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Introduction to Factory Automation Numerical Control
Build an autonomous robotic solution
Testing an autonomous robot build by human control
Programming a autonomous robot
Exploring sensors
Autonomous robot design challenge
Autonomous robot design challenge
Industrial applications build challenge
Industrial applications build challenge
Industrial applications build challenge
Industrial applications robot delivery
Manufacturing system design challenge
LESSON 09
LESSON 9 STARTER
Learning objective: Take initial ideas and develop them into a feasible model and proposal for a design challenge, develop
the design to meet the technical elements of the specification, begin to make your autonomous solution.
Set out the stages of your process
Layout your process in front of you and act it out. For example, if you intend on sorting out a mess of recyclable materials, then start by
making a pile. Identify ways in which you can sort them using either actual tools or other methods.
In this lesson you are going to card model your solution so that it pivots, moves and works with your items.
What is the purpose of model making? Answer the following questions…
Model making is a way for a business to save money. How?
- Model making helps business reduce the risk by supporting “good” decision making early
Model making is a way to communicate to others. How?
- Models are physical. They show people the size, scale, function and sometimes aesthetics of a solution
Model making is a way to prove new ideas. How?
- Models that move and “work” are better than sketches because they provide full 3D geometry of the solution in use
Model making is a skilled task. Why?
- Model making is not about making pretty card and paper examples. Model making to a high level requires the application of a
wide range of tools, materials, and an ability to problem solve without there being an existing solution to copy.
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Defining your parameters
Your robot will be limited by certain parameters. These will be factors that constrain your system. The following factors are
worth identifying and designing into your system
Number of axis – your robot will be able to reach any position in a 2D plane with 2 axes of movement. It will be able to reach
any space in a 3D area if it has three axes of movement. In CNC terms we refer these to the X, Y and Z axis. By reducing the
number of axes, you make your design simpler to program and cheaper for the manufacturer.
Working Envelop – the region your robot can reach is the working envelop. If you draw onto any sketch the area in which the
robot will operate, you will be able to identify where there might potentially be conflicts with other objects.
Payload – this represents the weight, shape and quantity of the objects being moved. The heavier or more complex your
object, the harder it is to move it from A to B and beyond.
Acceleration and accuracy – based on your build or program of the motors and articulating parts, you will be able to
manipulate the speed in which you move objects, and the accuracy in which you locate to points within the working envelop.
Repeatability – how often do you intend to repeat the process, and how will this be achieved? Do you intend to use sensors
to trigger the circuit.
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How could you use this system?
It doesn’t matter what your elected object
is, you can use certain systems for the
movement and organisation of everything.
Cars, pencils, ping-pong balls, could all fit
into certain systems with modification.
Task:
Quickly sketch out a modified solution to
your design task using the image left as the
expected format/arrangement.
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How could you use this system?
A conveyor belt is quite common in production
lines for objects that can be placed and removed
from the surface at stations along the line. This
could be human, or in this case a robot.
Task:
Add to your design the solution of using a
conveyor belt system (if you have not already)
for the movement of an item through the build
system.
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How could you use this system?
A linear slider system is used to extend in one
direction a beam, onto which an actuator might
be fitted. This will give you extended reach or
potentially a pusher or “fitting” arm that moves
into action once the object is in line with the
path of movement.
Task:
Quickly sketch out a use for a linear slider into
your design as either a pusher, an actuator, or a
fitter device.
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Set out some initial design ideas on paper
In your teams, each take a piece of template paper, and collectively start sketching ideas down. Talk and discuss as
you sketch. Worry less about the sketch quality and more on what the idea actually shows. Always keep in your mind
the goal you are trying to achieve.
Struggling to start?
Try this Design approach
You could start with the clawbot and modify this by targeting
areas to change. For example, the simple autonomous robot we built
earlier took the tower and arm of the Clawbot off, and placed
it onto a flat base. The base of the Clawbot was then
dismantled and turned into an area to store objects.
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The card modelling approach
Corrugated card is rigid in one direction (the direction of the
flute) and also provides you a chance to score, bend and hinge
using this same feature. The material is readily available to you
also, given its common use in outer packaging.
In this model, the engineer has considered the VEX parts
available and replicated them in card. A tower is both strong and
built to scale, allowing for the build of a VEX version later. The
arm or actuator is also built to scale compared to VEX parts, and
provides a clear indicator of whether through its full rotation the
autonomous robot will be able to complete its task, even reach
the conveyor and objects being manipulated.
The conveyor should also be modelled in card unless you are
going to be sharing this build with other teams or will be
provided with this build element by your teacher.
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Build your model
Using corrugated card, pegs, split
pins, different types of tape,
acetate and other any “craft”
materials, your task is to create a
moving, and where possible
functioning prototype model.
Simulate moving parts
Moving parts are tougher to create given the
properties of card compared to steel and
rigid plastic, but try to be creative and
introduce additional materials. Here a pencil
forms the steel shafts that will hold both the
gears and chain in place.
First, following the basic
instructions for working with craft
materials, then start to develop
your solution.
Remember! You are going to be
building in VEX, so it is worth
while at the model stage trying to
create “VEX” like card parts to
replicate the impending real build.
Structural parts
Use reinforcing ribs to keep the C channel shape,
otherwise you can make and build as you might
VEX. Note the rolled card to create the spacers
and the card motor to scale.
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Build Time
In your teams, identify the main frame structure you intend to
build and work on. Assemble this first. This will require the use
of larger metal parts, screws and nuts, and the larger allen key.
Remember to try and avoid cutting and forming the parts unless
it is essential to do so.
Second, attach the motors and manipulators to your system and
begin to test. You will have access to three motors from the
Clawbot kit, but also spares in the larger or add-on kits. For each
additional motor, you will need a motor controller.
Finally, build in the smaller functional elements that fine tune
the arrangement ready for testing. Use cable ties to neaten up
the build, adjust the position of features that pivot and lock in
place with shaft collars.
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LESSON 9 Plenary
As a class, let us consider the following questions?
A. What type of initial sketches work better for planning an initial idea?
B. How has your design specification developed and changed as your design has?
C. Why is it important that design documents remain fluid and adaptable as the project moves on?
D. What ideas did you reject as you settled on your final design?
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LESSON 9 Summary
Learning objective: Take initial ideas and develop them into a feasible model and proposal for a design challenge, develop
the design to meet the technical elements of the specification, begin to make your autonomous solution.
Today you have:
 Worked initial ideas into an actual design solution
 Improved your design solution by referring regularly to a technical specification
 Built the start of a final solution
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