1. ETHAN BLANKENSHIP
PETER BURKE
SCOTT CARPENTER
JIM CARROLL
CARLOS CASAS
ETHAN COOPER
JACOB CRACE
MEGR 3156 – SPRING 2015 2-24-15
TEAM 2
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2. INTRODUCTION
Our vehicle is a Robot designed to transport a 1.5lb pallet,
securely engaged, from one place to another.
Our vehicle is designed to be lightweight, cost efficient, well
balanced, user friendly and intuitively remotely controlled.
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3. OVERALL SYSTEM
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Our design consists of a 4 wheel direct drive robot with a vertical
lift system. Both the robot and the lift system are controlled with
an X-box controller and Arduino Uno.

4. FORKLIFT SYSTEM
ENGAGING AND SECURING MECHANISM
ACTUATION: securing arm is actuated using a HS55 Hitec servomotor. Torque
to actuate securing arm is .011 in lbf and the Power is 7.445 mWatts
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5. FORKLIFT SYSTEM
SAFETY FACTORS:
• S.F. for the two forklift rods is 491.
• S.F. for the forklift base RP is 165.
• The maximum deflection of the two forklift rods is 0.009 in2.
ADDITIONAL COMPONENTS:
• A linear bearing is used to reduce vertical lift coefficient of
friction to 0.002
• A pulley system is used to provide lift to the load.
• The max tension in the cable is 1.73lb when lifting the load.
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6. VERTICAL LIFT
ACTUATION: the vertical lift is performed using a
Pollou-994 DC motor.
RANGE OF MOTION: 4.58in vertically
• The rotating speed of the
motor while raising the
lift is 70 rpm
• The lift raises at 0.9 in/s
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7. VERTICAL LIFT
SAFETY FACTOR:
• S.F. of the sliding mechanism RP is 26
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8. VERTICAL LIFT
MANUFACTURING:
• The vertical lift rod and tube will be cut to length and ends will be
tapped for required screw size.
• The top, sliding system, and bottom will be RP.
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9. CHASSIS
CONFIGURATION: Aluminum sheet with cut outs and bent
up edges is designed to provide easy mounting areas.
• All items are mounted directly onto the chassis.
• Material used is Aluminum 6061 T6 0.040in sheet.
MANUFACTURING: Raw sheet-metal is cutout and then the edges
are bent up. All labor is performed by team members.
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10. CHASSIS
DEFLECTIONS: max deflection is 3.97x10-6 in
SAFETY FACTORS: 370
CHASSIS WEIGHT: 0.145lb
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11. DRIVETRAIN AND STEERING
CONFIGUTATION: 4 direct drive servo motors
FUNCTION: Propulsion
TURNING AND STEERING: Tank style. Max Turning Torque is 2.2inlbf
WHEELS: Custom Rapid Prototyped. S.F. is 462
CONFIGURATION: All wheel drive
GRIP TYPE: Mouse-pad
SAFETY FACTOR: coefficient of friction is 0.9 and our safety factor
while starting the incline is 1.07 from rest
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12. DRIVETRAIN AND STEERING
AXLES AND BEARINGS:
• servo motor shaft and arm are directly attached to wheel.
ASCEND THE INCLINE TORQUE: 3.365 inlbf
COEFFICIENT OF FRICTION: 0.9
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13. DRIVETRAIN AND STEEERING
DRIVETRAIN:
• Total servo motor Torque on the incline: 3.365 inlbf
• Power required to go up the incline: 1.34 Watts
• Rotational speed of each servo motor: 33.63 RPM
• Turning torque: moment of friction created from turning is
2.867 inlbf
• The drive moment is 4.554 inlbf. Therefore the driver moment is
greater than 10% of the turning torque which means the robot is
able to turn.
