.
SELECTED AND DETAILED SOLUTION:
Following is the snapshot of our final proposed solution to the problem:
“QUADRAL CUSTOM AGRICULTURAL TOOL”
LIST OF RESOURCES:
Following are the resources which are required for this solution:
1. Seeds for the seeding process
2. Fertilizer for the fertilization process
3. Water to be mixed with the fertilizer to perform “fertigation” process
4. A manufacturer/technician which can integrate all the components and as a result produce one final tool
5. Cost which is required to spend on all the components and resources, like wheel, roller, containers etc
6. Farmer which can use this tool and perform all agricultural operations
DOUBLE-DIAMOND APPROACH:
Following is the attached diagram of the double-diamond approach to our problem:
 LAB SESSION 2 (SKETCHING 101):
SKETCHES:
Following are the pictures of sketches required in this Lab Session:
LINES:
CIRCLES:
ELLIPSES:
SINGLE POINT PERSPECTIVE:
TWO-POINT PERSPECTIVE:
3D SKETCH (THREE-POINT PERSPECTIVE):
LAB SESSION 3 (FRAME YOUR DESIGN CHALLENGE):
 LAB SESSION 4 (BUILDING PERSONAS):
PERSONA 1: CHILD

DESCRIPTION:

Mukarma is a 20 year old engineering student. She has a hectic routine and a lot of academic burden. She is a
child of a single parent (mother) and has no siblings. She has become a victim of depression due to a stressed
daily routine and less recreation. Depression has caused a bad effect on her mental and physical health. She has
lost the motivation to do anything, due to which she has gained a lot of weight due to depression. Sleep paralysis
is also one of the effects of this situation. She is a person who cannot manage the abrupt burden and gets
depressed and stressed when there is an immediate burden of studies.

HOUSING:

She lives in a small yet cozy apartment. She lives there alone with her mother. She has a separate room over
there. Her apartment is on the second floor so there is no play area there.

CHARACTER:

She is introverted, has less confidence, socially awkward, short tempered, innocent, simple and an intelligent
person. She is also an overthinker and analyzes things deeply. She is very comfortable and humorous around the
people she knows and likes. She is emotional and less friendly.

HEALTH:

She has anxiety and extreme depression do to which she has following issues:

• Aggression

• Obesity

• Hair loss

• Migraine

• Hypertension

• Stress

Hobbies:

● She used to be a good painter but due to recent burden and stress of studies, she has lost the motivation to
do things she used to love.
● She is good at singing and loves to listen to music.
 ● Apart from the depressive phase, she likes being creative and is very artistic, but depression has killed
those creative thoughts.
● Photography is also one of her talents.

TECHNOLOGY:

She likes to use Instagram, Netflix, Facebook, and Snapchat and loves to enchant her depressed soul by sharing
memes on social media. In person, she is an introvert but on social media, she is extremely extrovert.

DAILY ROUTINE:

In her daily routine, she spends more than half of her day in university. Her eating pattern is also very bad, and
she consumes unhealthy food throughout her day. After getting home from her university, she spends most of the
time alone in her room and doesn't like to interact more. She spends very little time with family and is mostly on
the phone. Due to being tired throughout the day in university, the activity level after getting home is very less.
She is not interested in any sort of indoor or outdoor games and prefers being alone on the phone wasting time on
social media. She likes listening to songs too. She has a very bad sleeping pattern. She is either sleepy every time
or is sleep deprived.

CAUSE OF STRESS:

She was not that depressed child from the start, but the burden of studies made her a depressed one. As she got
into higher studies, she experienced a lot of stuff that put her into depression. She is sort of a nerd that’s why,
takes a lot of stress about studies. The favoritism in educational institutes, the unhealthy competition among
students, and the less encouraging behavior of people with her has made take this much stress. There are few
activities that cause recreation or make her fresh. The disproportionate burden of studies often takes her over. She
usually feels stressed the night before her exams. There is no one to encourage her or support her in what she
feels and that is why, her situation is untreated and not being known by others. She often wants to flee from this
world and also has suicidal thoughts. She is very alone as her single mother is usually very busy and pays less
attention to her. All her friends are really extroverts, so she socially fails to cope up with them. Her teachers are
not so interested in the mental health of the students, they come, teach and go. Her eating part makes her feel
unhealthy and low too. In short, there is no one to pay proper attention to her.

