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P09203RP1 MOTOR MODULE

GEN 2

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P09203 – 1kg Robotic Motor Module Gen 2 Platform This project is Sponsored by the Kate Gleason Foundation.

Team Members:

Lauren Farnsworth → Team Lead, DFMA, Process Design Expert

Mike Egan → Chief Engineer Matt Missel → Design Engineer, Machining &

Assembly Expert Greg Leaper → Systems Analyst and Website

Administrator

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Project Description Provide a product line of off-the-shelf motor modules and platforms

for diverse applications Scalable, modular, robust wheeled platform to carry payloads of 1kg

mass Module should be fully compatible with team P09204 Open architecture, Open source development Target audience is educational and outreach programs

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Customer Needs

Robust Modular (High-tech

Lego) Infinite effective

motion High overall system

efficiency

Open source and open architecture

Thorough documentation

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Design Rationale

Customer needs Identify what the customer really wants

Specifications Translate customer needs into engineering specifications

Concept generation Sketch approximately 20 concepts which have the

potential to meet customer needs and specifications Concept selection

Weight pros, cons, and risks of each concept Detailed design

Design Evolution

Initial Concept Final Design

ManufacturingUpper Housing

Solidworks Model Extruded FormBlueprint

Cut “Extrusion” Finished PartCNC Machined

ManufacturingLower Housing

Solidworks Model Blueprint Mastercam Toolpaths

4-Axis Machining Center Part in 4th Axis Finished Part

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Specifications and Testing

Specifications Testing Pass/Fail Criteria TestOperation speed of the motor module Speed is within 0.5 and 1 m/s

Ground clearance ------Steerable angle Steering angle is within ± 90° Module Turning test

System efficiency Drive and Steering efficiency is over 60% Drive Module Efficiency Steer Module Efficiency

Open source ------Open architecture ------

Low production cost ------ ---Prototype and development cost Under $1000 ---

Drive distance error Encoder error less than 6”Motors driven by PWM signal ------

Module must attach to platform within 10 – 120s

Methods of attaching motor module ------Platform must remain completely

functional after a 1 – 2ft fallDrop test

Motor Torque

Motor module attachment time

Velocity Test

Drop Test

Motor TorqueMust produce a stall torque of 40oz-in to 60oz-in

Module Assembly

Module Attachment Time

Motor Encoder Test

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Cost Breakdown

Prototype and Test Total Cost (3 MM, 1 IM)

Estimated Idler Unit Cost (Lot of 1 IM) $150.42

$811.95

Estimated Motor Unit Cost (Lot of 1 MM) $303.36

Estimated Motor Cost (Lot of 1000 MM) $148.33

Robotic Platform (2 MM & 2 IM) $567.85

RP1 MM Gen 1 Unit cost $404.70

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Estimated Molding Cost (lower Housing)

Current Material Unit Cost $8.03

Estimated Molding Material Unit Cost $0.13

Estimated Molding Process Unit Cost $0.47

Estimated Molding Tooling Unit Cost $0.41

Estimated Molding Total Unit Cost $1.01

Lot of 20000, 2 cavities per mold, Nylon

http://kazmer.uml.edu/Software/JavaCost/index.htm

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Future Design & Recommendations Further simplify lower housing Improve turn table design Make the lower housing a plastic part Make the upper housing an extruded part Order Motors earlier Verify vendor information

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QUESTIONS???