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14. DRIVETRAIN AND STEEERING
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SAFETY FACTOR: 462

15. POWER AND CONTROL
MAIN POWER CONTROL AND ITS ELEMENTS:
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16. POWER AND CONTROL
REMOTE CONTROL CIRCUIT:
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17. POWER AND CONTROL
REMOTE CONTROL USABILITY AND ERGONOMICS:
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18. POWER AND CONTROL
ON / OFF POWER SWITCHES:
OVERALL POWER USAGE FOR ONE LAP: 70.8 J
DEMONSTRATE THE USE OF STORED BATTERY ENERGY FOR TWO
RUNS: Using 4 AA Maxwell Batteries we have a total of 447 J to power the
robot. Safety factor for the first run is 6.37 and for the second its 5.57
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19. OVERALL SYSTEM
TOTAL WEIGHT OF ROBOT: 1.96lb
• Vertical Lift: .454lb
• Chassis: .571lb
• Drivetrain: .468lb
• Electronics: .467lb
ESTIMATED TOTAL TIME TO TRAVERSE THE COURSE: 2.33 min
STABILITY ON THE INCLINE: while on the incline 84% of the weight
is on the front axle of the robot, with the load.
ALL SUBSYSTEMS FIT TOGETHER IN THE SPECIFIED
VOLUME: Yes
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20. OVERALL SYSTEM
CLEARANCE FOR BOTTOM AND TOP OF RAMP:
minimum clearance on top of the ramp is 0.673 in.
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21. USE OF RAPID PROTOTYPING
CATALYST INFO AND BREAKDOWN:
PARTS DETAILS: see appendix
Volume
• 1 x Securing clamp arm 0.234 in3
• 1 x pulley 0.693 in3
• 4 x wheels 6.2 in3
• 1 x top lift assembly 0.27 in3
• 1 x sliding assembly 0.932 in3
• 1 x bottom lift assembly 2.107 in3
Total Volume 10.436 in3
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22. MANUFACTURABILITY OF THE VEHICLE
PARTS TO BE MANUFACTURED:
• 1 x Chassis 6 hrs
• 2 x 1/8” forklift rods 1 hrs
• 2 x vertical lift rods 4 hrs
• 1 x Drum support bracket 3 hrs
• 1 x motor mounting spacer 1 hrs
• 1 x counterweight 1 hrs
• Total manufacturing/machining 16 hrs
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23. MANUFACTURABILITY OF THE VEHICLE
MATERIALS TO BE USED:
• Aluminum 6061 T6 sheet 12in x 12in, 0.040 in thick
• Aluminum 6061 Rod 0.125 in dia
• Aluminum 6061 Tube 0.25 in dia
• Hardened steel Rod 8mm dia
• Steel Bar Stock .5in x 1in
HOW WE PLAN TO MAKE THE PARTS: Team members will be
using the schools machine shop to manufacture and machine parts.
Specific tools include: vertical band saw, drill, tap and die set,
grinding wheel, bending brake.
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24. Team 2 BUDGET
MATERIALS:
• Vertical lift $65.86
• Chassis $15.04
• Drivetrain $68.95
• Electronics $29.12
• Total Materials cost $178.97
SUPPLIES:
• 24Ga wires $5.49
• Solder $5.99
• Mouse-pad $4.99
• Total Supplies cost $16.47
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25. Team 2 BUDGET
RAPID PROTOTYPING:
• Total Volume 10.436 in3 at $5.00/in3 $52.18
• Total Rapid Prototyping cost $52.18
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26. Team 2 BUDGET
LABOR: hrs x cost = subtotal
• Machining 16 $30.00 $480.00
• Ordering parts 6 $10.00 $60.00
• Assembling 8 $10.00 $80.00
• Troubleshooting 20 $10.00 $200.00
• Repairing 15 $10.00 $150.00
• Soldering 7 $10.00 $70.00
• RP Set Up 1 $15.00 $15.00
• Total labor cost $1055.00
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27. Team 2 BUDGET
Materials, $178.98
Supplies, $16.47
Labor, $1,055.00
Rapid Prototyping,
$52.18
Budget Breakdown
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28. SUMMARY AND FUTURE PLAN
By meeting all the requirements set forth by the
competition rules, we are ready to begin manufacturing,
machining, rapid prototyping and building the entire robot.
Our calculation indicate that the robot is capable of
completing the obstacle course with outstanding
performance
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