PERSONA 2: TEACHER

DESCRIPTION:

Teacher teaches an engineering subject.

• Has limited time for interaction and to cover the course contents.
• Doesn’t have enough time for co-curricular activities.

• Has job insecurities.

• Workload.

• Teacher’s personal stress (home Issues).

• Financial pressure.

• Pursues conventional ways of teaching.

• Practices favoritism.

• Teaches uninteresting and boring subjects.

• Strict

CHARACTER:

A 34 years old caring, kind-hearted, observant, friendly natured, understanding human being.

OBSERVATIONS:

She observed an unusual behavior of the student in class. By talking to her, she came to know that her student is
very much depressed about the upcoming exams. Moreover, she has some family issues due to which she cannot
concentrate well on her studies and her academic record is getting worse day by day. The teacher also observed
no interest of students in co-curricular activities, having no interest in class participation, is always mentally
absent, lack of communication and no interaction with other students. After a keen observation, the teacher came
to know that her conversation is kind of related to suicidal thoughts. She sits alone, a bit rude to other classmates,
takes much time to understand things and always a bit confused.

CONVERSATION:

After having a deep conversation with the student, the teacher came to know that she has

• Suicidal thoughts

• Financial issues

• No family-time

• No motivation left because of these issues

PERSONA 3: MOTHER

She is a 45-year-old single parent. She is emotionally and physically unavailable most of the time for her child
because of her busy routine. The parents are going through separation and the father refuses to pay for child
support therefore, she works double shifts to manage all the finances. The child mainly spends time alone locked
up in her room as per the mother’s observations. The child avoids social interaction with friends or with the
mother herself even when she is available. Moreover, the mother has observed irregular sleeping and eating
patterns of her daughter. The mother has also shown concern towards the child’s poor academic performance.
Recalling her child's past routine, the mother also pointed out that she had a very creative mind and used to
indulge in various activities but recently showed no interest in anything.
 LAB SESSION 5 (SKETCHING 102):
SKETCHES:
Following are the snapshots of the sketches of Tyridium, X-Wing, and Car (a perspective 3D drawing of our
choice):
TYRIDIUM:
X-WING:
CAR:
 LAB SESSION 6 (ORIGAMI):
PAPER PLANE:
Following is the attached picture of Paper Plane:

STEPS TO FORM A PAPER PLANE:

Following are the steps involved to make a Paper Plane:
1. Take an A4 paper and fold it into half
2. Fold the upper two ends to form a triangle
3. Fold the upper side toward back while leaving 2.5 cm from the bottom
4. Move the paper towards right, and form the same triangle like before
5. Make another two folds and form two triangles, and then make a half-diamond
6. Make a diamond shape at the front of the plane
7. Fold half of the diamond on either sides
8. Strengthen the edges of the plane
9. Make the flaps of plane by folding the edges, and then curve the ends slightly for more lift
JUMPING RABBIT (COMPLEX 3D OBJECT):
Following is the attached picture of Jumping Rabbit:

STEPS TO MAKE JUMPING RABBIT:

Following are the steps involved to make a Jumping Rabbit:
1. Take a squared paper of 21x21 cm.
2. Fold the paper into half from either sides
3. Fold it into half again on either sides, and then rotate the paper in clockwise direction
4. Fold the paper into half from either sides
5. Form a triangle from top of the paper
6. Flip the paper and form a diamond shape from the top end, and then turn the paper over
7. Hold the sides of the paper and pull them down in order to form another small diamond shape
8. Form the ears of the rabbit
9. Form the inner body of the rabbit
10. Fold the bottom side up to form its legs
11. Turn the paper over, and the jumping rabbit has been made
 LAB SESSION 7 (PAPER MACHE 1):
FLOWER VASE:
Following are the steps involved in making a Flower Vase:
1. Take old newspapers and cut them into thick strips
2. Make a paste of glue and water, take it as 1:1 ratio
3. Dip those strips into the mixture
4. Take it out from the mixture and start pasting the strips onto the flower vase
5. Let it dry for a day or few hours
6. As it dries, take the mold out from the flower vase
7. Lastly, the mold attains the shape of the vase
8. Paint the vase of your favorite color
BOWL:
Following are the steps involved in making a Flower Vase:
1. Take an old newspaper and cut it into small pieces
2. Blend the newspaper with water inside a blender
3. Take the newspaper out and stain it
4. Mix the newspaper with the glue and make a dough out of it
5. Take a bowl and paste the mixture all over the bowl
6. Let the bowl dry for two days under the Sun
7. As soon as it dries, remove the mixture from the bowl
8. Try making a bowl from the both sides, i.e; inside and outside
9. Spray the bowl of your favorite color
 LAB SESSION 8 (PAPER MACHE 2):
3D MOLD (SOLIDWORKS):
Following is the attached snapshot of “Core and Cavity of the Table” which I have selected as my mold:
3D PRINTED MOLD:
Following is the attached picture of the printed 3D Mold of “The Queen of Chess”:
OBJECT MADE WITH PAPER CLAY:
I used the same paper clay from Lab 7 and put it into the 3D mold as shown in the previous heading. Following is
the result of the printed 3D mold:
 LAB SESSION 9 (SKETCH A ROBOT):
SKETCH 1:
Following is the attached snapshot of my first sketch for a companion care robot:

