The University of Western Ontario

Faculty of Engineering
Mechatronic Systems Engineering Program

MSE 2202 — Introduction to Mechatronic Design

FINAL EXAMINATION—April 14, 2014

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 16 pages in this examination (the last 2 are blank). It is your re-
sponsibility 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 /26

5 /12

6 /10

Total /100
MSE 2202b—Final Exam 2014 Page 2 of 16

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
L
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 2014 Page 3 of 16

1. Compare and Constrast (12 marks)

In less than 50 words per item, compare and contrast four (out of five) of the following:
(a) Address bus and data bus

(b) Encoder and potentiometer

(c) Electromechanical system and mechatronic system

(d) Selection design and parametric design

(e) Customer requirements and engineering specifications

 MSE 2202b—Final Exam 2014 Page 4 of 16

2. Short Answer Questions (24 marks)

(4) (a) How does a typical microcontroller (e.g., the ATmega328 used in the Arduino) convert analog signals to digital
signals (input) and perform digital to analog conversion (output)? What are the limitations of these processes?

(4) (b) Describe the input signal used to control a typical RC servo motor that moves through a 180◦ range. How does
the signal need to vary to utilize the full operating range of the motor?
 MSE 2202b—Final Exam 2014 Page 5 of 16

(4) (c) Describe what the Quality Function Deployment method is and provide reasons why it is a particularly valu-
able tool during the early stages of the design process.

(4) (d) Proper consideration of human factors in design may lead to improved customer satisfaction and safety. Pro-
vide examples of features that should be considered when designing safe and user friendly products.
 MSE 2202b—Final Exam 2014 Page 6 of 16

(4) (e) Outline the steps involved in obtaining a local copy of a codebase from a version control repository, checking
in changes to the local repository and then integrating changes back into the main branch of the repository.
Use specific git or mercurial commands in your answer.

(4) (f ) Outline the purpose of mates in a SolidWorks assembly. Provide examples of 3 different mates that might be
used in a typical assembly.
 MSE 2202b—Final Exam 2014 Page 7 of 16

3. Microcontroller Design (16 marks)

Consider the development of a simple Arduino-based project that will ensure that a door is not left open unin-
tensionally when it is dark outside. A microswitch embedded in the door frame is used to determine if the door is
open or closed. A photoresistive light sensor is used to sense whether it is light or dark outside. If the door is left
open for more than 30 seconds when it is dark, a piezoelectric buzzer (that sounds a fixed frequency tone when
energized with 5 V) should sound and an LED should be turned on simultaneously.

(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
piezoelectric buzzer may be shown as a block labelled “Buzzer.”

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 2014 Page 8 of 16

(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 2014 Page 9 of 16

4. CAD Modelling (26 marks)

Consider the part shown below. The base cylinder is 40 mm in diameter and 50 mm tall. The cylindical protrusion
is 25 mm in diameter and 10 mm tall. A 14 mm diameter hole runs through the main axis of both cylinders. Two 5
mm square holes extend through the entire cylinder. The centre of the bottom hole is 15 mm from cylinder base
and the hole centres are 20 mm apart. In all parts of this question, be sure to clearly state any assumptions.

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(10) (a) Describe the steps required to model the part using a solid modelling CAD package such as SolidWorks.
 MSE 2202b—Final Exam 2014 Page 10 of 16

(10) (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 2014

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 16
 MSE 2202b—Final Exam 2014 Page 12 of 16

5. Heat Transfer (12 marks)

One technique for measuring convection heat transfer coefficients involves bonding one surface of a thin metal-
lic foil to an insulating material while the opposite surface is exposed to the fluid flow conditions of interest. An
electric current is passed through the foil, causing heat to dissipate uniformly within the foil. The corresponding
00
flux, Pelec , may be inferred from the related voltage and current measurements. If the insulation thickness L and
thermal conductivity k are known and the fluid temperature (T∞ ), foil temperature (Ts ), and insulation temper-
ature (Tb ) can be measured, the convection coefficient can be determined. Assume that L = 10 mm, k = 0.040
W/m·K, T∞ = Tb = 25◦ C and Pelec 00
= 2000 W/m2 .

Foil ( , )

Foam Insulation ( )

(4) (a) Determine the convection coefficient when water flows over the surface. In this case, the foil temperature Ts
is measured as 27◦ C.
 MSE 2202b—Final Exam 2014 Page 13 of 16

(4) (b) Alternatively, determine the convection coefficient when air flows over the surface and the foil temperature
measurement is measured as Ts = 125◦ C. The foil has an emissivity of 0.15 and is exposed to large surroundings
at 25◦ C.

(4) (c) In each case (water and air flow over the foil), what error (expressed as a percentage) would be incurred by
assuming that all of the dissipated power is transferred by convection only?
MSE 2202b—Final Exam 2014 Page 14 of 16

6. Design Reflection (10 marks)

Consider the mail delivery 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 2014 Page 15 of 16

Additional Work
MSE 2202b—Final Exam 2014 Page 16 of 16