dr. m. mert ankaralı - capstone designcapstone.eee.metu.edu.tr/files/2018/12/...design... ·...
TRANSCRIPT
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An Informal Introduction on Mechanical Design and Manufacturing
Dr. M. Mert Ankaralı Desisted Robotics Corp. & Middle East Technical University
Department of Electrical and Electronics Engineering, Middle East Technical University, November 30, 2016
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What is my (academic) story?
Assistant Professor(?), METU Electrical & Electronics Eng.
PhD from JHU Mechanical Engineering
MS from METU Electrical & Electronics Eng.
BS from METU Mechanical Engineering
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Design Process (OL)
Ideas, requirements Design (CAD)
Component/material selection Manufacturing
Assembly Product/Prototype
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Ankarali et al. 2011 & Saranli et al., 2011
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Design Process (CL)
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Ideas, requirements Design (CAD)
Component/material selection Manufacturing
Assembly Product/Prototype
Feedback reduces
uncertainty
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Design (CAD)
• USE CAD software • If your design looks good, then your final product will
probably be good
CAD designs by Dr. Alican Demir
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Epoxy
Shell heat-shrink
Signal and Groundwires
± 5V supply wires
Main cable bundle
PCB heat-shrink
Circuit board
Graphite shellBNC plug RCA plug
Silver PCB-Shellconnection
Epoxy + 5V
– 5VHigh torque servo motor (Hitec HS-325HB)
Adjustable Battery fixtureLithium Polimer Battery (Pro-Lite V2)
Servo Motor Controller (by Parallax inc.)
RF tranceiver & Serial adapter (xBee 1mW) (by Parallax.inc)
Quadrotor(X-3D-BL ResearchPilot by Ascending Technologies)
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Design (CAD)
• Take advantage of open source CAD drawings of the commercial components
• Improve/update your design considering the other steps
CAD designs by Dr. Alican Demir
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Epoxy
Shell heat-shrink
Signal and Groundwires
± 5V supply wires
Main cable bundle
PCB heat-shrink
Circuit board
Graphite shellBNC plug RCA plug
Silver PCB-Shellconnection
Epoxy + 5V
– 5VHigh torque servo motor (Hitec HS-325HB)
Adjustable Battery fixtureLithium Polimer Battery (Pro-Lite V2)
Servo Motor Controller (by Parallax inc.)
RF tranceiver & Serial adapter (xBee 1mW) (by Parallax.inc)
Quadrotor(X-3D-BL ResearchPilot by Ascending Technologies)
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Component/material selection
Probably, it won't work
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Component/material selection
Now, it may work
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Component/material selection
Have ever seen this ?
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Component/material selection
Most convenient type of ball bearings
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Component/material selection
Example ball bearing unit mounting
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Component/material selection
Alternative: Custom bearing/ball bearing housing May require some gluing
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Manufacturing
3D Printer: It’s a huge privilege for you, so use it
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Manufacturing
• Design for 3D Printer
• Part orientation is important • Minimization of support material • Inclusion of undercuts and other
manufacturing constraining features • Reduction of part count in assembly
Courtesy of Dr. Ulas Yaman
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Manufacturing
• The build on the left can be broken into the two builds on the right, which may be stronger and can be assembled together later
• Note the reduction in the amount of support material and the reduced build height
Courtesy of Dr. Ulas Yaman
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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ManufacturingProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
• Material properties
• Good enough for many applications • Secret trick
• Soak the 3D printed part into a super glue (loctitie) pool and you will obtain a stronger material
• Note that holes and other passages will be (partially) filled with glue. Thus, design your part considering this and you may need to to some cleaning
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Manufacturing
Courtesy of Dr. Ulas Yaman
Sheet cutting: Laser or water-jet
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Manufacturing
Courtesy of Dr. Ulas Yaman
Common materials: Plexiglass (acrylic), polycarbonate (lexan), aluminum, wood, …
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Sheet cutting: Laser or water jet
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Manufacturing
A sturdy structure design method based on sheet cutting
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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ManufacturingProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Machining (Hand or CNC): Turning & Milling
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ManufacturingProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Machining (Hand or CNC): Turning & Milling
Sometimes machining is unavoidable
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Assembly
This is NOT an assembly tool Use these folks instead
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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Assembly
Is there a way to build structures with minimal amount of manufacturing?
YES: T-slot framing (a.k.a LEGO for engineers)
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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AssemblyProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
• Widely used for industrial and hobby robotics and similar applications
• Can build giant structures as well as miniaturized ones
• They are precise and strong enough to build real machines
T-slot framing
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AssemblyProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
• T-slot systems consists of square extruded aluminum beams, various special connectors and the hardware
• The modularity is based upon the T-slot concept of their profiles
• The “T” shaped slots present on all sides, allow for infinite positioning along the axis.
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AssemblyProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
T-slot framing example connections and topologies
T and L shaped corners Motor mounting
T-slot + 3D Printing Enclosures
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Quiz ?
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
What is the trick for increasing the material strength of 3D printed parts ?
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Questions
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements