2014 Engg1200 Pa Signed

Doc I.
D: 2014-ENGG1200-PC
Version: 3.0
Date: 16/07/2014

ENGG1200 PROJECT A AERIAL DEPLOYMENT

The Br i ef
This document is a client-specified brief. Supplementary information will be communicated
through the Problem Solving Sessions and announced via Blackboard. If your design team
requires further information or detail, please contact your project .

Rol es
Work submitted as part of this course must be designed and built entirely by engineering
students enrolled in ENGG1200, Semester 2, 2014. Project leaders, tutors and university
technicians can be used as consultants for specific information. Your team is required to
engage in clarifying any or all of these specifications to deliver the project at the tender
competition, being at Demonstration Day in Week 13.

Saf et y
Part of this course requires you to manufacture and assemble components yourselves.
Since this is a university project, the university has duty of care for your safety. You are
therefore required to complete this work in the Student Technology Centre (STC) where
university staff can supervise your work.

No toxic or dangerous materials will be allowed. The determination of safe materials will be
made by comparison to the Hazardous Substances List at
http://www.uq.edu.au/ohs/hazardous-substances (The University of Queensland, 2014).
This check must be submitted as part of Build Risk Assessment in the Preliminary Memo
(due Week 4) and is required for approval prior to construction.

Doc I.D: 2014-ENGG1200-PC
Version: 3.0
Date: 16/07/2014

CONTENTS
1 Introduction ................................................................................................................... 3
2 Aims .............................................................................................................................. 3
3 Design Specifications .................................................................................................... 4
3.1 Deliverables ............................................................................................................ 4
3.2 Supplied Equipment ................................................................................................ 4
3.2.1 Linear rail ......................................................................................................... 4
3.2.2 Motor and motor driver ..................................................................................... 5
3.2.3 Torque rod ....................................................................................................... 6
3.2.4 Mounting flange ............................................................................................... 6
3.2.5 Payload ............................................................................................................ 7
3.3 Overview of operation ............................................................................................. 7
3.4 Design Constraints .................................................................................................. 7
3.4.1 Mounting points ............................................................................................... 8
4 Models & Simulations .................................................................................................... 8
4.1 Structural Modelling ................................................................................................ 8
4.1.1 CAD CAM Interface specifications ................................................................... 8
4.2 Behavioural Modelling ........................................................................................... 10
4.2.1 Relevant physics: ........................................................................................... 10
4.2.2 Modelling and simulation tasks ...................................................................... 11
5 Build / Manufacture ..................................................................................................... 12
6 Material Selection ........................................................................................................ 12
7 Critical Design Review ................................................................................................ 12
8 Evaluation ................................................................................................................... 12
8.1 Equipment ............................................................................................................ 12
8.2 Testing procedure: ................................................................................................ 13
8.3 Design Objective Function .................................................................................... 13
8.3.1 Starting position above horizontal: ................................................................. 14
9 FAQs ........................................................................................................................... 15
10 Revision Status ........................................................................................................... 15
11 References .................................................................................................................. 16

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1 INTRODUCTION
There are occasional instances in the commercial sector where there is a need to deliver an
airborne payload over a barrier and into a specific location. Such instances might include
needing to put out a raging forest fire, contain a nuclear accident in a reactor core or
delivering food and equipment to civilians inside a guarded perimeter. In order to achieve
such a trajectory an aircraft carrying the payload would need to come in at a predetermined
speed and relatively low altitude and quickly alter its acceleration to launch the payload in a
trajectory similar to that shown in Figure 1.

Because this is a high risk manoeuvre the Defence Materiel Organisation (DMO) is seeking
bids for the design of an Aerial Deployment System that can be attached to the
undercarriage of an aircraft to achieve predefined trajectories. Your company has been
asked to prepare a tender bid for the detailed engineering design.

Figure 1: Airbourne delivery trajectory
2 AIMS
Each team is to design and build a working proof of concept scale model to meet the design
specifications listed below.

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3 DESIGN SPECIFICATIONS
3.1 Deliverables
Each team will manufacture a proof of concept payload deployment mechanism (PDM). The
PDM will include the following features:

1. A CNC machined quick release plate to interface your model to the clients linear
actuator.
2. An arm, consisting of zero or more articulated sections.
3. A payload holder (which may be part of the arm).
4. Your team will write the controller input to specify the acceleration and deceleration
of the trolley.

Teams will be provided with a $100 budget for procuring your design. Tax invoices will be
required for reimbursement. Reimbursement will only be given for parts and materials used
in the final design, within reason. Refer to the quality section of the marking criteria for marks
allocated with minimising cost (Section 8.3).
3.2 Supplied Equipment
The client will provide test equipment consisting of the following components:
1. Linear rail with sliding trolley
2. Motor and motor driver
3. Torque rod
4. Mounting flange
5. Payload
3.2.1 Linear rail
The linear rail has a usable length of 3 m and is mounted at a height of 1.5 m. The friction
coefficient is not specified. The maximum velocity of the trolley on the rail is 10 m/s and the
belt can withstand accelerations of over 9 g.

Photographs of the actual rail are shown in Figure 2, and videos of it in operation are
available on the Blackboard Project A page.

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Figure 2: Linear rail (left) and the torsion bar assembly (right). View to the mounting
flange end
3.2.2 Motor and motor driver
The trolley is driven by a Sanyo-Denki 12 Nm stepper motor: model 103-H89222-6341. The
datasheet is available on Blackboard. The motor will be driven at 240 Volts.

Each revolution of the motor advances the trolley by 280 mm.

Teams will interface to the motor by providing a .csv file containing two columns, the first
being time values in milliseconds, and the second being corresponding target velocities in
m/s. Velocity values can be either positive or negative. Times can be specified down to
tenths of milliseconds if necessary. From testing the maximum achievable acceleration is
expected to be approximately 10 m/s
2
. The velocity is effectively limited by the acceleration
and length of rail.

Motor control files must be submitted via the Blackboard assignment submission (under
week 13 on the learning pathway) by 4:30pm on Monday the 27
th
of October, or the
default profile will be loaded for your team on demonstration day. The default profile is:
t(ms),v(m/s)
0,0
600,8
900,0

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3.2.3 Torque rod
The torque rods are manufactured from high-tensile spring steel with a shear modulus of
79.29 GPa and a yield stress of 1500 MPa. The torsional yield stress is approximately 45 %
of the tensile yield stress. The gauge length is 200 mm. Two diameters will be available for
teams to choose from: 3 mm and 5 mm.

As there are a limited number of torque rods, it is important that teams ensure that they do
not plastically deform the torque rod. Teams are therefore asked to show calculations of
maximum deflection for their design compared to the yield deflection or the rod. The rod will
be measured after each test, and marks will be deducted if a team deforms the rod
plastically.
3.2.4 Mounting flange
A drawing of the torsion rod assembly (thumbnail shown in Figure 3 below) is available on
the Blackboard Project A page. Note the pawl on the rear view that will allow the swing arm
to twist the torsion bar in the clockwise direction from the equilibrium position only. See
Section 4.1.1 for details of the quick release plate interface.

Figure 3: A drawing of the torsion bar assembly is available. Clock-wise from bottom:
Isometric view, front view, side and read view

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3.2.5 Payload
The payload shall be a standard size, type 1 or type 2 tennis ball. Specifications for this can
be found at:
http://www.itftennis.com/technical/publications/rules/balls/appendix-i.aspx
3.3 Overview of operation
The trolley slides along the linear rail under the influence of the motor. The torque rod is
mounted on the trolley. It is oriented horizontally, and perpendicular to the linear rail. One
end of the torque rod is fixed against rotation. The other end of the torque rod engages with
the mounting plate where the PDM is attached. Note that the test rig will be mounted in a
right-handed fashion, i.e. the arm will hang on the right-hand side of the rail, facing the
throwing direction.

When the PDM rotates clockwise about the axis of the torque rod, the torque rod acts as a
torsional spring, storing energy as the trolley accelerates and releasing energy when the
trolley decelerates. This energy is to be used to launch the payload. When the PDM rotates
counter-clockwise past the equilibrium position, the torque rod disengages at the fixed end,
allowing the PDM to rotate freely without losing energy into the torsional spring.
3.4 Design Constraints
The model must fit within the following constraints, as shown in Figure 4.

1. The PDM must protrude no wider than w =120mm from the adaptor plate.
2. The PDM must extend no more than r =500mm radially from the torsion pin at any
time.
3. The PDM, including quick-release plate, arm, payload holder and payload must
weigh no more than 3kg.
4. The projectile launch must be propelled exclusively by the energy of the linear
actuator.
5. The model must be safely and securely constructed.
These specifications are essential for safety reasons. Any models which do not meet these
specifications will not be tested.

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Figure 4: Design envelope for the quick release plate, arm and payload
3.4.1 Mounting points
In addition to the quick release plate, one other mounting point on the test rig will be made
available. A point on the trolley, but not attached to the torsion bar may be used as a trigger
mounting point. This point will be 150mm below and 150mm to the left of the centre of the
quick-release plate interface, as shown in the drawing linked from Section 3.2.4. This
mounting point is intended to actuate triggers only, and should not be used to absorb large
forces such as stopping the motion of the swing arm.
4 MODELS & SIMULATIONS
Tenders are expected to use models and simulations to inform the design process and
assess the likely performance of their design.
4.1 Structural Modelling
Teams will be required to model the quick release plate in CREO computer-aided-design
software. Three students from the team should attend the three structural modelling
workshops in week 7, 8 and 9, and submit their design files for manufacturing with a CNC
mill.
4.1.1 CAD CAM Interface specifications
Teams are to design and CNC mill their quick-release plate. The purpose of the quick-
release plate is simply to connect your swing arm to a mounting flange on the test rig.
CNC milled parts will be cut from aluminium blanks of 12 mm thickness and 75 mm diameter
as shown in Figure 5 below.

