Design and Manufacturing Lab

Project Overview

The goal of this design project was to create a mobile robot capable of entering a controlled arena, capturing, carrying, and discharging balls to topple five sealed target bottles within a five-minute time limit. The project required teams to design, prototype, and compete with their robot against other teams in identical arena setups, simulating real-world engineering challenges with a strict budget and performance requirements.

Key Skills

• Collaborative Design Process: Led and participated in design sessions, employing decision matrices and sketches to evaluate and select the best robot concept from team members’ proposals.
• 3D Modeling and CAD: Used SolidWorks extensively to create detailed part models, preview assembly interactions, and ensure design accuracy for manufacturing.
• Advanced Manufacturing Techniques: Operated various machinery, including metalworking lathes, milling machines, bandsaws, CNC machines, and T-slot aluminum (8020) to fabricate key components of the robot.
• Sheet Metal Fabrication: Gained expertise in sheet metal bending and water jet cutting, applying these techniques to produce precise, durable parts for the robot.
• Prototyping and Testing: Assembled and tested the robot, iterating on the design to enhance performance within the competition's time constraints.

Problem Statement

In a 5′ x 20′ enclosed arena, five sealed target bottles containing water are positioned for toppling. Each team had access to either tennis or racquetballs stored in upright buckets within the arena. The primary task was to design a mobile robot that could efficiently release the provided balls to knock down all five targets within the five-minute time limit. Teams competed in adjacent arenas, requiring real-time strategy and precision to outperform competitors.

Design Rules

• Control System: Each robot used a standard wireless controller with two proportional and three relay-controlled motors.
• Size Contraints: The entire robot had to fit within a 17″ × 12″ × 15″ container after each lab session.
• Start Zone: Robots had to start within a designated area and could not be touched during the run.
• Ball Recovery: Balls that touched the floor couldn’t be reused, making efficiency in targeting essential.
• Material and Budget Contraints: A budget of $50 was allotted, and each team received a limited amount of aluminum extrusion and motors from the lab.