Ghost Robots
Monday, December 13, 2010
Kyle's Reflection
Sunday, December 12, 2010
Final Team Documentation




Our final design consisted of four main components. First the main component, the harvester. The harvester ended up similarly to how we originally designed. We changed from 3 paddles to 2 paddles after testing the sketch model. Our final model finished with 2 paddles. These paddles were made of acrylic and delrin spacers, with aluminum axles connecting the harvester to a planetary motor. The acrylic and delrin were laser cut and the aluminum was turned down on the lathe. The harvester can be run forwards or backwards. The harvester design and manufacturing went well with minor issues with the axles. In the end the harvester performed well in competition and was getting enough power to successfully pull in balls.
Laura's Reflection
Before I began ME250, I was warned by numerous people that the class has potential to take over your life; they couldn’t have been more right. From the first lecture that outlined what we would be doing and learning, I knew that this class would take more work and dedication than my other classes. Despite the extra work and added stress, this class was very valuable to me and taught me many things that I will continue to apply in my engineering curriculum. I learned many things on teamwork, design, manufacturing, and how achieve a goal within a time budget.
On teamwork, I learned that dividing and conquering is the best way to go about a task when resources and time are scarce. Often I would come to lab with my team and each of us would be assigned our own task. At the end of lab we would come together again and re-evaluate what needs to be done before the next milestone. If necessary we would schedule a time to meet in order to make the requirements for the next due date, with each of us contributing something. As a team, I think we worked well together. Each of us had our strengths, so we assigned each task accordingly. We did have to work around a split team however, Cole was in the lab section before the rest of the team, so it took some extra communication to have a productive lab. Despite not being able to work entirely as a team twice a week, having a team in two sections was very beneficial from a manufacturing standpoint. We only scheduled machining time outside of lab twice for the entire project. We were very thankful for this due to our busy schedules. Overall, as a team we worked very well together with everyone contributing what they could and making sacrifices accordingly.
From a design standpoint, my knowledge in design in general increased greatly. I thought that the FRDPRC tables as well as the comparison charts were very beneficial. They are a logical way to make a decision. I have even started incorporating them into other aspects in my life (design decisions for BAJA SAE as well as major life decisions that need a logical foundation). The way designing something was broken down in lecture was also very helpful; it made this huge, mind boggling problem shrink down into something more comprehensible. It also allowed me not to get overwhelmed by the project and to take it one step at a time. I also enjoyed learning a different CAD program. I am on the BAJA SAE Team where we use CATIA. It was helpful to see the benefits and differences of each program. I think that Solidworks is a very good program to learn on and I thought that the tutorials were very helpful. As for the design of our robot, it was very interesting to me to make a decision as to what we want our “bot” to accomplish and then see it in CAD, step by step. The entire design process of our “bot” also helped me decided what I want to do with my life, whether it be manufacturing or design/product development. Seeing our robot go from rough ideas to a working CAD model made the decision clear for me that I should be tailoring m education towards design.
In the manufacturing of our “bot”, I became more familiar with the machines. Through BAJA, I have already had experience on the mill and drill press, but through this project I became more comfortable using these machines and familiar with the lathe. I also learned how to use the water jet and laser cutter. It was good experience to have machine parts and then have them line up accordingly in order to assemble our robot. We ran into a little snag when the water jet shifted our base plate by about an eighth inch. We had to re-drill some holes and fix a few parts in order to get everything to assemble correctly. However, once we did, it was very exciting to see a working robot that we designed and built.
Overall, this course was a very good experience. As stressful as it was, it was good to have the experience of a big project in a short time budget. For future classes, a more involved machine shop training would be very helpful as well as more available machines. I spend a lot of my time in the Wilson Center for BAJA and I saw many teams using the tables there because of the chaos in the ME shop. And even with my previous machining experience, I thought that the training just touched upon what we needed to do. Another helper in the shop would also be incredibly helpful, especially considering the number of people who have never been in a shop before. It was truly wonderful to see our robot go from the drawing board to coming in 4th at the competition. Thank you so much for making that possible!
Ethan's Reflection
I learned a lot about myself, engineering and manufacturing in ME 250. As a member of the Solar Car Team here at Michigan I have learned a bit about the design process, but not as much about the manufacturing process. ME 250 taught me a lot about this process. This class was informative because it was a good combination of both the theoretical side of engineering and the hands-on, practical side. Before taking this class, I had experience working with wood, but I had never made a part from metal, let alone on a mill or a lathe.