FEEDBACK FROM STAKEHOLDERS:

The stakeholders wanted to update the robot by making it more interactive. This could be done by replacing its
flaps with proper robotic arms which would then perform more functions which the penguin-hands couldn’t do.
Moreover, an additional LCD display was suggested by them so that the end-user can surf through the internet or
play games etc while interacting with the robot. In addition to this, it would also interact with the end-user and
communicate with him/her, because the previous robot could only express its emotions, and now the updated
robot would express emotions, perform various tasks, and interact more intuitively with the user. Therefore, two
major changes were made in the original idea of a “Companion Care Robot”.
SKETCH 2:
 LAB SESSION 10 (OPEN-ENDED LAB):
CHOPPING BOARD 1:
SKETCH:

DESCRIPTION:
Often after chopping vegetables, one of the most cumbersome tasks is to cleanly put those vegetables into the
frying pan. At times, the vegetables fall out and get wasted. In order to avoid this, I have designed a chopping
board which is multi-purpose. It can chop the vegetables and can help in adding them into the pan as well. For
this purpose, its flaps on either side are used. The flaps help in confining all the chopped content at one point so
that they can easily be added, without falling out. This design would not only facilitate the user, but avoid the
wastage of food as well.
CHOPPING BOARD 2:
SKETCH:

DESCRIPTION:
At times, when we quickly want to fry french fries, chopping them out would take a lot of time, maybe an hour or
so. I have designed a chopper especially for potatoes in which we only need to put the potato, and apply force
from the top. The patterned squares made with the blades help in cutting the slices for the fries just according to
the required size. In this way, only in one cycle and in a matter of a few seconds, the potatoes are chopped
quickly. This design solution saves the time of the user and doesn’t let him/her exhaust out.
CHOPPING BOARD 3:
SKETCH:

DESCRIPTION:
It is a multi-purpose chopping board which can serve as a fruit/vegetable-carrying basket as well. When we want
to wash the vegetables or fruits before chopping them out, we can place them inside the basket. The tiny holes all
around would help in draining the water out. After rinsing the basket and vegetables out, it can be used as a
chopper. All we need to do is apply force on the top edge, it would transform it into a simple chopping tray. This
is how it fulfills the purpose of a basket and a chopper.
 LAB SESSION 11 (TEAR DOWN 1):
ZENBO ROBOT:
“Zenbo Robot” has been selected as the object for our first tear down experiment. It is a Care Companion Robot
which helps its user in education and health. It provides AI-powered tuition, AI recognition technology, and
offers a Zenbo Lab platform where one can learn programming easily. In the field of health and care, it provides
medical services by monitoring the heart rate, blood pressure, sugar level etc of the patient through intelligent
medical tools.
FORM OF THE ROBOT:
The Zenbo Robot consists of following main components:
HEAD:
Its head has the ability to move up, down, right and left. It can pan as well.

BODY:
Its body consists of a camera, LCD display, Sonar and IR sensors, speakers, microphone, Gyroscope, Battery etc.
All of these components attached to its body are integrated together in such a way to help in sensing the
environment, so that it may respond accordingly.
LOCOMOTION:
Since it provides assistance, companionship, and entertainment to its user, it performs cheerful and adorable hand
gestures and movements, which might suddenly attract the attention of the elderly, adults or even kids. The
wheels help it to move from one place to another in a steady fashion.

