EML2322L Design Report Template

EML2322L Design Report Template
Table of Contents
(for this report template, not for the submitted design reports)
Cover Page ... 3

Introduction / Problem Statement .... 4
Background Information .. 5
Conceptual Design Generation .... 8
Design Report 1 Submission Instructions 11
Selection of Design Concept 13
Peer Evaluation for Design Report 2 ................... 18
Detailed Design .... 17
Peer Evaluation for Design Report 3 ................... 18
Design Review Instructions . 22
Design Report 3 Resubmission Instructions 23
Changes / Corrections in the Prototyping Phase ..... 25
Competition Paperwork Submission Instructions .... 26
Prototype Development and Testing 27
Discussion / Conclusion ... 28
Report Appendices ... 30
Common Report Errors and Weaknesses 32
Links to Project Templates and Reference Documents ....... 34
NOTE: All instructions in red (and hyperlinks) should be deleted from this template
after reading and prior to printing the report for submission.
EML2322L Design and Manufacturing Laboratory

Design Report 1, 2, 3, 3 Resubmission, or 4
(denote appropriately for each submission)
Team Number
Team Member Name (1) (i.e. Mike Braddock (1))
Team Member Name (2)
(List in alphabetic order by last name and retain number in parenthesis)
Instructor: Mike Braddock

Semester
Date
NOTE: do not change formatting on this page or in any part of the template
Introduction / Problem Statement

Print the Design Project description and Design Project Schedule in color and neatly highlight the following:
1. project design specifications (i.e. ALL objectives and constraints) in yellow (including important
dimensions in the description body and on the accompanying drawings)
2. evaluation criteria in blue
3. project deliverable dates in orange
4. underline in red ink any other information you feel may be important for the projects success
Note: Only one Introduction / Problem Statement is submitted for each group.
Background Information (Team Member Name (1))

To assist in this important phase of the project, relevant research has been assembled on the topics listed
below. INDIVIDUALLY answer the following questions based on the background information
provided on the course website. If other sources are used, they must be cited. ANSWERS MUST BE
IN YOUR OWN WORDS AND SHOULD SHOW CLEAR UNDERSTANDING OF THE MATERIAL
PRESENTED. Copying off the course website or any other source is PLAGIARISM and will be
treated as such. Leave subheadings and questions in your printed responses and use complete sentences and
paragraphs to present your answers in an organized manner.
This is the only chance you will have to do background research, so please take the exercise seriously
and use the Internet to perform image and knowledge searches on relevant topics to improve your
understanding of how each may influence your design choices.
1. Electric DC motors
What type of power supply is used for this project? What are the pros and cons of brush-type versus
brushless-type DC motors? If cost is an important factor for the project, which type of motor would be the
better choice?
Change font color to black and type your response here.
2. Robot controllers
Summarize the difference between relay and proportional control. For what type of function on the project
might each type of control be used? How many control channels of each type (relay and proportional) do the
laboratory controllers provide?
3. Mobile robotic platforms
Summarize three commonly used mobile platform types for robotic applications and explain the pros and
cons of each. Which type of mobile platform did you select for your conceptual design and why did you
select it over the other options?
4. Steering mechanisms
Summarize three common methods of steering for robotic applications and explain the pros and cons of each.
Which steering method did you select for your design and why did you choose it over the other options?
Would front or rear steering more desirable for your design and why?
5. Wheels and tires

What are the differences between regular wheels and caster wheels? When would each type of wheel be
used? What are the pros and cons of pneumatic versus semi-rigid versus solid tires/wheels? Which type(s)
of wheel(s) do you believe would be most beneficial for the project and why?
6. Friction coefficients
Why are friction coefficients important for this project? What are typical static friction coefficient ranges for
common wheel materials (plastic and rubber) in contact with concrete surfaces?
7. Bucket and ball lifting mechanisms / manipulators
Summarize and graphically illustrate (by hand or by including downloaded images which clearly help
explain the concepts) common types of manipulator mechanisms and explain the pros and cons of each.
What type of manipulator does your conceptual design use to grab the buckets/balls for this project? (Do not
feel limited to the two types of manipulators noted above.)
8. Ball hoppers
explain the concepts) common options for ball hoppers and explain the pros and cons of each.
9. Ball sorting mechanisms / strategies
explain the concepts) common options for sorting balls and explain the pros and cons of each. If not
applicable for the current semesters project, write N/A in the response area.
10. Ball dispensing mechanisms / strategies
explain the concepts) three methods for dispensing balls.
11. Gears / gearing

What are gears? What is the purpose of gearing? List five types of gearing, a common application for each,
and explain why a particular type of gearing is useful in each application (perform additional research to
answer this last part). How will gears be beneficial on this project?
12. Materials / material selection
List the pros and cons of steel, aluminum, plastic, wood and 80-20, as well as three common applications of
each. What materials will be best suited for which parts of the project?
13. Material properties
Define the following material properties and explain why each might be important for this project: cost,
density, ductility, machinability, stiffness, strength and weldability.
14. Balls
What information about balls is useful for the project and why? Be specific (i.e. quantify size(s), weight(s),
material(s), coefficient(s) of restitution, etcetera, with actual numbers).
Conceptual Design Generation (Team Member Name (1))

