Design for Manufacturing and Assembly The objective of this project will be to gain insight into the challenges and satisfaction involved in the design of a complex, engineering system. This project will include numerous aspects of the design process. It will allow you to perform a system design study, experience the challenges of working as part of a design/build team, and help you develop an appreciation for conflicting requirements as well as limits on technology and resources, issues which are always present in a product development project. The primary purpose of this project is to provide insight into the design process and to help you identify those decisions in the design process which most significantly influence the design and fabrication of the product. In particular there will be significant emphasis placed upon issues related to "robust, low-cost design." Finally, this project will allow for the opportunity to validate the results of your engineering design efforts through the fabrication and testing of a prototype system.

A. OPPORTUNITY There are numerous situations which require the identification, location and retrieval of hazardous items and thus require mechanical systems which can operate in a high risk environment. If low-cost, reliable and robust mechanical systems could be used to perform these tasks, then human operators could be removed from the associated risk. In order to make such systems available to a wide range of users it is desirable to explore the potential of developing an low-cost, autonomous system which can provide this capability. Along with the development of the necessary technology it is imperative that its efficient implementation in a form suitable for mass production, low-tech operation and inexpensive maintenance be determined. This project will involve the concept definition, product design study and documentation and finally prototype validation of an autonomous surface vehicle capable of locating, retrieving and returning a "hazardous" canister typical of those used in the gbledoff process in the glackplak industry. This "proof-of-concept" program will also be tasked with developing an economic assessment and manufacturing plan based on a production level of 200 units per month starting in June 1999. A preliminary market assessment indicates that a cost of $1000 per unit should be a target sales price. Representatives of the glackplak industry will be visiting ME470, Inc. on Dec. 5,1997 to view a concept prototype and witness a validation test.

B. PROJECT REQUIREMENTS: Each design team must:

1. Develop a design for the autonomous retrieval system and document the design in the form of a detailed design proposal. The greatest measure of merit will be associated with meeting all project scheduling and cost goals and demonstrating a robust design. System modeling, performance analysis and simulation of the system and its operation are critical components of the design proposal. The proposal should not only detail the design of the vehicle but must identify the most critical technical, operational and economic factors associated with the design. The results of this project must also be presented in a Critical Design Review.

2. Fabricate a prototype for the system described by the proposal. The prototype must be capable of demonstrating the autonomous operation of the basic vehicle, its ability to locate a "typical canister", retrieve it and return to the start location. The prototype will also be used to demonstrate the durability, repairability and storage of the proposed design. The prototype must be a full scale though it need not use the same materials as the actual production system.

3. Develop a validation test plan and be prepared to demonstrate the operation of the vehicle on December 5, 1997. This test plan is intended for testing in a controlled (in-door) environment.

4. Follow established procedures for collecting and reporting engineering activity, time spent on the project and cost accounting records for the entire project.

C.SPECIAL CONSIDERATIONS AND SYSTEM PERFORMANCE REQUIREMENTS:

1. The "typical" hazardous canister is a circular cylinder, 8" diameter and 2" high with mast and homing target mounted on the top. The canister weights 5 lbs. The mast is fit with three retaining rings, each of which are capable of supporting the weight of the canister. A typical canister is available for you to study.

2. The retrieval vehicle (henceforth referred to as RV) must be able to be packed for shipping and ground handling in an 10" x 12" x 15" container. It must be able to be removed from its storage container, assembled and prepared for operation in 5 minutes by one person and weigh no more than 5 lbs. Though 5 lbs is the upper bound on the vehicle weight, low-weight along with low-cost are considered to be important design goals.

3. During the prototype demonstration, the RV will be positioned at three different locations relative to the canister in an open area and, after event initiation from each location, must be able to locate the canister which will be located within 30 ft of the RV, retrieve the canister and return to the starting location. Trials will be conducted from each of the three locations without regeneration of any of the RV's fuel supplies. The entire process must be completed within 3 minutes. All operations must be autonomous.

4. The surface on which the retrieval is to be performed can contain loose or rigid cables, wires or hoses with diameters up to 1 inch.

5. The RV and all subsystems must be powered with electric or stored mechanical energy sources. No chemical (solid, liquid or gas) sources will be allowed.

6. All electronic components (i.e. motors, servos, computers, wiring, circuit boards, etc.) must be able to be removed from and reinstalled into the baseline vehicle in 30 minutes by two people with manual hand tools only.

7. The proposed production plan and associated manufacturing facility should be based upon an output of 200 units per month beginning in June 1999.

8. Since environmental impact is an issue in all product development projects, the "recycle-ability" of the vehicle and the nature of all the proposed fabrication processes will be strongly considered in the product assessment. 9. Economic assessment should be based on a proposed sales price of $1,000. per unit.

D. SPECIAL CONSIDERATIONS FOR THE PROTOTYPE AND PROOF-OF-CONCEPT DEMONSTRATION The prototype system for the proof of concept demonstration should satisfy the following:

1. Any material can be used in fabrication but care must be taken to differentiate between prototype weight and actual system design weight.

2. Each design team will be provided a Parallax Stamp II microprocessor, Serial servo controller (8 channel), electric motor, motor speed controller, 3 miniature servos, ultrasonic transmitter/receiver and rechargeable battery packs as well as appropriate manuals for this equipment.

3. Total additional prototype costs cannot exceed $150.

4. All parts fabrication and assembly must be accomplished using the manufacturing facilities provided for this project.