2. Proposal Phase

Due September 11th, 2009

Proposal Phase


CNC Router Proposal


2.0 The Team

Ariel Swingley was selected for her dependability in projects, positive attitude and intense work ethic. She also attended MASEI over the summer and already has basic knowledge about robots and what all it takes to create them. She also has other positive capabilities such as being Google Sites savvy, which is important because that is the medium of our DP for engineering, this year.

Diana Barlow was selected because of her unwavering work ethic and positive attitude. She is a very dependable project partner because she will keep others on task and does not accept bad work or laziness. She also attended MASEI over the summer, which puts her ahead of the curve than most in robotics.


2.1 Team Description


Diana Barlow (left) and Ariel Swingley (right) are seniors at High Tech High Media Arts and are graduating in June of 2010. Both Diana and Ariel spent their summer at MASEI and are very used to being the only girls in a in a large class of male engineers. Each are straight A students and wont let this project beat them because neither accepts failure.


2.1.2 Individual Biographies

Ariel Swingley was born on April 13th, 1992 in San Diego and has lived here her entire life. She is currently 17 and trying very hard to decide where she would really like to go to college. Ariel wants to be some kind of surgeon (leaning closer to Neurosurgery) when she gets older, despite the fact it will be about 20 years of college, medical school, residencies, etc.


Diana Barlow was born in San Diego on May 12, 1992. She has been going to High Tech since the 8th grade and is now currently enjoying her senior at High Tech High Media Arts. Diana likes crafts and projects she gets to work with her hands so engineering is a great opportunity for her. Diana wants to be an Obstetrician Gynecologist when she grows up, because she loves babies.


2.2 The Project

    For our senior project we would like to build a CNC Router. A CNC Router is essentially a computer numerical controlled Router, meaning that we can program the computer to tell the CNC Router to cut or drill out any shape from a plank of wood. By building it, we would save our class time and money when building future projects. We also plan on entering our CNC Router into the Science Fair.


2.2.1 Essential Question

    How can we build a fully operational CNC Router capable of cutting out any design we create on the computer by the end of the semester?


2.2.2 Primary Group Components

    Both Ariel and Diana will be in charge of the design, programming and construction of the CNC Router. Structure assembly is something both Ariel and Diana have successfully done before with projects and will be less of a challenge than programming, which neither have previously attempted


2.2.3 Materials:

Please Note: The X&Z gantry, Y rails and motion control systems will be built by MAE students and have been designed by: Patrick at http://buildyourcnc.com/default.aspx  
The final table, wiring scheme, and cooling system will be designed and built by MAE.  

MDF pieces:
Y-axis rail support (1)
Y-axis rail support reinforcement (1)
Gantry sides (2)
Z/Y plate (1)
Z-axis rail supports (2)
Z-axis middle supports (4, 2 long and 2 short)
Router/spindle mounts (2)
Z-axis lead screw/vacuum mount top (1)
Z-axis lead screw/vacuum mount bottom (1)
Curved Y-axis back support


Components added for roller chain system:
Motor mount for z-axis (1)
Y-axis roller chain connector pieces (2)
Components added for lead screw system:
Motor mounts for the X, Y and Z axes (4)
Y-axis lead screw mounts (2)
X-axis lead screw mounts (4)


Hardware List:
Screws (#8) 1" (24)

Screws (1/4"):
1" (12)
1-1/2" (88)
2" (15)
3-1/2" (16)

Screws (3/8"):
2" (14)
3" (1)


Nuts:
#8 (24)
1/4" (88)
Cross dowels (75)
3/8" (15)


Washers:
For #8 Screws (24)
For 3/8":
Small (16)
Medium (12)
Large (8)
X-Large (12)
Small L-Brackets (corner braces) (2)

Bearings:
V" Groove (3/8" Inside Diameter) (16)
Standard with 1/2" Inside Diameter for Lead Screws (2)
Couplings - 1/4" to 1/2" (1)
        Note: If the motors have 3/8" shafts, 3/8" coupling bores are supplied.
Steel Collars (1/2" Inside Diameter): (2)
Z-axis 18.5" lead screw (1)
Anti-backlash nut (1)

Supplemental Components for Lead Screw System:
Small L-Brackets (30)
Screws (#8) @ 1" (48)
Nuts #8 (48)
Wood Screws (12)
Steel Collars (1/2" Inside Diameter): (6)
Standard with 1/2" Inside Diameter for Lead Screws (6)
Washers for #8 Screws (8)
X-axis 6' lead screw (2)
Y-axis 3' lead screw (1)
Anti-backlash nuts (3)
Couplings - 1/4" to 1/2" (3)