After completing the background research, brainstorm ideas to solve the problem. Good sketches are
essential for explaining concepts. Each group member must submit one set of neatly drawn hand sketches
which clearly illustrate a complete design solution and contain the following:
Typed written description referencing each sketch by figure number to explain the concepts and
material selections for each part of the design. Include the maximum robot velocity for the selected
motor speed and wheel size using this reference chart (these components can be changed in the future
after performing calculations to decide which combination will work best for your conceptual design)
MINIMUM of five pages of hand sketches; each on its own page, drawn as large as possible with
unique and sequential figure numbers(i.e. 1A, 1B, etc. for team member 1)
Three orthographic views (front, side, top) of the entire conceptual design
One isometric view of the entire conceptual design
Separate detailed sketches of each mechanism / subunit (i.e. ball manipulator, hopper, dispenser)
including at least two orthographic views and an isometric view of each.
Explicit dimensions showing overall size of robot, frame, control box, motors, wheels, hubs,
object manipulator(s), hopper, release mechanism(s), and attachment brackets (note: some
designs will not have all of these components and may include others)
Draw all parts true scale. Use leaders to clearly label all components and materials. Ensure design satisfies
all project constraints. Place your name on each sketch and in each report section, as shown in this template.
Key points about this assignment:
This is NOT a rough draft, but rather a detailed presentation of the best and most complete solution
you can come up with based on your research
This is the only opportunity you will have individually to generate a real solution to the design
problem, so take this assignment seriously, as it sets the stage for the rest of the project
Do not submit stick drawings lacking detail that show you invested no serious effort synthesizing a
real solution, but rather sketch real components that will be used on the project
If your conceptual design incorporates components not stocked in lab, you must provide a data sheet
and/or catalog page to validate specifications and cost
The first two weeks of the semester are the time to research and compare different ideas; this
assignment presents the idea you conclude is best after doing so
Design Report Examples can be found on the course webpage under the Design Project menu. Do
NOT copy the examples. The instructions in this template are the final authority for design reports.
After taking EML2023 you know what proper sketches looks like, so invest time to create them. Unclear,
messy, small, incomplete, and improperly scaled sketches lacking significant detail will be harshly
graded. Hand drawn sketches are an important communication skill that only improves through practice, so
leverage this opportunity to improve your drawing ability. Hand drawings take a significant amount of
time, so plan to spend 12-15 hours on this assignment. It typically helps to begin drawing using light line
weights that are easy to erase or ignore, and after the sketch contains all desired components, darken line
segments as appropriate to show depth, detail, and contrast.
At the conclusion of this report, each group should have as many possible solutions as it has members,
giving the team a variety of ideas to evaluate when selecting the final design to refine and prototype during
the remainder of the course. The following checklist details everything required for each students
Conceptual Design Generation submitted in Design Report 1.
Conceptual Design Generation Checklist

CONCEPT QUESTIONS (ANSWER IN THE BRAINSTORMING PHASE):
1. Does the design satisfy all constraints noted in the project description?
2. Have realistic materials been selected for each part of the design and justified using the
background research? This is the stage at which you investigate material choices; if you
havent done so, you havent finished your research.
3. Can all mechanisms and components used in the proposed design be purchased for the
allowable budget or manufactured using laboratory resources? If not, you need to do more
research and speak with course TAs or the instructor prior to D.R.1 submission.
ORTHOGRAPHIC & ISOMETRIC VIEWS:
1. Are front, side, top, and iso views of entire design neatly drawn as large as possible and on
separate pages? If more space is needed than an 8.5x11 sheet provides, use multiple pages or
an 11x17 sheet folded to fit inside the 3-ring binder. Use unique & sequential figure numbers
and place the drawers name on each sketch and in each report section, as shown in this template.
Always hole-punch landscape-oriented pages at the top of the page, not at the bottom.
2. Does each view show clear and substantial detail of the entire design, including the frame,
control box, motors, wheels, hubs, mechanism(s), and attachment brackets?
3. Are all parts drawn true scale (i.e. with accurate scaling) and clearly dimensioned? Include
explicit dimensions showing overall size of robot, frame, control box, motors, wheels, hubs,
mechanism(s), attachment brackets, and any objects which must be manipulated.
4. Are leaders included to clearly label components and material selections (which are
discussed in the written description)?
DETAILED VIEWS OF OTHER MECHANISMS (MANIPULATORS, HOPPERS, DISPENSERS, ETC.):
1. Is each mechanism neatly drawn as large as possible and on separate pages? If more space
is needed, use multiple pages or an 11x17 sheet folded to fit inside the 3-ring binder. Use
unique & sequential figure numbers and place drawers name on each sketch and in each report
section, as shown in this template.
2. Does each view show clear and substantial detail, including attachment method / bracket(s)?
Include at least two orthographic views and an isometric view of each mechanism.
3. Are all parts drawn true scale (i.e. with accurate scaling) and clearly dimensioned?
4. Are leaders included to clearly label components and material selections (which are
discussed in the written description)?
WRITTEN DESCRIPTION:
1. Is the description typed and placed at the beginning of your Conceptual Design Generation
report section?
2. Does the description clearly explain how each part of the design works while referencing
each sketch by figure number? If you have nothing meaningful to say about a sketch, do not
include it in the report.
3. Does the description clearly justify each and every design choice made in your conceptual
design drawings based on the background research or physical testing? For example, why
was a certain type of mobile platform or steering mechanism selected, from what material is each
part of your design made, and why was each material selected? If you are unsure about the
reasons for any of your choices, return to the background research and then speak with course
TAs. Statements lacking logical justifications are conjecture and will be ignored.
4. Does the description include the maximum robot velocity estimation for your selected drive
wheels and motors? Pay attention to the units noted on the robot velocity chart and make sure
your wheel and motor combination offer an appropriate balance of controllability and speed by
testing the example mobile platforms found in lab during office hours.
5. Is the description well written? Does the content of each sentence flow logically with the next?
Are paragraphs used to clearly organize thoughts? Is the description clear and concise, like all
good technical writing? No one is going to give your ideas the consideration they might deserve
if you cant explain them effectively. If your opening paragraph is difficult to read or full of
errors, we arent going to waste our time reading the rest.
Design Report 1 Submission Instructions