Previously, the experience that I had on the Solar Car Team was on the operations division, and had never worked with CAD or experienced the design process. Taking this class helped me become a more important member of the Solar Car Team by teaching me about this process. Learning SolidWorks enabled me to put my thoughts into tangible items.
Along with this, this class enabled me to take something from thoughts and ideas to a CAD model and even further to a completed item. Seeing, and being a part of this process was thrilling. Not many more classes at the University will allow me to do something like this again.
Furthermore, I learned a lot about myself in this class. There are always ups and downs in any project like this, and it is important to keep your head up and help others on your team to do the same. A group cannot go forward without all of the members of the team. I think it was also important that one of the people in our group really stepped up and took over the team. Even though our leader wasn’t a formally elected entity, it was important to have a person to go to make sure everything was in line and to keep us in line as to what needs to get done and when.
As for the class, I believe that starting the design process sooner would be nice for the class. It seemed like we had to decide what our machine was going to be very quickly. There was not a whole lot of time available to “sleep” on ideas we had discussed. I believe more time would have been nice. In addition, I wish that I would have looked at other team’s designs in the previous years to get a better idea as to the amount of power the motors had. This was the fundamental design flaw in our robot.
One concern I had was the manufacturing of the each of the tables. I know that it was hard for some teams to execute their robots due to the minor discrepancies in each of the tables. One team in particular designed a machine based upon the CAD model and it fit in one of the tables and not the other. Based upon our robot, one of the tables had more balls in the middle of the table that were closer together. Due to the lack of power in our motors and the way we had to play the game, it would have been advantageous to play on the other table. This needs to be fixed for next year.
Finally, I disagree with the way that “ties” were handled. I believe that something better needed to be done than whoever pushed the flipper over wins the game. This was to our disadvantage, and luckily never harmed us, but I thought it was unfair to the teams that could have scored had they beaten them to the flipper compared with the teams who were fastest to the flipper but were unable to score. Some sort of play-off could solve this.
In conclusion, I had a good time in this class and had a great group to design a robot with, but fourth place? I’m disappointed that I stayed for 3 hours to beaten just before the podium. In all seriousness, this class was an overall great experience and will help me in the future.
Saturday, December 11, 2010
Cole's Final Thoughts
When it comes to the manufacturing of a design though, things get much more interesting. I have done a bit of manufacturing in the past, but nothing on the scale or precision of our robot. Being able to get hands on experience with amazing tools such as the laser cutter and water jet was one of the highlights of this course for me. Although our design was fairly complex, we took advantage of the precision tools that we had access to (laser cutter and water jet) to manufacture our most complicated parts so that the building of our robot was similar to the assembly of a car or some other pre-fabricated machine. Even with this simple approach though, we encountered unforeseen obstacles that added to our assembly time and set us back slightly. I learned that you can’t always count on holes to always line up, and that metal is a lot less forgiving then other materials such as plastic or wood. There were multiple instances where holes in our parts were correct when aligned with one other connecting part, but when the entire assembly was put together there was just enough misalignment to require re-drilling the holes. I also learned that even with computer controlled machines you can have make errors that affect your entire project. While we were water jetting our main base plate, the material shifted by about an eighth of an inch, changing the perimeter features of the design. We were able to overcome this issue with a slight modification of just a few of our parts, but it just goes to show that everything can’t go as planned.
One of the biggest things that I felt was lacking was an introduction to hands on manufacturing during the first part of the lab section. Our first opportunity to manufacture real components was with our own designs, which may not lead to the best first experience. A large portion of the design process comes from knowing what can and cannot be manufactured and how the machining process works. If machine training was taught before or concurrent to design, I think it would be much more beneficial and lead to more robust and well thought out designs. The digital world of CAD does not always transfer easily to the real world, and I feel that there is a lack of emphasis on that fact. My other concern is in regards to the electronics provided in the kit. Although it is useful to be able to choose the output gear ratio of the motor, the motors proved to be quite weak even with high gear ratios. I feel that the demand on these motors grows with the complexity of the problem to be solved, and that the current problem to be solved requires more powerful motors.
Overall I am pleased with my performance in this course, but I feel that the greatest thing that I could have done was stick to a stricter personal schedule. Even though we had deadlines and assignments throughout the design process, I feel that I could have been more productive and successful if I had set machine goals to stick to. Basically by saying what components I wanted functioning by a given date, I think our fabrication and assembly time could have been put to better use, and allowed us time to troubleshoot our robot in more depth and possibly solve our issue of underperforming motors.
Tuesday, December 7, 2010
Competition Video
Here is our video for the upcoming slotbots competition. Be sure to stop by and check things out on Thursday.