dr. m. mert ankaralı - capstone designcapstone.eee.metu.edu.tr/files/2018/12/...design... ·...

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

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

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

Design Process (CL)

Product/Prototype



IdeasRequirements

Ideas, requirements Design (CAD)

Component/material selection Manufacturing

Assembly Product/Prototype

Feedback reduces

uncertainty

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



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)

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



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)

Component/material selection

Probably, it won't work

Product/Prototype



IdeasRequirements


Now, it may work

Product/Prototype



IdeasRequirements


Have ever seen this ?

Product/Prototype



IdeasRequirements


Most convenient type of ball bearings

Product/Prototype



IdeasRequirements


Example ball bearing unit mounting

Product/Prototype



IdeasRequirements


Alternative: Custom bearing/ball bearing housing May require some gluing

Product/Prototype



IdeasRequirements

Manufacturing

3D Printer: It’s a huge privilege for you, so use it

Product/Prototype



IdeasRequirements

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



IdeasRequirements

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


Product/Prototype



IdeasRequirements

ManufacturingProduct/

Prototype



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

Manufacturing


Sheet cutting: Laser or water-jet

Product/Prototype



IdeasRequirements

Manufacturing


Common materials: Plexiglass (acrylic), polycarbonate (lexan), aluminum, wood, …

Product/Prototype



IdeasRequirements

Sheet cutting: Laser or water jet

Manufacturing

A sturdy structure design method based on sheet cutting

Product/Prototype



IdeasRequirements


Prototype



IdeasRequirements

Machining (Hand or CNC): Turning & Milling


Prototype



IdeasRequirements

Machining (Hand or CNC): Turning & Milling

Sometimes machining is unavoidable

Assembly

This is NOT an assembly tool Use these folks instead

Product/Prototype



IdeasRequirements

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



IdeasRequirements

AssemblyProduct/

Prototype



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

AssemblyProduct/

Prototype



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.

AssemblyProduct/

Prototype



IdeasRequirements

T-slot framing example connections and topologies

T and L shaped corners Motor mounting

T-slot + 3D Printing Enclosures

Quiz ?

Product/Prototype



IdeasRequirements

What is the trick for increasing the material strength of 3D printed parts ?

Questions

Product/Prototype



IdeasRequirements

dr. m. mert ankaralı - capstone designcapstone.eee.metu.edu.tr/files/2018/12/...design... ·...

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