Submit the first design report in one clean, white 1 three ring binder with round rings (not D-shaped) and a
clear cover in which the cover page is placed. Begin each report section on a new page. Use page lifters at
the front and rear of the notebook and page dividers with computer-generated labels to organize each report
section for the grader. Glue page divider labels in place so they cant fall out as the notebook is transported.
Do not use page protectors, as they make it difficult to leave feedback while grading. Hole punch
consistently when assembling the report and do not staple pages.
ORDER REPORT SECTIONS IN THE FOLLOWING SEQUENCE:
1. Cover Page (one per group inside the clear notebook cover)
2. Introduction (one per group)
3. Background Information (Team Member Name (1), i.e. Mike Braddock (1)))
4. Conceptual Design Generation (Team Member Name (1))
5. Background Information (Team Member Name (2))
6. Conceptual Design Generation (Team Member Name (2))
7. Etcetera
Important Notes Regarding D.R.1 Submission:

1. The appearance of your work is a reflection of the effort invested; therefore before submitting your report,
ask yourself if the content is something you would be proud showing in an interview or submitting to a boss.
Incomplete or poor quality work on D.R.1 is an indication you are unable or unwilling to commit the necessary
time to the course and you should seriously consider dropping the class. Consequently, students who receive
lower than 60% on D.R.1 will be dropped from the course due to their inability to meet the ABET objectives
listed in the course syllabus and the burden they will subsequently place on rest of their teammates.
2. Make high quality copies of your final conceptual sketches to show your group while D.R.1 is being
graded (keep the copies and submit the originals). Failure to copy sketches results in an individual grade
penalty of 10% on D.R.1 because you will be unable to share your ideas with your teammates.
3. Assemble the report BEFORE lab. If any members content is not in the design report notebook for prompt
submission at the start of lab, hand-write LATE next to the members name on the cover page before
submission. Failure to do so will result in the entire group receiving a LATE penalty. From this point
onward, this option will not exist: the entire team will be penalized for any work not submitted on time.
4. If any teammate(s) does not communicate with your group or equally contribute to preparing the report,
hand-write DNC (did not contribute) next to his/her/their name(s) on the cover page before submission in
lab. If you dont flag this behavior now, it will only get worse moving into the more demanding D.R.2.
[This is the end of Design Report 1;

please review the Common Report Errors and
Weaknesses section of this Design Report Template
before printing this submission]
Selection of Design Concept

Only one submission of this section is required for each group and it must be completed as a team.
1. Review the decision matrix example and provide the same level of clarity and assessment justification.
2. Divide your designs into logical subsystems (e.g. mobile platform, ball manipulator, ball hopper/sorter,
ball release mechanism, etc.) and evaluate each separately to select the best overall solution.
3. Create a decision matrix for each subsystem to unbiasedly select the best concept.
a. For each matrix, list the objectives/criteria used to evaluate the concepts. Accurately define
all objectives; do not assume the objective name explains what youre evaluating.
b. Explain in detail how the objectives are chosen and how the weighting factors are assigned.
c. Sample criteria may include velocity (or time), controllability, size, modularity, manufacturing
time, or material cost. Dont limit yourselves to these criteria; decide what design considerations
are important for each subsystem and use those criteria (minimum of five) for each matrix.
d. If an objective can be quantified, effort must be invested to do so, without exception.
e. Review the crane hook decision matrix example for additional guidance.
4. Include detailed justifications explaining how magnitudes and scores are assigned for all concepts
in each matrix.
a. Quantitative objectives must be supported by clear calculations (including units) organized
in tabular format with supporting data in Appendix A.
b. Qualitative objectives must be supported with (1) written explanations justifying the score
assignments, (2) logical comparisons of each concept, (3) reference to sketches illustrating the
relevant features being tested, and (4) evidence of testing. When comparing each concept,
explain why Concept A scores higher or lower than each of the others.
c. This section requires significant detail to clearly justify each magnitude assignment. When
evaluating quantitative parameters like cost or manufacturing time, include supporting data for
each objective showing how the magnitudes reported in the matrices are determined.
d. Use the material price list on the course website to create accurate cost summaries and use
the experience obtained in lab making parts and the time estimation guides for the
manufacturing time summaries. TAs will gladly provide assistance if asked specific questions.
e. When organizing the report, compare all concepts with respect to each objective as opposed to
discussing all objectives for each concept.
5. Present analyses and calculations in report appendices.
a. Analyses should include calculations of motor torques for the winning design (amount
required to drive the robot and operate each mechanism) and robot speed and estimated
task completion times (object manipulation, sorting, release times, etc.) for each concept.
b. Show a clear sample calculation with units for each computed value.
c. Include a top view of the arena showing the exact (dimensioned) path each conceptual
design will follow when navigating the course . Use arrows and different line types to show the
robots planned path through the arena; label and explain each path segments distance and
estimated velocity; and include a summary table showing the estimated total driving distance.
6. Use Excel for all calculations tabulated in the appendices.

