The University of Western Ontario

Faculty of Engineering
Mechatronic Systems Engineering Program

MSE 2202 — Introduction to Mechatronic Design

FINAL EXAMINATION—April 11, 2016

Name:
Student Number:

CLOSED BOOK 3 HOURS INTRAMURAL

CHEATING: University policy states that cheating is a scholastic offence. The commission of a scholastic offence
is attended by academic penalties that might include expulsion from the program. If you are caught
cheating, there will be no second warning.
AIDS: You are permitted the use of a nonprogrammed calculator in this examination. No other aids are
permitted (i.e., NO books, notes, wireless devices, or other information processing devices). All
sheets (including rough work) must be handed in; no part of the examination may be taken from
the room.
GRADING: Marks will be assigned on the basis of correctness of solution, and thoroughness and clarity of pre-
sentation. All sketches must be properly labelled.
NOTE: It is recommended that you start the examination by first reviewing ALL questions and then schedul-
ing your time appropriately.

There are 18 pages in this examination (the last 3 pages are blank). It is your
responsibility to ensure that no pages are missing.
Record your answers to all questions in this booklet.

Question Earned Mark Total Marks

1 /12

2 /24

3 /16

4 /22

5 /6

6 /10

7 /10

Total /100
MSE 2202b—Final Exam 2016 Page 2 of 18

S TANDARD A RDUINO F UNCTIONS

abs() char() loop() setup()

analogReference() constrain() lowByte() shiftIn()
analogRead() cos() map() shiftOut()
analogWrite() delay() max() sin()
byte() delayMicroseconds() micros() sizeof()
bit() digitalRead() millis() sqrt()
bitClear() digitalWrite() min() tan()
bitRead() float() noTone() tone()
bitSet() highByte() pinMode() word()
bitWrite() int() pow()
byte() long() pulseIn()

U SEFUL F ORMULAS

00 dT T2 − T1 T1 − T2 ∆T
Heat flux (conduction) [W/m2 ]: qcond = −k = −k =k , T1 > T2 = k
dx L L L
00
Heat flux (convection) [W/m2 ]: qconv = h(Ts − T∞ ), Ts > T∞
Heat flux (radiation)† [W/m2 ]: 00
qrad = εEb (Ts ) − αG = εσ(Ts4 − Tsur
4
)
Heat rate (radiation)† [W/m]: qrad = hr A(Ts − Tsur )
† 2
Radiation heat transfer coefficient [W/m ·K]: hr = εσ(Ts + Tsur )(Ts2 + Tsur
2
)
Stefan-Boltzmann constant: σ = 5.67 × 10−8 W/m · K4
First law of thermodynamics for closed system: ∆Esttot = Q − W
Thermal and mechanical energy over interval, ∆t: ∆Est = Ein − Eout + Eg
Thermal and mechanical energy at an instant, t: Ėst = Ėin − Ėout + Ėg
∆T
Heat rate [W]: q = q 00 A =
Rt
L
Thermal resistance (conduction) [m2 ·K/m]: Rt,cond =
kA
1
Thermal resistance (convection) [m2 ·K/m]: Rt,conv =
hA
1
Thermal resistance (radiation) [m2 ·K/m]: Rt,rad =
hr A
00
Rt,c
Thermal resistance (contact) [m2 ·K/m]: Rt,c =
Ac
∆T 1
Total thermal resistance [m2 ·K/m]: Rtot = ΣRt = =
q UA
1 1 1
Thermal resistance with parallel conductors: = +
Rtot R1 R2

†
Assumes radiation exchange between a small surface at Ts and a much larger, isothermal surface that completely surrounds
the smaller one. It is also assumed that α = ε for the surface.
MSE 2202b—Final Exam 2016 Page 3 of 18

1. Compare and Constrast (12 marks)

In less than 50 words per item, compare and contrast four (out of five) of the following:
(a) Bias error and random error

(b) USB and I2C

(c) Emissivity and absorptivity

(d) Machine code and assembly code

(e) CPM and Gantt chart

 MSE 2202b—Final Exam 2016 Page 4 of 18

2. Short Answer Questions (24 marks)

(4) (a) Define PWM and describe how it works. What is a typical use of PWM?

(4) (b) You have built a robot that uses 2 DC motors to directly drive a wheel on either side of the chassis (similar to
the MSEbot). After performing some initial tests, you realize that the robot has a tendency to veer to the right.
Describe how you would modify the robot or the code that controls the robot to allow it to drive straight over
an extended distance.
 MSE 2202b—Final Exam 2016 Page 5 of 18

(4) (c) Discuss the importance of geometric tolerances. Provide concrete examples of their use.

(4) (d) What is Charlieplexing? Describe how it is typically implemented.