FUNCTION OF THE ROBOT:

This robot offers social companionship to its user. It assists the user in his/her educational activities and also
monitors the health, thus ensuring the safety of the people. It can control and even connect to smart home
devices, can interact with the user as if understanding his pains and gains, interacts with connected services and
may also order items online. Its “camera” enables it to capture pictures and videos. In this way it intelligently
learns “face and emotion recognition”. In cases where it notices a slight decline in any health variable of the user,
it notifies it to the other friends or family members of the family. If you are feeling sad or depressed, it can also
cheer you up. It can hear you, and replies according to your stated question or statement.
DESIGN FOR MANUFACTURING (DFM):
Steel, aluminum, rubber and bioplastics are used to form the shape of the robot. “Aluminum” is preferred since it
can be easily machined and manufactured. If the robot is supposed to withstand harsh environments, then “steel”
is preferred.“Plastics” can replace metal components in some applications. “Acrylics” are preferred where
low-stress structural parts are to be used. Thus, the type of material and the manufacturing process are mainly
dependent on the weight of the robot, its pay-load capacity, its resistance to shock and impact, and the type of
environment it is supposed to work in.
DESIGN FOR ASSEMBLY (DFA):
While designing the robots, it is very important to incorporate the ease of assembly in it. This ease is also
important since it enables the components to be easily debugged and saves time of the person maintaining it.
Zenbo Robot can be easily assembled or disassembled by tightening or loosening the screws. These screws hold
different parts of the robot in its place. Its wheels, head, torso, LCD, charging port, emergency button etc can then
be easily assembled/disassembled. Each joint of the robot can also be assembled or disassembled.
SCHEMATIC DIAGRAM:
Following is the attached schematic diagram of the Zenbo Robot:
 LAB SESSION 12 (TEAR DOWN 2):
INDUCTION MOTOR:
I have taken out the “Induction Motor” from an exhaust fan and have torn it down.
FORM OF THE OBJECT:
The exhaust fan consists of an induction motor. On opening the motor by loosening the screws, I have found two
main components. One of them is called a “stator”, and the other one is called a “rotor”. Stator has coils inside
it, and the rotor consists of slant windings all over it. For this reason, it is known as a “squirrel-cage motor”.
EXHAUST FAN:
Following is the attached picture of the fan:

OUTER BODY:
Following is the attached picture of the outer body of motor:

STATOR:
Following is the attached picture of the stator:
ROTOR:
Following is the attached picture of the rotor:

FULL IMAGE:
Following is the attached picture of all the components of the Induction Motor:
FUNCTION OF THE OBJECT:
AC supply is provided to the stator winding, which produces changing magnetic flux. This changing/revolving
magnetic flux is known as “Revolving Magnetic Flux (RMF)”. The relative speed between RMF and the rotor
windings causes an emf to be induced in the rotor. Due to this induced emf, current is also induced in the rotor.
As a result of this induced current, the rotor also produces its magnetic flux. As two magnetic fields interact with
one another, due to repulsion the rotor starts to move and speeds up. This is known as “Faraday’s Law of
Electromagnetic Induction”.
The rotor shaft is attached to the fan of the exhaust. So in this way the fan moves when input in the form of
current is given to the motor. Hence, “electrical energy” is converted into “mechanical energy”.
DESIGN FOR MANUFACTURING (DFM):
The materials used in the motor are “aluminum” and “copper”. The outer body of the motor, stator and rotor are
made of aluminum, and the coils of the rotor are made of copper. Since aluminum is an excellent conductor of
heat, it is used as a frame for motors. Furthermore, it is easier to machine aluminum sheets and bars, that is why it
is used to make such components. Meanwhile, for good electrical conductivity, copper wires are used. As copper
has low resistivity, so it has more electrical conductivity. This makes copper an excellent conductor of electricity.
DESIGN FOR ASSEMBLY (DFA):
An induction motor is easier to “assemble” or “disassemble”. Rotor is placed inside the stator, and then the outer
body which is cut into half is brought together from both sides in order to enclose the motor. Four screws are
tightened in order to assemble it. Likewise, for disassembling the motor, we simply need to loosen those screws
and open the motor while rotating its outer body gently. On disassembling, we can see the stator and rotor, where
the rotor is placed inside the stator.
SCHEMATIC DIAGRAM:
Following is the attached schematic diagram of the Induction Motor: