Table of Contents
Special Thanks…………………………………………………………………….1
Implications of Technology……………………………………………………….2
ABET Graduate Attributes………………………………………………………..4
Introduction……………………………………………………………………….6
Concept……………………………………………………………………………7
Design for Six Sigma……………………………………………………………...9
Gemba………………………………………………………………………..9
Kano Analysis………………………………………………………………..10
Quality Function Deployment (QFD)………………………………………..11
Risk Mitigation……………………………………………………………….13
Input Specification Document………………………………………………..13
One Page Scope Statement…………………………………………………...13
Failure Modes and Effects Analysis (FMEA)…………………………….17
Computer Science Design………………………………………………………...19
Overview of Progress………………………………………………………...19
Computer Specifications……………………………………………………..21
Primary Objectives…………………………………………………………...21
Secondary Objectives………………………………………………………...25
Hardware Selection…………………………………………………………..28
Speed Controller………………………………………………………...28
Open Source Motor Controller (OSMC)…………………………..29
MC1-HV Speed Controller…………………………………………30
RoboteQ AX2550…………………………………………………..30
AmpFlow Dual Speed Controller…………………………………..31
Motherboard……………………………………………………………..32
Parallax Basic Stamp 2 40 Pin Module…………………………….32
Itermec Pen Computer……………………………………………...33
Laptop Computer…………………………………………………...34
VIA Mini ATX Motherboard……………………………………….35
iTuner Power Supply……………………………………………….36
Netgear MA311………………………………………………………….36
Hard Drive……………………………………………………………….37
Joystick………………………………………………………………….38
Program Considerations……………………………………………………...38
In-depth Computer System Design –UML…………………………………..40
Actors/Goals List………………………………………………………..41
Use Cases………………………………………………………………..42
Sequence Diagrams……………………………………………………...43
Domain Model…………………………………………………………..43
Class Diagrams………………………………………………………….44
Open Source Project………………………………………………………….45
Conclusion……………………………………………………………………46
Mechanical Design………………………………………………………………..47
Manufacturing Considerations……………………………………………….47
Component Selection………………………………………………………...49
Motors…………………………………………………………………...49
PGM-132…………………………………………………………...51
Black MAX…………………………………………………………51
S28-400 Magmotor…………………………………………………52
Briggs and Stratton Etek……………………………………………52
Batteries…………………………………………………………………53
Optima Yellow Top………………………………………………...54
Concorde Sun Xtender……………………………………………...55
Power Transmission……………………………………………………..56
Suspension Elements…………………………………………………….58
Treads and Wheels………………………………………………………60
Tank Tread Design…………………………………………………………...62
Suspension Design…………………………………………………………...67
Tensioner……………………………………………………………………..70
Chassis Design……………………………………………………………….72
Finite Element Analysis, Chassis…………………………………………….76
Simplifying Structure for Export………………………………………..76
Importing the Model into ANSYS………………………………………80
Meshing the Model……………………………………………………...81
Applying the Boundary Conditions……………………………………..82
Load Case #1: Distributed Weight………………………………………82
Load Case #2: Focused Weight 1……………………………………….88
Load Case #3: Focused Weight 2……………………………………….90
Load Case #4: Focused Weight 3……………………………………….93
Load Case #5: Front Load……………………………………………….96
Load Case #6: Side Load………………………………………………..99
Load Case #7: Positive Bending Moment……………………………….100
Load Case #8: Negative Bending Moment……………………………...102
Summary of Chassis Analysis Results…………………………………..104
Chassis Modifications…………………………………………………...105
Load Case #4: Focused Weight 3 (Revisited)…………………………...107
Conclusions……………………………………………………………...109
Finite Element Analysis, Axle……………………………………………….111
Initial Steps: Designing the Axles……………………………………….111
Applying the Boundary Conditions……………………………………..112
Axle Load Case #1: Ideal Loading……………………………………...113
Axle Load Case #2: Complex Loading………………………………….115
Conclusions……………………………………………………………...118
Computer Enclosure………………………………………………………….119
Heat Exchanger Design………………………………………………………122
Mass Flow Rate………………………………………………………….123
Flow Regime…………………………………………………………….125
Head Loss………………………………………………………………..126
Free Convection Heat Transfer…………………………………………127
Conclusions……………………………………………………………...129
Final Design………………………………………………………………….130
Classes Used………………………………………………………………………133
Updated Six Sigma………………………………………………………………..135
One Page Scope Statement…………………………………………………...135
Input Specification Document………………………………………………..137
Risk Mitigation……………………………………………………………….138
Sponsorship Loss…………………………………………………………………139
Looking Back: A Survey of Progress………………………………………...139
Looking Forward: Now What?………………………………………………140
Small Robot #1…………………………………………………………..141
Small Robot #2…………………………………………………………..141
Electric/Hybrid Vehicle…………………………………………………141
Final Decision………………………………………………………………..142
Schedule…………………………………………………………………………..144
Budget……………………………………………………………………………..147
Conclusion………………………………………………………………………...151
Appendix A: Unified Modeling Language Documents…………………………..152
Appendix B: Concept Sketches and Design Iterations……………………………167
Appendix C: Time Sheets…………………………………………………………189
Appendix D: Component Data Sheets…………………………………………….196
RoboteQ AX2550 Electronic Speed Controller……………………………...197
VIA EPIAm Main Board……………………………………………………..205
iTuner 200W Power Supply………………………………………………….211
Netgear MA311 Wireless PCI Card…………………………………………215
Fujitsu MPF3204AT 20GB Hard Drive……………………………………...217
Sunon DC Brushless Blower…………………………………………………219
Concorde Sun Xtender PVX-1040T AGM Battery………………………….221
Optima Yellow-Top Deep Cycle AGM Battery……………………………..225
Deltran Power Tender PLUS Battery Charger……………………………….227
Powerpole 175A Dual Connectors (SB175)…………………………………231
Briggs and Stratton Etek DC Electric Motor………………………………...233
Anti-Ratchet Snowmobile Drive Sprocket…………………………………..237
Snowmobile Tread…………………………………………………………...238
Hobart Hander 140A MIG Welder…………………………………………..239