Motion Electronics:
stepper motors (3)
stepper motor drivers (3)
power supply
breakout board

Software:

Mach3Pro


2.2.4 Preliminary Sketch



2.2.5 Specific Team Member Components
    Ariel Swingley will be in charge of the CNC Router. Finding the the best router and formatting it to fit the CNC mill's specific needs will require a consider amount of math, exact measurements, and patience. Since the primary component of the mill is that it can cut things out on it's own it will also need to know exactly when to turn off and turn on as well as being powerful enough to cut through all different types of materials.

  Diana Barlow will be focused specifically on the four axis that the router travels upon. These axis are necessity for the CNC Router to function and they have to be set up perfectly for it to work well. She would also like to focus her attention on securely connecting the CNC Router to the table.


2.3 Problems

    By building the CNC Router the group hopes to solve the problem of human error when making exact pieces (such as the frame) for HTHMA’s AUV. We would reduce the time it takes build each experimental piece so the AUVSI team can focus on making the best robot as a whole.


2.3.1 Limitations

    The biggest limitations to achieve success will be the team’s slender knowledge of coding. Another limit would be designing our own version of the CNC Router to fit our own needs, such as the table size. We are also very limited with the amount of space we have inside the shop because we would be taking up a lot of room with our final product.


2.3.2 Measuring Success

    The group plans to measure the success of their project by whether or not they can build an efficient CNC Router that can cut and drill with precision. We would also at least enter into the Science Fair with our final product.


2.3.3 Specific Math and Engineering Connection

    Ariel Swingly knows that the CNC Router will be a very complex machine to build, and will require considerable amounts of electrical engineering, geometry, algebra and trigonometry. Ariel and Diana will need to figure out exactly how exactly the machine should be put together for it to work, then using algebraic, trigonometric and geometric formulas and techniques, make the structure perfectly supported so that no stress is put upon the motors due to faulty alignment. The team will need to use electrical engineering techniques such as wiring and programming to make the CNC Router to fallow exact commands so it can cut things out perfectly.

    Diana Barlow’s connection between math, engineering and the CNC Router relvolves around the use of electrical engineering techniques such as coding and wiring to complete the project. Every piece built must be perfectly measured to result in a presice and accurate project.


2.3.4 Subcomponents

    Ariel Swingley’s engineering subcomponent will be updating the DP on the team’s Google Site page with all the up to date robotic information as well as the step by step process and components. Making sure the DP is constantly organized and polished so anyone can look at it and fallow to exactly what step is currently being completed, is a huge standard of the DP that will be met.

    Diana Barlow’s engineering subcomponent will be to digitally capture the process of designing, building and finalizing the CNC Router. That way there will be lots of evidence to show the amount of drafts, revisions, designs, and construction that went into our final product, as well as the challenges we encountered and triumphed.


2.4 CNC Router Legacy

    We will be contributing to the AUVSI competition by building a machine that is able to build custom pieces specifically for our AUV. By having a machine build all the pieces instead of making them with tools we eliminate a lot of error accumulated by humans making them from scratch. This will also help majorly reduce the amount of time spent building pieces that may not work well, so scratching and trying another design will take half as much time.

    On another note, by building our own CNC Router, our knowledge of coding, problem solving and designing will tremendously increase. We can then have more than just one coder working on all the sensors for the AUV as well as take on some of the CAD and SolidWorks 3D modeling, making the whole AUV completion process all around smoother.


2.5 Honor Components:

Ariel Swingley:
    For my Engineering Honors component I will be mentoring: juniors taking engineering for the first time, seniors who need help with project components and helping the students enrolled in the AUVSI X-Block Karl holds. Along with teaching others my skills in project management, drafting and design during school hours, I will hold office hours Monday and Wednesday from 3:30 pm to 4:30 pm. Passing on all the knowledge and experience I have gained in this engineering program to younger students is the very core element in keeping this program moving forward.

Diana Barlow:
    As my Engineering's honors component, Karl wanted to put me in charge of shop tools and material organization. I would design a new layout of where and how all the tools will be kept and I make labels or for everything. I am also creating a binder listing every major tool along with its name, model, maintenance, and manual. I would also create special care maintenance list to display behind every major tool. Organization is key in engineering and a really important component for success.




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