 MSE 2202b—Final Exam 2016 Page 6 of 18

(4) (e) How is a product design specification created? What is its purpose in the design process?

(4) (f ) You and a colleague are working together on a piece of software and are using a distributed version control
system to support the development process. Describe how changes are pushed, pulled and merged. Use spe-
cific git or mercurial commands in your answer.
 MSE 2202b—Final Exam 2016 Page 7 of 18

3. Microcontroller Design (16 marks)

Consider the development of a simple Arduino-based project that will implement an anti-lock brake system. The
inputs to the system include the brake pedal and sensors in the wheel hub that detect the rotational speed of the
wheel. If the brake pedal is depressed and a rapid deceleration is detected (faster than would normally be possible
at the speed prior to braking), it indicates that the wheel has locked up. To prevent this condition (and decrease
stopping distance), the brake calliper should be disengaged until the wheel turns freely and then the calliper can
then be reengaged.

(6) (a) Using the schematic layout in the figure below as a basis, draw a complete schematic that shows how the
required components would be connected to the Arduino. Be sure to include any additional components
(e.g., resistors, capacitors, diodes, switches) that might be necessary for the circuit to operate properly. The
brake pedal, wheel speed sensor and brake calliper may be shown as blocks labelled “Pedal”, “Speed sensor”
and “Calliper,” respectively.

5V

3V3 5V Vin
D13
Power
RST D12

AREF D11

IO REF Arduino D10

N/C D9

D8

D7

D6

D5

A0 D4

A1 D3
Analog Input

A2 D2
TX
A3 D1
RX
A4 D0

A5 SCL

SDA
GND
 MSE 2202b—Final Exam 2016 Page 8 of 18

(10) (b) Write a complete Arduino sketch that would implement the required functionality for this system, assuming
that the components are connected as shown in your schematic.
 MSE 2202b—Final Exam 2016 Page 9 of 18

4. CAD Modelling (22 marks)

Consider the part shown below. Each face is 3 mm thick. The round base of the part is 20 mm in diameter with an
8 mm diameter hole centred in the round section. The tab that extends from the base is 11 mm wide and 11 mm
high. The length of the part (from the tip of round base to the back of tab) is 25 mm. The hole in the tab is 6 mm
in diameter and its centre is located 6.5 mm from the bottom edge. In all parts of this question, be sure to clearly
state any assumptions.

(8) (a) Describe the steps required to model the part using a solid modelling CAD package such as SolidWorks. Aim
to keep the model as parametric as possible.
 MSE 2202b—Final Exam 2016 Page 10 of 18

(8) (b) Using the drawing template provided on the following page, generate a properly laid out and labelled drawing
of the part. Use third-angle projection and include all relevant dimensions and tolerances.
(6) (c) Using design guidelines for manufacturing and assembly, what modifications could be made to improve the
part design? You may use annotated sketches or text in your answer.
 MSE 2202b—Final Exam 2016

UNLESS OTHERWISE SPECIFIED: FINISH: DEBUR AND

DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR: MECHATRONIC SYSTEMS ENGINEERING
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D

MFG

Q.A MATERIAL:
DWG NO.
A

WEIGHT SCALE: SHEET 1 OF 1

Page 11 of 18
 MSE 2202b—Final Exam 2016 Page 12 of 18

5. Electronics CAD (6 marks)

(3) (a) Most electronics CAD packages, such as EAGLE, are able to output Gerber files. What information do these
files contain and how are they used?

(3) (b) What is autorouting and why should it usually be avoided?

 MSE 2202b—Final Exam 2016 Page 13 of 18

6. Heat Transfer (10 marks)

Consider a plane composite wall that is composed of two materials of thermal conductivities kA = 0.1 W/m·K and
kB = 0.04 W/m·K and thicknesses LA = 10 mm and LB = 20 mm. The contact resistance at the interface between
the two materials is known to be 0.30 m2 ·K/W. Material A adjoins to a fluid at 200 ◦ C for which h = 10 W/m2 ·K,
and material B adjoins a fluid at 40 ◦ C for which h = 20 W/m2 ·K.

(5) (a) Determine the rate of heat transfer through a wall that is 2 m high and 2.5 m wide.
 MSE 2202b—Final Exam 2016 Page 14 of 18

(5) (b) Calculate and sketch the temperature distribution.

MSE 2202b—Final Exam 2016 Page 15 of 18

7. Design Reflection (10 marks)

Consider the tesseract collecting robot that you designed as part of the course project. Describe an element of
your design that differs between the prototype and the final design, as a result of challenges that were experi-
enced during the prototype phase. That is, how was the final design refined to address a (significant) shortcoming
identified by the prototype?
MSE 2202b—Final Exam 2016 Page 16 of 18

Additional Work
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