Mechanisms and Fabrication Part II ME2110 Spring 2019 Kyle Saleeby
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1 Mechanisms and Fabrication Part II ME2110 Spring 2019 Kyle Saleeby
2 Mechanisms and Fabrication Part II Kyle Saleeby With much appreciation to Dr. Chris Saldana and Dr. Tom Kurfess ME2110 Spring 2019
3 Lesson Objectives v Understand design considerations and tradeoffs for advanced fabrication techniques with including CNC machines, laser cutters, and 3D printers v Understand good practices for robust, consistent, and quality prototype robot designs v Exposure to resources for mechanisms and fabrication methods 3/ 63
4 Individual Competition v Triggering -> One action No additional energy Clean, repeatable v Things that get you DQ d.. Damage to the track (Scratches, WD-40, etc ) Not triggering Projectiles (including unintentional rubber bands) 4/ 63
5 Standard of Quality v Devices in the Trash Can Dumpster outside v Devices in the scrap bin Break down components Take out screws and nails v Begin early 5/ 63
6 Standard of Quality v Hot Glue Gun Don t leave plugged in v Shop Rules Clean up after yourselves 6/ 63
7 Saws, Wood, and Metal v Wood blades vs. Metal blades Teeth per inch Desired quality of cut WOOD METAL 7/ 63
8 How to cut wood 1. Mark your cut Pencil or Sharpie Carpenter s pencil 2. Mount your stock Clamps or vice Workbench in Idea Lab 3. Starting the cut Small, slow cuts 4. Finishing the cut Push, not pull Near handle / guard of saw (not tip) / 63
9 Laser Cutting Benefits Drawbacks Very Small Kerf Non-Contact Cutting Precise, Repeatable Relatively cheap Relatively thin materials 2D Constrained design Limited materials (non-chlorine) / 63
10 Laser Cutting Focused beam heats material Gas-Assisted OR Gas blows away melted material Material is burned or vaporized Image [2] / 63
11 Types of Cuts Raster Vector Cut Vector Engrave / 63
12 Types of Cuts Raster Vector Cut Vector Engrave / 63
13 Power Density Power of a laser matters far less than power density!"#$% &$'()*+ =!"#$% -."* /%$0 [W/m2 ] 6mm Spot Diameter 503!"#$% &$'()*+ = : ; >3/: ; 0.6mm Spot Diameter 503!"#$% &$'()*+ = @ : ; 44. 2A3/: ; 100X Higher Power Density! / 63
14 Power Density for Common Materials Cutting thin plastic ( mm) Process Power Density (W/mm 2 ) Process Rate mm/min Hard Wood Engraving mm/min (1.5-3mm deep) Tissue Removal N/A Cautery 5-10 N/A / 63
15 Design for Laser Cutting Considerations Disadvantages 3D -> 2D Components Carefully plan joints, shear load Kerf of Laser Consider Aesthetics: Illumination, Light, Opacity Design for Assembly Difficult to hide fasteners Shear, Brittle Fracture (Acrylic) / 63
16 Fastening with Acrylic T-Nuts Attachment Only Nut width = thickness of acrylic Finger Joints Load Bearing (somewhat) Joint width = thickness of acrylic Image / 63 [3]
17 Fastening with Acrylic Recommend combination of T-Nut with finger joints. Add epoxy for permanent joints. / Image 63
18 Laser Ablation UV Laser, lower wavelength Minimum spot diameter limited by wavelength of light Allows for higher power density with extremely small spot size / 63
19 CNC MACHINING INTRODUCTION 19/ 63
20 Ideal Lab CNC Machine EMCO E350 3-Axis Mill Siemens 828D Controller 20/ 63
21 CNC Manufacturing v Computer Numeric Control of machine tools v Typically refers to CNC Machining (cutting) v Also, involved in many many other things Grinding Welding and fastening Pick and place machines (electronics assembly) Injection molding Thermoforming 21/ 63
22 Machine Tools v 5 basic tools Flat endmill Ball endmill Center drill Drill Edge-finder v Other tools Fly cutter (shell mill) Chamfer tool Reamer Single point tap Automatic Tool Changer (ATC) on Emco E350 Mill Left: Fly cutter / shell mill Right: Insert Endmill 22/ 63
23 Controlling a CNC Machine v External CAD + CAM software Geometrical based design Voxel based design v Internal control software Feature based 23/ 63
24 ShopMill Internal control software v Impressive 3-axis capabilities v Intro to machining concepts without Gcode v Easy to create, edit, and simulate most CNC operations v Leads to full CAM training with Fusion / 63
25 Fusion 360 External CAD + CAM software 25/ 63
26 ROBOT DESIGN DO S AND DON T 26/ 63
27 Wire Management v [Do] Wire Management Cables and wires Strings What can catch wires? Zip tie ends Lose duct tape Bolts and screws 27/ 63
28 Wire Management 1. Wire harness 2. Spiral cover 3. (Cleanly cut) Zip ties Balance successful functionality with clean design 4. Duct tape 5. Twisties 28/ 63
29 MyRio Indication Feedback v [Do] Realtime Feedback from MyRio v Basic LED Feedback Built-In LED status / state indicators On / off combinations Flashing protocol v Advanced LED Feedback External LEDs connected to MyRio (add resistors!) External LED / LCD screen (digikey, adafruit, sparkfun) 29/ 63
30 Selectable Functionality v [Don t] Live programming of MyRio Modifying code each round Re-uploading code for different home zone Drop your computer in the competition 30/ 63
31 Selectable Functionality v Modular and movable design Pegged limit switch v DIP Switches Digikey, Amazon v SPST (Toggle) Switch) Easier to mount and solder Cheap, robust v Push button with LED feedback Mechatronics kit 31/ 63
32 Auxiliary Sensors v [Do] Checkout other sensors! v Light-sensitive diode v Ultrasonic range finder v Potentiometer, encoder / 63
33 Lesson Objectives v Understand design considerations and tradeoffs for advanced fabrication techniques with including CNC machines, laser cutters, and 3D printers v Understand good practices for robust, consistent, and quality prototype robot designs v Exposure to resources for mechanisms and fabrication methods 33/ 63
34 References v Advanced Measurement and Instrumentation v Autodesk Fusion 360 Intro to CNC 34/ 63
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