2020 UC MET Battlebot Team 15lb Bot Senior Design II Report Senior Design Proposal submitted to the Department of Mechanical and Materials Engineering College of Engineering and Applied Science University of Cincinnati in partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical Engineering Technology by Fred Schroeder Isabella Long Mathew Itapson December 2019 Thesis Advisor: Dr. Janet Dong 15lb Bot SD II Report Fred Schroeder, Isabella Long, Mathew Itapson TABLE OF CONTENTS TABLE OF CONTENTS ....................................................................................................... 1 LIST OF FIGURES ................................................................................................................ 2 LIST OF TABLES .................................................................................................................. 3 ABSTRACT ............................................................................................................................. 4 PROBLEM DEFINITION AND RESEARCH .................................................................... 4 PROBLEM STATEMENT ...................................................................................................................................... 4 BACKGROUND .................................................................................................................................................... 4 RESEARCH ............................................................................................................................ 5 CURRENT STATE OF THE ART ..................................................................................... 10 END USER ............................................................................................................................ 17 CONCLUSIONS AND SUMMARY OF RESEARCH ..................................................... 17 CUSTOMER FEATURES ................................................................................................... 17 PRODUCT OBJECTIVES .................................................................................................. 18 QUALITY FUNCTION DEPLOYMENT .......................................................................... 21 DESIGN ................................................................................................................................. 24 PROJECT MANAGEMENT ............................................................................................... 46 BUDGET, PROPOSED/ PROJECTED .................................................................................................................. 46 SCHEDULE ....................................................................................................................................................... 46 PLAN FOR FABRICATION & ASSEMBLY ......................................................................................................... 48 THEORETICAL SYSTEM TESTING .............................................................................. 61 PREDICTED PERFORMANCE ........................................................................................ 64 WORKS CITED.................................................................................................................... 69 REFERENCES: .................................................................................................................... 69 APPENDIX A ........................................................................................................................ 71 XTREME COLLEGIATE CLASH TECHNICAL REGULATIONS ............................ 71 APPENDIX B ........................................................................................................................ 77 APPENDIX C ........................................................................................................................ 83 APPENDIX D ........................................................................................................................ 88 APPENDIX E ........................................................................................................................ 92 1 15lb Bot SD II Report Fred Schroeder, Isabella Long, Mathew Itapson LIST OF FIGURES Figure 1. Huge, a battlebot known for its tall UHMWPE frame and large vertical spinner. (7) ........................................................................................................................................... 7 Figure 2. Minotaur, a bot whose powerful drum spinner has earned it 15 wins in only 3 years of combat. (8) ..................................................................................................................... 7 Figure 3. Tombstone, one of the more famous horizontal spinner wielding battlebots. (9) ..... 8 Figure 4. Maximus, a wedge bot. (10) ...................................................................................... 8 Figure 5. 2014 UC Battlebot .................................................................................................. 10 Figure 6. 2016 UC Battlebot .................................................................................................. 12 Figure 7. 2017 UC Battlebot .................................................................................................. 13 Figure 8. 2018 UC Battlebot .................................................................................................. 14 Figure 9. 2018 UC 60lb Battlebot .......................................................................................... 15 Figure 10. 2019 UC Battlebot ................................................................................................ 16 Figure 11. Full House of Quality ............................................................................................ 21 Figure 12. Rooms 1-4, 6, and 7 of the House of Quality ........................................................ 22 Figure 13. Room 8 in the House of Quality ............................................................................ 22 Figure 14. Room 5, Benchmark Satisfaction, in the House of Quality ................................... 23 Figure 15.Wedge Bot Concept ................................................................................................ 24 Figure 16. Drum Spinner, One-Piece Concept ....................................................................... 25 Figure 17. Drum Spinner, Multi-Piece Concept ..................................................................... 26 Figure 18. Final Concept Design ........................................................................................... 29 Figure 19. Final Frame Design .............................................................................................. 30 Figure 20. Isometric and top view of drum spinner weapon. ................................................. 32 Figure 21. Transparent weapon showing internal aluminum support plates and bushings .. 33 Figure 22. Weapon with internal support block/tensioning system ........................................ 33 Figure 23. Final Drivetrain Design ........................................................................................ 34 Figure 24. Rear Plate Stress Test ........................................................................................... 35 Figure 25. Rear Plate Displacement Test ............................................................................... 36 Figure 26. Top Plate Stress Test ............................................................................................. 37 Figure 27. Top Plate Displacement ........................................................................................ 37 Figure 28. Results of 6 foot drop test, with the top of the drum shown at left, and the bottom impacting site at right. Note the stress concentrations between the internal support plate locations........................................................................................................................... 38 Figure 29. Side view showing angle of second 6 foot drop test. Gravity was exerted in the downward facing direction. ............................................................................................. 39 Figure 30. Alternate view of 45 degree angled drop test, 6 foot height, impacted side ......... 39 Figure 31. Frame Dimensions ................................................................................................ 48 Figure 32. Frame Drill Locations for Major Cuts ................................................................. 49 Figure 33. Frame Weapon Belt Hole Dimensions .................................................................. 49 Figure 34. Top Plate Dimensions ........................................................................................... 50 Figure 35. Skid Dimensions .................................................................................................... 51 Figure 36. Skid Alternative Nut Placement ............................................................................ 51 Figure 37. Full drum assembly, transparent to show internal components ........................... 53 Figure 38. Face cuts on the lathe ........................................................................................... 54 Figure 39. Drum, after milling first groove ............................................................................ 55 Figure 40. Finished outer drum grooves; backup and main