The University of Western Ontario

Faculty of Engineering
Mechatronic Systems Engineering Program

MSE 2202 — Introduction to Mechatronic Design

FINAL EXAMINATION—April 11, 2015

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 /28

5 /10

6 /10

Total /100
MSE 2202b—Final Exam 2015 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/m]: 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 2015 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) Analysis and design

(b) ADC and DAC

(c) Ultrasonic and infrared range sensors

(d) Centralized and distributed version control

(e) Dimensional and geometric tolerances

 MSE 2202b—Final Exam 2015 Page 4 of 18

2. Short Answer Questions (24 marks)

(4) (a) Describe how the signal sent to a continuous-rotation servo motor (or 2-wire DC motor interfaced with a VEX
29 motor controller) can be varied to control the direction and speed of rotation of the motor.

(4) (b) Discuss the importance of well-defined engineering specifications. How can a design engineer ensure that
the engineering specifications will lead to solutions that fully address the design problem?
 MSE 2202b—Final Exam 2015 Page 5 of 18

(4) (c) Computer-aided engineering tools permit potential design solutions to be explored without building and test-
ing physical prototypes. Describe two such tools and discuss at least one shortcoming or limitation of each
that may lead to misleading results.

(4) (d) How is anthropomorphic data used in product design? Provide examples of how the use of this data can lead
to better design solutions.
 MSE 2202b—Final Exam 2015 Page 6 of 18

(4) (e) Outline the purpose of constraints when building a SolidWorks model. Provide examples of 3 different con-
straints that might be used in a typical model.

(4) (f ) Give two examples of wireless communication protocols that are used for consumer electronic products. Con-
sidering that these protocols operate around 2.4 GHz, describe how multiple devices are able to communicate
simultaneously.
 MSE 2202b—Final Exam 2015 Page 7 of 18

3. Microcontroller Design (16 marks)

Consider the development of a simple Arduino-based project that will control a “smart” toaster oven. The user
interface consists of a pushbutton to start/cancel the toast cycle and a rotary knob (potentiometer) that allows
the user to select the desired degree of toasting. A thermistor is used to measure the internal temperature of the
toaster. Using these inputs, a resistive heating element must be controlled to produce the desired toast level. It is
expected that the toast cycle will be adjusted based on the internal conditions of the toaster.

(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
thermistor and heating elements may be shown as blocks labelled “Thermistor” and “Heating element,” re-
spectively.

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 2015 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 2015 Page 9 of 18

4. CAD Modelling (28 marks)

Consider the part shown below. It is 25 mm in length, height and width. Each face is 1.5 mm thick. The holes are
horizontally centred on each face. The round hole is 4 mm in diameter and extends through the part; the hole
centre is located 8 mm from the top edge. The square holes are 4 mm on each side and extend though each face;
the square hole centres are 4.5 mm from the bottom left edge. In all parts of this question, be sure to clearly state
any assumptions.

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(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 2015 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 2015

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 2015 Page 12 of 18

(6) (d) How would the part and part modelling process change if it is to be manufactured from sheet metal?
 MSE 2202b—Final Exam 2015 Page 13 of 18

5. Heat Transfer (10 marks)

Consider a small wall charger with outer dimensions of L = 50 mm, w = 20 mm and d = 45 mm. When plugged into
an electrical wall outlet, but not in use, the charger has a surface temperature of Ts = 33◦ C. The charger surface
has an emissivity of ε = 0.92. The room air temperature is T∞ = 22◦ C and the wall temperature is Tsur = 20◦ C. The
conduction heat transfer coefficient is k = 1.0 W/m·K and the free convection heat transfer coefficient is h = 4.5
W/m2 ·K.

Wall

Charger

Air

(5) (a) Assuming that there is negligible heat transfer from the back of the charger to the wall and outlet, determine
the rate of electricity used while the charger is plugged in.
 MSE 2202b—Final Exam 2015 Page 14 of 18

(2) (b) If the cost of electricity is $0.14/kW·h, determine the daily cost of leaving the charger plugged in.

(3) (c) Now, if the assumption of Part (a) does not apply (that is, heat transfer from back of charger to wall and outlet
is significant), draw a labelled equivalent thermal circuit of the system.
MSE 2202b—Final Exam 2015 Page 15 of 18

6. Design Reflection (10 marks)

Consider the home service robot that you designed as part of the course project. Describe an element of your de-
sign that differs between the prototype and the final design, as a result of challenges that were experienced 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 2015 Page 16 of 18

Additional Work
MSE 2202b—Final Exam 2015 Page 17 of 18
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