Note that the centre hole will allow an M6 bolt to pass through, which screws into a
corresponding, but threaded, hole on the mounting flange. The centre bolt can be used to

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fasten your swing-arm to the quick release plate, but additional features will be required to
transfer torque to the arm.

The holes at 60mm pitch circle diameter (PCD) are to mate with metal pins. These pins are
strongly affixed to the adapter plate on the test rig and these pins transmit torque from the
adapter plate/torque rod assembly into your quick release plate. Teams must design and mill
features on the plate to ensure the torque is transferred to the arm, and the arm is secured.
Note that the alignment of the 60 mm PCD holes and other features will determine the
equilibrium angle of the arm.

Figure 5: Interface dimensions. +Z axis is out of the page

Pl ease Not e:
Teams must comply with the axis indicated as the parts are manufactured in fixtures
aligned with these axes.
Tool Path must be approx. 150Kb in file size per side (maximum machining time for
both sides is 2hrs)
Tool is 5mm end mill
Vericut screen shot showing axis is required in jpg format and submitted with tool
path file.

File Name Format:
(Project)_(student email).tap e.g. MINE_S123456.tap
(Project)_(student email).jpg e.g MINE_S123456.jpg

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Your files are to be submitted using the specified formats via electronic submission (refer to
Blackboard for more details).

All components should be available for collection around 5 working days after the
submission deadline.

Non-compliant submissions will be returned for resubmission with 10% penalty. Designs
with excessive non-functional features, decorations and incorrect axis will be deemed non-
compliant.
4.2 Behavioural Modelling
In order to achieve the aims of the project, teams will need to model and simulate the
behaviour of their system.
4.2.1 Relevant physics:
The following equations may be a useful starting place for modelling your system.

Ener gy i n a spr i ng:
The energy, U, in J oules, stored in a torsion spring is:
U =
1
2
2
[1]

where:
is the spring constant, and
is the angular displacement (radians)

Tor que and angl e of t wi st :
=
T.L
G.I
p
[2]

where:
is the angular displacement (radians),
L is the length of the object the torque is being applied to,
T is the applied torque (Nm),
G is the shear modulus (GPa), and
I
p
is the torsion constant for the section

Visit http://www.engr.colostate.edu/~dga/mech325/chapter_summaries/J UVINALL_EQS_CH12.pdf
(J uvinall & Marshek, 2000) for more details.

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Li near and angul ar mot i on:
Linear motion Angular motion
+
[3]
+
[7]
=
1
2
(
)
[4]
=
1
2
(
)
[8]
=
+
1
2
2

[5]
=
+
1
2
2

[9]
2
=
2
+ 2
[6]
2
=
2
+ 2
[10]

where:
is the final velocity (m/s),
is the initial velocity (m/s),

d is the displacement (m),
a is the acceleration (m/s),
t is the time (s),
is the angular acceleration (rad/s
2
), and
is the final angular velocity (rad/s),
is the initial angular velocity (rad/s), and

is the angular displacement (rad).

4.2.2 Modelling and simulation tasks
In order to achieve the aims of the design, teams should model and simulate key elements
of the system as shown in Table 1 below.

Table 1: Modelling and simulation requirements
Rod deflection Present calculations of the yield deflection for the torsion rod.
Physical System Present modelling results and key equations showing response of the
system to inputs. This should include graphs showing:
Projectile trajectories for all arm/payload holder configurations.
Projectile distance for several values of maximum acceleration.
Maximum rod deflection for several acceleration profiles.

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5 BUILD / MANUFACTURE
The university will supply:
A linear rail, motor and motor driver
A trolley which moves along the rail
The torsion rod and rod mount.
The flange that is fitted to the torsion rod.
Payload a standard tennis ball.
Barrier a moveable barrier 1.5m high

Each group will be required to do the following:
Design and build their own payload delivery system including any links and the
payload holder.
Design and submit for manufacturing, a quick-release plate which will interface with
the torsion rod flange. Design their own quick-release plate using computer aided
design (CAD) software. The quick release plate will be machined on the Universitys
computer numerical controlled milling machines (CNC). The quick-release plate will
interface your PDM onto the clients adapter flange.
Supply control input to the motor driver (protocol to be specified)
6 MATERIAL SELECTION
Students have freedom to choose materials for their parts. The quick-release adaptor plate
will be CNC machined from aluminium. Material selections and selection criteria should be
justified in the final report.
7 CRITICAL DESIGN REVIEW
In week 10 teams will be required to demonstrate progress in their design. This review is
worth 5% of your final grade and the criteria will be advised.
8 EVALUATION
Designs will be tested in week 13. The site will be an open sportsground at UQ.
8.1 Equipment
The test rig consisting of a linear rail, motor and motor driver will be set up at the site.
Specifications for the height and length of the rail are provided in Section 3.2.

