P18319: Lockheed ATLAS

Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

The goal of the Detailed Design phase was to take the chosen 2DOF robotic arm concept, and finish the design documents. Prototyping was given priority during this phase to support the early completion of a Proof of Concept.

A mid-phase quad chart was sent out November 13 detailing the status half way through the detailed design phase.

Prototyping both the motors and linear actuator, a speed calculation was performed to ensure the components will be able to meet the speed requirement. The Proof of Concept, Final Prototype, and the Apparatus Design were all finalized leading into MSD II. Process Sheets were created for the specialized processes used for the design.

An updated Bill of Materials was created, along with an updated budget and updated test plans for the proof of concept.

By prototyping this phase, many risks have been tested and mitigated, which can be found on the updated risk assessment. Plans for next phase were also generated as we move into focusing on the manufacturing of the Proof of Concept and Final Prototype, as well as any troubleshooting needed as the design progresses.

Detailed Design Review Items
Mid-Phase Progress Report
Current Status
Initial Prototyping
Final Design & Drawings
Special Manufacturing Processes
System Architecture
Software Flowcharts (Top Level, Calibration, Config File)
Bill of Material (BOM)
Updated Risk Assessment
Plan for MSD II
Phase IV Closeout and Plans for MSD II
Lessons Learned
Peer Review from Last Phase

Progress Report

The following progress report was sent our November 21, 2017 documenting what was accomplished through the first half of the detailed design phase. public/Detailed Design Documents/Mid-Phase_Quad.JPG

Current Status

Phase IV Delieverable Status
Mid-Phase Progress Report Completed
Engineering Requirements Completed
CAD Models Completed
Mechanical Drawings Completed
Electrical Schematics Completed
Assembly Drawings Completed
Bill of Material Completed
Updated Risk Assessment Completed
Completed Test Procedures Completed
MSD II Plan Completed

Prototyping, Engineering Analysis, Simulation

NEMA 23 Speed (GIF) NEMA 17 Speed (GIF) Linear Actuator Speed (GIF)
public/Detailed Design Documents/Videos/NEMA23 Speed.gif public/Detailed Design Documents/Videos/NEMA17 Speed.gif public/Detailed Design Documents/Videos/Linear Actuator.gif
Arm Movement (GIF)
public/Detailed Design Documents/Videos/Robot Arm.gif
Side View Bottom View Assembled
public/Detailed Design Documents/Pictures/Apparatus3.jpg public/Detailed Design Documents/Pictures/Apparatus2.jpg public/Detailed Design Documents/Pictures/Apparatus1.jpg

Speed Calculation

public/Detailed Design Documents/Analysis/Speed Calc.PNG

Software for Prototyping

All of the code that was used in prototype testing can be found here.

Ethernet Confirmation

The Ethernet FeatherWing board was confirmed to read in TCP/IP using an application called Packet Sender during prototyping.

Instructions for the setup of Packet Sender for this application and a quick example of the output be found here.

Drawings, Schematics, Flow Charts, Simulations

The drawing bank houses all drawings associated with both the proof of concept, final prototype, and the apparatus.

Proof of Concept
public/Detailed Design Documents/Pictures/17-11-3.JPG
Final Prototype
public/Detailed Design Documents/Pictures/17-12-6.PNG
public/Detailed Design Documents/CAD/ATLAS A-01.PNG
Calibration Process
public/Detailed Design Documents/Videos/ATLAS Calibration.gif

Apparatus Design

The apparatus on both the proof of concept, as well as the final prototype are identical.

public/Detailed Design Documents/Pictures/Final Apparatus.png

public/Detailed Design Documents/Apparatus Assembly Drawing.PNG

Process Sheets

3D Printing

The team utilized 3D printing technology to help aid in the reduction of machining lead time. The 3D Printing Work Instruction document, also known as Instruction 3D-01 documents the process the team used to ensure proper printing of components.

Carbon Fiber

Carbon Fiber is also utilized in the ATLAS design. The Carbon Fiber Work Instruction document, also known as Instruction ARM-01 documents the process to safely work with carbon fiber.

System Architecture

public/Detailed Design Documents/ATLAS System Architecture (rev. 3).png

Software Flowcharts

Top Level Flowchart

public/Detailed Design Documents/TopLevelFlowchart.png

Calibration Sequence

public/Detailed Design Documents/CalibrationSequence.png

Config File Setup & Stepper Motor Control

public/Detailed Design Documents/ConfigFile.png public/Detailed Design Documents/StepperControl.png

Bill of Material (BOM)

X-01 POC Prototyped BOM
public/Detailed Design Documents/BOM Closed MSDI.JPG

Most of the raw materials were ordered in excess to support the final prototype build. This is what lead to the over budget scenario. This BOM includes both the initial prototype and the parts that were prototyped. The BOM for just the initial prototype is also available.

A-01 Final Prototype BOM
public/Detailed Design Documents/Final BOM Estimate.PNG


Budget Breakdown

A full budget breakdown of phase 1 and the expected cost of phase 2 can be found by clicking the following link.

Test Plans

Test plans conducted for prototype can be found for this excel sheet. Test plans to be conducted for final design can be found for this excel sheet.

Risk Assessment

Updated risks, including risk tracking and risk mitigation can found on the Risk Management excel sheet.

public/Detailed Design Documents/Overall Risk Close MSDI.PNG

public/Detailed Design Documents/RiskCharts Closed MSDI.PNG

Plan for MSD II

The ATLAS Master Schedule below has been updated to reflect MSD II key tasks and milestones.

ATLAS Master Schedule
public/Problem Definition Documents/MasterSchedule.PNG

The schedule for MSD II is outlined on the MSD II Gantt Chart below.

MSD II Gantt Chart
public/Detailed Design Documents/ATLAS Gantt Chart MSD II.png

Phase IV Closeout & Actions

Phase IV Gantt Chart
public/Detailed Design Documents/ATLAS Gantt Chart Phase IV.png

Remaining Action Items


Lessons Learned

Peer Review Feedback from Preliminary Design Phase

Team Member Peer Review Action Feedback
Harvick Tang Add tracking functionality to Gantt Chart. Integrated Expected Completion % and Revised End Date columns to Gantt Chart.
Sarah Bentzley Keep everyone informed on what I am working on and to ask for assistance with tests and software as needed. Regularly worked with other team members to set up software for tests and confirm functionality of motors and sensors.
Matt Craven Be more accepting of proposed ideas instead of shutting them down. Gave further thought into proposed designs ideas, while still maintaining an important manufacturing perspective.
Mark Min Get a head start on schematics and individual tasks to have more time to help testing Had more free time to help Mike test equipment, such as the FSR.
Mike Kelly Don't get flustered over mistakes and stay calm when things do not go as planned. Kept a progressive outlook to finishing tasks, and accepted when tasks took an unexpected turn.
Kyle McAlinn Get more familiar with the manufacturing processes Matt is going to use for prototyping and building. Discussed some of the special manufacturing processes involved with the design such as cutting carbon fiber. Became familiar with the 3D printer and created the special process sheet for that.

Course Feedback

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