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8.2 Testing procedure:
1. Before the presentation, the barrier distance will be chosen by the team and put in
place.
2. The team will be required to provide the control signal to the stepper motor driver.
3. The team will attach their model to the test rig and load the payload.
4. A tutor will assess the safety, robustness, dimensions and weight of the model and
connection before testing.
5. Once the model is attached it must behave independently. That is, there shall be no
physical interaction between the model and team members.
6. Repeat runs will be completed to confirm the repeatability of the launch.
8.3 Design Objective Function
Teams should maximise the launch efficiency (25%), land the payload as close as possible
behind the barrier (15%), achieve high repeatability of launch (20%) and have a high build
quality (40%). Teams will be able to set the distance to the barrier. The barrier height will be
1.5m. The various dimensions used in evaluation of performance are shown in Figure 6.

Figure 6: Testing and evaluation specifications

The specific weightings of the marking criteria are defined as:

demonstration mark = 0.25
1

2
1
+ 0.15
2

2
3
+ 0.2 + 0.4 [11]
where:
l
1
, l
2
, l
3
are the acceleration length (m), the flight length (m) and the distance past the
barrier (m) respectively,
k
1
, k
2
are scaling factors such that the best performing throw receives 100% of the
available mark for that term,
h (m) is the height of the barrier,
Q is the build quality, and
R is repeatability.

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See the FAQs (Section 9) for a discussion of how l
1
will be calculated.

Q = Bui l d Qual i t y:
The build quality mark incorporates many important but subjective factors such as:
Simplicity of design
Fitting/Interface of CNC machined part
General craftsmanship (e.g. are all sharp edges removed, is the prototype well
finished)
Innovation and creativity, i.e. unique solutions.
Cost effective design

R = Repeat abi l i t y:
Accuracy of subsequent deployments
8.3.1 Starting position above horizontal:
As shown in Figure 4 and Figure 6, the design intent of this brief is for teams to begin with
the swing-arm hanging below the rail. Starting with the arm above the rail and exploiting the
extra initial gravitational potential energy is an innovative solution, however the design
objective function in Section 8.3 does not allow for fair marking of these designs. As such, a
minimum value of 0.4 metres (the approximate equivalent rail length required to build up
equivalent energy) will be used in the marking of these designs.

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9 FAQS
Common project-specific questions and answers are provided in Table 2 below.

Table 2: Project C Q&A
Item # Question and Answer
1
Q: Can I get multiple parts manufactured using the Universitys CNC machines?

A: No. We only have capacity to manufacture one part per team. Please purchase
materials and use the tools in the STC to manufacture the rest yourselves.
2
Q: Are we just aiming to fling a tennis ball as far as possible?
A: Yes and no. As described in section 8 you will get maximum marks if you
minimise the length of track you use, land your payload as close as possible
behind the barrier AND maximise the distance that you fling the ball.
3
Q: If I accelerate the trolley forwards and then backwards again before releasing
the payload, does that mean that my acceleration length (
1
) in the marking criteria
will be calculated as zero?
A: No. The acceleration length,
1
, will be calculated as the sum of all stepper
motor steps in the forward direction. Steps in the backward direction will not be
added (nor subtracted).
4
Q: Can I use the figures in the brief in my reports?
A: Yes, there is no need to re-invent the wheel. It is extremely important that you
reference where you got the figures though. As with anything in your report that
isnt your own work, if you dont reference it, it could be considered
10 REVISION STATUS
The project brief revision status is shown in Table 5. The table will be updated following
major document revisions, approval and issue.

Table 3: Revision status
Rev Description Date of Issue: By:
1.0 2013 project brief re-formatted into new
style.
15/07/14 MA
1.1 Equation variables update, citations added 19/07/14 MS

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Date: 16/07/2014

11 REFERENCES
The University of Queensland. (2014). Hazardous Substances. Retrieved J uly 16, 2014,
from The University of Queensland: http://www.uq.edu.au/ohs/hazardous-substances

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Doc I.

is the final velocity (m/s),

is the initial velocity (m/s),

is the final angular velocity (rad/s),

is the initial angular velocity (rad/s), and

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