a. Report a reasonable number of significant figures for each parameter based on the level of
precision accompanying your computations or estimations.
b. For example, if computing estimated robot velocity, consider the precision of your measured or
computed values and use the appropriate number of significant figures (e.g. 2.3 ft/sec versus
2.3456 ft/sec; the latter boasts much higher precision than an estimate could reasonably possess
and makes us look foolish).
7. At this stage in the design process it is common for a new idea to arise which the team concludes is
best after comparing it to the previously submitted concepts; in this case, simply add this new
concept to the decision matrix (or matrices) to investigate if it achieves a higher score.
a. This could be an entirely new concept or a combination of the groups individual concepts
submitted in D.R.1. This is a common and beneficial occurrence in the design process. Just
evaluate the new idea against the other conceptual designs to decide which one is the best.
b. In other words, if there are four members in your group and you came up with a new combined
design, your decision matrix will now have five concepts evaluated. Adding a new concept to
one matrix does not require you to add a new concept to the others.
c. When evaluating new concepts include a basic sketch that clearly illustrates the new idea.
d. This is the last chance to improve your conceptual designs. For example, you may decide after
additional testing a different combination of drive wheel and motor would be better in regard to
robot speed and controllability. In this case simply include a new design in the mobile platform
evaluation matrix, explain the change(s), and evaluate the new platform against the other designs.
e. The goal at this stage is to select the combination of ideas that best meet the objectives and
weighting factors your group agreed are best for this design project. Be encouraged to evaluate
any new ideas your group has come up with in pursuit of selecting the best combination.
[section length is typically 30-40 pages including appendices]

Submit the second design report in one clean, white 2 three ring binder with round rings (not D-shaped) and
a clear cover in which the updated cover page is placed. Begin each report section on a new page. Use page
lifters at the front and rear of the notebook and page dividers with computer-generated labels to organize
each report section for the grader. Glue page divider labels in place. Do not use page protectors. Hole
punch consistently when assembling the report and do not staple pages.
1. New Cover Page (with updated report number and date)
2. Design Report 1 Grade Sheet (original copy completed by TA or instructor)
3. Design Report 1 (complete and untouched from original submission, including page dividers)
4. Concept Selection Checklist (original copy completed by TA for first two evaluation matrices)
5. Selection of Design Concept (original submission with TA feedback)
6. Final Selection of Design Concept (with TA feedback implemented)
a. Concept Selection Checklist accurately completed by team
b. decision matrices (printed in landscape orientation)
c. objective definitions, weighting factor justifications, and detailed magnitude and score
assignment explanations
d. decision matrix calculations and assessment data should be organized in tabular format and with a
table of contents in Appendix A
7. Appendix A: Decision Matrix Calculations & Justification Data
8. Appendix B: Robot Path Illustration, Speed & Time Calculations
9. Appendix C: Wheel and Lifting Motor Torque Calculations
10. Appendix I: Meeting Minutes (all members completed meeting minutes)
Refer to Appendices section of DRT for details about the report appendices.
D.R.2 GRADING NOTE: the ideal number of group members is four. To compensate individual effort,
report submissions by groups with five members which are not of excellent quality will be penalized, and
reports submitted by groups with three members will be graded more leniently.

Detailed Design
Only one submission of this section is required for each group; however all work should be distributed
equally among team members and computer-generated.
1. Provide a detailed written description of how the final design accomplishes the project goals.
a. Explain the function and selection of each subsystem based on research, analysis, and testing.
b. Explain the material selection for each part of the design.
2. Present complete CAD generated part and assembly drawings.
a. Use required drawing templates for all drawings.
b. Include detail drawings of all components used on the project (manufactured and OTS).
The only exception to this requirement is fasteners, which are specified completely in the BOM.
c. Include dimensions, tolerances, units, material specifications, surface finish specifications,
appropriate hole & thread notes, part quantities, unique part names & numbers, designer
and drawer names, and part deburring notes.
d. Use the provided detail drawings for OTS parts (e.g. motors, wheels, and 80/20 accessories).
e. Assembly drawings must contain a BOM clearly labeling all parts of the assembly with
sequential and uniquely numbered leaders and balloons; this typically requires multiple
views/pages for clarity. If a part is present in multiple assemblies, it maintains the same balloon
number; therefore, each BOM containing a subsequent appearance of this part will have a jump
in the number sequence.
f. Include subassembly drawings of each subsystem/mechanism that show necessary assembly
dimensions (in the proper orthographic views). For clarity, it is often necessary to break a
subsystem into multiple subassembly drawings.
3. Provide a project schedule showing intermediate deadlines and responsibilities.
a. Schedule each manufactured part and include time for assembly of each subsystem,
preliminary testing, design changes, final testing, and competition.
b. Assign group member responsibilities and completion deadlines for each task based on the
time estimates compiled for the concept selection matrices (update times if necessary).
c. Do not pair up group members on tasks; this is not an efficient use of resources. Everyone
receives the same training and should be capable of performing the same manufacturing tasks. If
anyone needs additional help, that group member should seek additional training in TA office hours.
4. Provide a project budget showing the costs for all materials and components used on the project.
a. Budget should include all items in the final BOM.
b. Purchased items must not exceed the project budget.
c. Items provided free of charge (e.g. wheels, motors, and fasteners) must be noted as such.
5. Include your team number on both sides of the robot using characters which are at least 3 inches
high. Color, font, and background shade is at the teams discretion, but ensure the team number can be
easily seen for identification purposes.
[section length is typically 35-50 pages depending on the complexity of the design]
Peer Evaluation for Design Report 2, 3, 3R, or 4 (OPTIONAL)

Group Number: _____
TA: _____________________
The design reports are the hardest part of this course, requiring by far the largest amount of effort. If any
member(s) in your group does NOT do an equal amount of work on any of the design reports, this is
your opportunity to inform me so the proper corrective action can be taken. Examples include students
who repeatedly fail to complete their weekly project assignments, dont show up for scheduled team
meetings (or arent prepared when they do), repeatedly make excuses why he/she cant do their work, dont
have the proper software installed on their computer, claim they arent good at CAD (or writing, or
calculations, or ), submit work that is subpar and requires other members to redo it, wait until last minute
to submit their work to the rest of team for feedback and editing, etcetera. Realize everyone occasionally has
a bad week, so Im not asking to hear about the one time someone doesnt show up prepared or doesnt
complete an assignment; but rather Im asking to hear about the member(s) who offer more excuses than
results while working on this challenging project.
Please be specific in explaining why you feel the following member(s) did not contribute their part to one (or
more) of the design reports. Attach additional pages as necessary, as well as your group meeting summaries I
asked all groups to use. I will assume any group not submitting peer evaluation sheets was completely
satisfied with their teammates performance on the design reports. Submission of this evaluation is
NOT a requirement for any of design reports.
Example: Michael did not perform an equal amount of work on the second or third design reports. He rarely
attended our groups design meetings and when he did, he always arrived late, would only stay for about 30
minutes and rarely contributed anything helpful. He refused to work on CAD drawings because he claimed
he wasnt good at SolidWorks, that he learned AutoCAD at the last school he attended and that he would do
more of the groups manufacturing during that phase of the project (which was not helpful for this part of the
project and only an empty excuse, since logically one person can only do the work of one person once
manufacturing commences).
The work Michael did on the decision matrices showed little effort, did not follow the guidelines or
formatting in the design report template and had to be redone by the rest of the group. Specifically,
objectives were not clearly defined, magnitudes were computed incorrectly and magnitude justifications
were poorly explained, if at all and did not use the provided cost or time estimation templates.
Michael repeatedly failed to submit his assignments to the rest of the team in time for proofreading, and
consequently those sections show low effort and will now reflect poorly on the rest of our team. Michael
was asked to complete the illustration of the robots trajectory, but claimed he didnt know how to make it
the day before it was due. Michael was also asked to create the teams budget but failed to use the provided
template for material costs, didnt include all necessary items, and once again did not complete it in time for
anyone to proof it.
As a group we feel Michael only contributed about 20% of what he should have as an equal member of this
group. Each week he was assigned clear tasks, but acted helpless, offered excuse after excuse, and refused to
attend the TA hours for assistance on his assignments.
To explain how the work was divided for the second report we are including a breakdown of what
tasks were performed by which team members:
Selection of Matrix Objectives: Josh 40%, Sam 30%, Robert 30%, Michael 0%
Definition of Matrix Objectives: Sam 60%, Robert 40%, Michael 0%
Weighting Factor Justifications: Josh 80%, Michael 20%
Magnitude Assignments / Justifications: Josh 30%, Sam 30%, Robert 30%, Michael 10%
Robot Speed Calculations: Josh 50%, Robert 50%
Robot Path Illustration: Sam 80%, Michael 20%
Wheel & Lifting Motor Torque Calculations: Josh 50%, Robert 50%
Detailed Written Description: Sam 10%, Robert 90%
CAD Models (Custom Designed Parts): Josh 20%, Sam 60%, Robert 20%, Michael 0%
Main Assembly Model: Josh 20%, Sam 60%, Robert 20%, Michael 0%
Subassembly Models: Josh 20%, Sam 60%, Robert 20%, Michael 0%
Detail Drawings (Off the Shelf Parts): Josh 20%, Sam 20%, Robert 60%, Michael 0%
Detail Drawings (Custom Designed Parts): Josh 20%, Sam 20%, Robert 60%, Michael 0%
Assembly Drawings: Josh 20%, Sam 20%, Robert 60%, Michael 0%
Subassembly Drawings: Josh 20%, Sam 20%, Robert 60%, Michael 0%
Bill of Materials: Sam 75%, Josh 25%
Project Schedule: Josh 80%, Michael 20%
Project Budget: Robert 80%, Michael 20%
Final Report Assembly & Printing: Josh 20%, Sam 60%, Robert 20%
Note: estimations accurate to approx. 10%
All the members who sign below agree to these statements and hope you can have a talk with Michael
so he will be more helpful during the prototyping phase of this project.
Josh X
Josh X
Sam Y
Robert Z
Sam Y
Robert Z
Please submit this page to the course instructor personally the day your group submits their associated
design report in lab.

Submit the third design report in a clean, white 2 three ring binder with round rings (not D-shaped) and a
clear cover in which the updated cover page is placed. Begin each report section on a new page. Use page
4. Design Report 2 Grade Sheet (original copy completed by TA)
5. Design Report 2 (complete and untouched from original submissions and grading, including
appendices and page dividers)
6. Detailed Design (assemble in the following sequence)
a. Final Design Checklist accurately completed by team
b. written description
c. project schedule
d. full BOM table containing every item / balloon number used on the entire project
e. assembly drawings of entire robot with BOM containing smaller subassemblies
f. assembly drawings and BOM of subassembly 1
g. detail drawings of all parts in subassembly 1
h. assembly drawings and BOM of subassembly 2
i. detail drawings of all parts in subassembly 2
j. repeat for remaining subassemblies
7. Appendix D: Estimated Project Budget
Refer to Appendices section of template for details about the report appendices.

Design Review Instructions

The purpose of the formal graded design review is to allow the TAs to provide valuable feedback on each
groups final design, engineering drawings, and other project details. Each group will receive a grade using
the Final Design Review Checklist / Grade Sheet distributed in lab. Since a copy of the checklist is provided
to each group, the expectation is that each team comes to the design review with all YES marks on the
checklist.
TIPS FOR GOOD DESIGN REVIEWS:
1. Arrive prepared with a complete and printed D.R.3 your group is proud of; the alternative wastes
everyones time and hampers the TAs ability to provide valuable feedback.
2. Write down all TA feedback so your group can review the comments outside lab and the TA can examine
and critique more of the report.
3. Ask TAs to explain anything you dont understand, but dont argue with them. Every TA is invested in
their groups success and the feedback offered is done so with three goals in mind: (1) to improve
designs, (2) to make designs easier to manufacture, and (3) to improve your D.R.3 grade.
4. During the design review the TA will likely catch several weaknesses and mistakes, since (s)he is
knowledgeable about the requirements for each assignment. The feedback provided during the formal
design review can typically improve a groups performance and grade 10-15%, if heeded.
5. The design review is the last chance for a TA to help improve your teams design; if your group brings
poor or incomplete work, you will not receive a second review.
Mistakes and weaknesses noted on the Design Review Grade Sheet which are not corrected will be doubly
penalized when the D.R.3 re-submission is graded. All drawings updated after the design review must
possess updated revision letters (e.g. update Rev. A to Rev. B, or Rev B to Rev. C).
Design Report 3 Resubmission Instructions

Submit the third design report resubmission in a clean, white 3 three ring binder with round rings (not Dshaped) and a clear cover in which the updated cover page is placed. Begin each report section on a new
page. Use page lifters at the front and rear of the notebook and page dividers with computer-generated labels
to organize each report section for the grader. Glue page divider labels in place. Do not use page protectors.
Hole punch consistently when assembling the report and do not staple pages.
4. Design Report 2 Grade Sheet (original copy completed by TA)
5. Design Report 2 (complete and untouched from original submissions and grading, including
appendices and page dividers)
6. Final Design Review Checklist / Grade Sheet (original copy completed by TA)
7. Design Report 3 Original Submission (complete and untouched with TA comments from design
review, including appendices and page dividers)
8. Detailed Design Resubmission (revised and reprinted with updated drawing revision letters for all
drawings edited/modified after D.R.3 original submission)
9. Appendix D: Estimated Project Budget (revised and reprinted)
[This is the end of D.R.3 Resubmission;

Changes / Corrections in the Prototyping Phase

As noted previously, groups which submit a solid D.R.3 for the design review will receive valuable feedback
which greatly facilitates project manufacturing. Groups are given one week to incorporate the feedback into
their project. After the D.R.3 resubmission, each design change and drawing correction must be
accompanied by an Engineering Change Notice Form, which is a formal document used to track
changes and corrections once the prototyping and testing phases of the project commence. Since ECNs
are a required part of the design process when working in industry, becoming familiar with them now will
help you in the future.
Each group will complete and submit several ECNs during the project prototyping phase, as no design is
perfect and no team is immune to making a few mistakes, so do not fear the need to fill out ECNs. Groups
are never penalized for filling out ECNs, but rather for not filling them out when a design change or mistake
has been identified.
Groups with poor quality and/or incomplete D.R.3 resubmissions will have to create many more ECNs than
others. As shown on the plot below, there is an indirect trend between the number of ECNs necessary for a
team to complete and that teams projects performance, so take D.R.3 seriously so your group has a solid
design and manufacturing plan transitioning into the prototyping phase of the project.
Competition Paperwork Submission Instructions

The following documentation must be submitted in appendices E thru I in your groups design report
notebook at the beginning of lab the day of competition.
Appendix E: Final Budget & Purchase Orders (account for all materials used on final prototype)
Appendix F: Engineering Change Notice Forms (completed and signed by your groups TA)
Appendix G: Robot Wiring Schematic (use template off course webpage)
Appendix H: Final Assembly Drawings & BOM (should match final prototype)
Appendix I: Meeting Minutes (all members completed meeting minutes)
Prototype Development and Testing

Only one submission of this section is required for each group.
1. Show photographs of the prototype and close-ups of key design details. Highlight focus-areas with
leaders or circles using photo editing software. Reference photos by figure number in the report body.
2. Discuss the prototyping and testing phases. Identify deficiencies in the design and improvements that
were made. Did everything work as intended the first time or were adjustments and modifications
required? Be honest, as redesigns will not affect your grade, but rather provide opportunities to learn.
3. Design improvements are an important aspect of any successful prototype and should be viewed as
exactly that: improvements. It is wrong to feel unforeseen changes are indicative of weak design skills.
Experience greatly enhances your design and manufacturing skills.
4. OPTIONAL NOTE for groups whose project performance was subpar: Use D.R.4 as an opportunity
to provide a detailed analysis of what went wrong. Ignore the typical page length noted below. Include
new detail and assembly drawings showing modifications to improve the design. This is a chance to earn
some of the points lost in the dynamic evaluation of your projects performance.
[section length is typically 5-7 pages with photos containing highlights]
Discussion / Conclusion
Only one submission of this section is required for each group.
1. Discuss how well the design solved the problem and what you would do differently if you tackled
this problem again. Objectively review the strengths and weaknesses of your design. Pointing out
weaknesses will help you learn what to do differently next time and can help your final grade.
2. Include a group photo showing all team members with names in the caption.
[section length is typically 1-2 pages]

Submit the final design report in a clean, white 3 three ring binder with round rings (not D-shaped) and a
clear cover in which the updated cover page is placed. Begin each report section on a new page. Use page
1. Cover Page (with updated report number and date)
2. Everything in Design Report 3 Resubmission (complete and untouched after grading, but insert the
following two new sections between the Detailed Design section and the report appendices)
3. Prototype Development and Testing
4. Discussion / Conclusion
5. Appendix I: Meeting Minutes (all members completed meeting minutes; append to existing)
Groups are not required to submit updated detail drawings with the final design report since they were
already submitted with the ECNs in Appendix G. The only exception is for groups which are using D.R.4 as
an opportunity to provide new detail and assembly drawings showing how they would improve their design.
Appendices
Appendices organize your reports by placing related material in one centralized location. Group required
items in the sequential appendices listed below:
Appendix A: Decision Matrix Calculations & Justification Data
Appendix B: Robot Path Illustration, Speed & Time Calculations
Appendix C: Wheel and Lifting Motor Torque Calculations
Appendix D: Estimated Project Budget
Appendix E: Final Budget & Purchase Orders
Appendix F: Engineering Change Notice Forms
Appendix G: Robot Wiring Schematic
Appendix H: Final Assembly Drawings & BOM
Appendix I: Meeting Minutes
NOTES ABOUT APPENDICES:
1. Place appendices at the back of the report. Each appendix should have its own cover page using the
template included on the following page. Separate each appendix with a labeled page divider.
2. Explain the analyses and calculations documented in appendices A, B, and C. Include all notes,
calculations, and units necessary to reproduce the logic behind the decisions made during the project.
Present notes and calculations in a neat and logical manner and use proper grammar. Use complete
sentences. For example, The torque on the lifting arm motor was calculated by ....
3. Appendix A must contain a table of contents directly after the title page.
Appendix A: Decision Matrix Calculations & Justification Data
LEAVE THE REST OF EACH

APPENDIX COVER PAGE BLANK
Common Report Errors & Weaknesses

1. Background questions not answered adequately. If you answer a question and state something is
better than something else, explain why. Be explicit and thorough, yet concise when answering
background research questions. If you make general statements like steel is very heavy or aluminum is
very light, re-read the background research and pay attention this time.
2. Poorly presented conceptual designs. Youre training to become an engineer, not a cartoonist. Do not
present sketches lacking clear detail of real parts or sketches of ideas that have not been thought through.
For example, if you dont know how a component is commonly attached, conduct more research until
you do.
3. Weak conceptual design selection criteria. Present good, unbiased reasons how your group selected its
best concept. Explain why you chose each objective for the different evaluation matrices, how you
selected their weighting factors, and how you assigned the scores. Every single magnitude assignment in
your groups evaluation matrices must be justified using logical data.
4. Poorly thought out design. Is the design realizable? Can the design be assembled? How will specific
parts be manufactured and attached to one another? If you dont know how a part will be produced, you
have not done enough manufacturing research. Have part tolerances been reviewed to find a balance
between part function and manufacturing time? Are the required part tolerances obtainable using
processes available in the lab? Have costs been considered? If you dont know the answers to these
questions, you need to do more work. Engage the laboratory staff with questions.
5. Poorly detailed parts. Obey the rules summarized in the Dimensioning Rules document and the Final
Design Review Checklist. Engage the lab staff with questions about your drawings, part tolerances,
material choices, and surface finish specifications.
6. Figures / tables not labeled properly or not referred to in the report body. All figures and tables
must be labeled with captions. Figure captions should be placed below figures; table captions should be
placed above tables. Reference each figure and table in the text by number. Do not capitalize references
to figures and tables, such as fig. 1A and table 2 unless they are the first word of a sentence. Number
figures sequentially according to each members group number and capitalize figure and table captions
(e.g. Fig. 1A, Fig. 1B for team member 1; and Table 1, Table 2).
7. Formatting. Although every person in the group contributes their own work to the design report,
formatting must be consistent throughout; therefore all reports must use this template. Do not change the
formatting within (i.e. page margins, font style/size/color, line spacing, etc.). Use provided subheadings
to separate material in major sections. Print all report sections single sided and orient punched holes for
notebook rings at the TOP of all pages printed in landscape orientation. Do not assemble reports last
minute with poor print quality, mismatched hole-punching, or misspelled team members names. If you
invested serious effort into the design project, the design report should show it.
8. Calculation Reporting Errors. Use appropriate significant figures relative to the precision of the
measured or computed value. For example, do not report estimated manufacturing times as 4.751 hr
because they are only estimates, so 4.8 hr would be more appropriate. The common exception to this
rule is US currency, which is traditionally reported as $XX.XX. Since reporting an estimated cost to the
nearest cent is unreasonable, it makes sense to report currency to the nearest half or quarter dollar with a
note in the table footer saying costs reported to the nearest quarter or half dollar.
9. Organization. Take time to clearly organize your thoughts. Sections should be well written so the
content of each sentence flows logically with the next. Dont throw disconnected sentences together.
Write to the point, using as few words as necessary. Use paragraphs to separate your thoughts or points.
Youve received a lot of education to get to this point and you are expected to use it in this course. If
your writing isnt easy to read, dont complain about the low grade you receive on it.
10. Grammar / Style. Your writing, spelling, and grammar will be evaluated to ensure they are at a
collegiate level. Every sentence in the design reports should apply to this particular project, as opposed
to just being a generality. Write in third person without exception. Insert two spaces between sentences
and a blank line between paragraphs to reduce eye fatigue. Final drafts should be well proofed because
writing mistakes will be harshly penalized.
11. Examples of Common Grammar Problems. Never use trite words or phrases such as: usage, utilize,
in order to, or very. Check homonyms. Ensure subject / verb agreement. Understand what a proper
noun is and isnt. Understand the difference between commas, colons, and semicolons, and use each
appropriately. Review the difference between apostrophes used to make nouns possessive and to form
contractions. Do you know the difference between affect (a verb) and effect (a noun)? What about
farther and further? Watch out for comma splices, run-on sentences and dangling participles. Always
include a referent with this, such as this type of steering; with no referent, this only confuses the
reader. The same applies for it, so use it sparingly. Very is an unspecific determinate. If you ask ten
people how big very large is, you would get nine different answers. As engineers, we must do a better
job quantifying something than by using very. Finally, never end a sentence with a preposition.
These points might seem overly picky; however, covering the basics will greatly improve your
ability to communicate effectively, which is a key element of a good engineer. Solid grammar and
spelling skills will also keep us from quickly losing credibility with a customer who might not be
capable of understanding what we do technically, but who can understand our inability to write at
an eighth grade level. In short, avoid these ignorant mistakes.
Links to Project Templates and Reference Documents

The following documents are all on the course website; these links are simply provided to help you
locate the documents quickly. Related documents are grouped and listed in chronological order.
MAIN PROJECT DOCUMENTS

Design Project Description (the design project for this semester and the rules governing it)
Design Project Schedule (the project schedule everyone should follow week-to-week)
CONCEPTUAL DESIGN GENERATION (D.R.1)

General Tips (helpful tips for the course / project from Mike & the TAs)
Background Information Research (assorted topics pertinent to solving the design project)
Example Design Reports (a collection of good and bad drawing examples with feedback explaining what
were looking for in your drawings; follow the requirements listed in the Design Report Template (i.e. this
document), but these examples should provide helpful tips)
TIPS FOR WORKING EFFECTIVELY

Tips on Working Effectively in Groups (helpful strategies for facilitating equal participation)
Project Meeting Template (required document for tracking individual responsibilities and underperforming
teammates; this must be filled out for every planned group meeting)
Individual Evaluations (peer evaluations filled out to assess your teammates performance)
Project Tips (strategies to facilitate working more efficiently on the project once prototyping commences)
SELECTION OF DESIGN CONCEPT (D.R.2)

Decision Matrix Example (Crane Hook; Adobe pdf format with digital comments)
Project Decision Matrix Example (Mobile Platform; Adobe pdf format)
Project Decision Matrix Template (Mobile Platform; Excel format)
Electric Motors and Drives (lecture notes on calculating estimated robot velocity)
Robot Speed & Time Calculations (use and modify this spreadsheet to calculate the estimated speeds of your
conceptual designs so you can decide how fast the final robot design should be to complete the task;
remember faster robots are less controllable (and vise-versa), so its important to find a prudent balance that
suits the current project description by testing the mobile platforms provided in lab)
Drive Wheel Motor Torque Calculations (use this example to compute the drive wheel torque required to
move your robot and compare to the actual torque values published in the Motor Specifications)
Lifting Motor Torque Calculations (use this example to compute the torque required for any motors used to
lift or rotate a load and then compare to the actual torque values published in the Motor Specifications)
Useful Motor Torque Equations (useful equations for calculating the necessary motor torque for performing
various functions.)
Time Estimation Guide for Parts Manufacturing (since manufacturing time should be an objective in each of
your matrices, this document provides time estimates for the assigned parts manufactured earlier in the
semester, as well as typical motor mounts, sheetmetal parts, and most any other operation performed during
robot prototyping; you should provide similar estimates for your different conceptual designs)
Material Price List (prices for common materials found in the lab; since cost is likely to be an objective in
your evaluation matrices, these prices allow you to easily create cost summaries for your groups different
conceptual designs)
Concept Selection Checklist / Grade Sheet (used by your TA to evaluate your conceptual selection; this is
an excellent checklist for your team to use as well)
DETAILED DESIGN (D.R.3)

Mechanical Power Transmission (lecture notes explaining different ways to transmit torque which are
applicable for the design of your groups wheel hubs)
Tap and Drill Chart (standardized fastener and threading information and instructional video)
Drill Sizes Chart (commonly available drill sizes; dont specify anything not on this list!)
Motor Mount Design Guide (tips for designing motor mounting brackets)
Wheel Hub Design Guide (tips for designing wheel mounting hubs)
Sheetmetal Design Guide (tips for designing sheetmetal parts)
Motor Specifications (dimensions and output torques for electric motors provided in the lab)
Part CAD Models (CAD models of all the motors, control box, 80-20 accessories, etc.)
SolidWorks Part Drawing Templates (links to templates with must be used for this course)
Lab Material Sizes (table showing common material sizes stocked in the lab)
Lab Fastener Sizes (table showing common fastener sizes stocked in the lab)
Fastener Reference Sheet (quick reference sheet with compiled highlights from Fastener Lecture Notes)
Dimensioning Rules (rules that will greatly improve your part drawings)
Design & Manufacturing Tips (LOTS of helpful tips that will improve your designs and your drawings,
allow you to select better tolerances, and empower you to ask better questions)
Design For Manufacturing Examples (great examples showing how to apply the tips presented above to
design parts which are easier to manufacture, saving valuable time)
Mobile Platform Assembly Drawings and BOM Example (follow this example in all of your assemblies)
Project Schedule Template (Excel template to use for presenting your teams schedule)
Project Budget Template (Excel template to use for presenting your projects budget)
Final Design Review Checklist / Grade Sheet (used by your TA to evaluate your Design Report #2
submission; this is a great checklist for your team to use when completing D.R. #2)
PROTOTYPING
Purchase Order Template (submit to purchase parts once construction commences)
Engineering Change Notice Form (use to track changes / corrections after D.R.3 is resubmitted)
Wiring Schematic Template (use to document how to properly wire your groups robot)
CLASS COMPETITION
Competition Paperwork Checklist (list of items to be submitted for grading the day of class competition)

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Cover Page ... 3

EML2322L Design and Manufacturing Laboratory

Instructor: Mike Braddock

Introduction / Problem Statement

Background Information (Team Member Name (1))

5. Wheels and tires

11. Gears / gearing

Conceptual Design Generation (Team Member Name (1))

Conceptual Design Generation Checklist

Design Report 1 Submission Instructions

Important Notes Regarding D.R.1 Submission:

[This is the end of Design Report 1;

Selection of Design Concept

6. Use Excel for all calculations tabulated in the appendices.

[section length is typically 30-40 pages including appendices]

Design Report 2 Submission Instructions

[This is the end of Design Report 2;

Peer Evaluation for Design Report 2, 3, 3R, or 4 (OPTIONAL)

Design Report 3 Submission Instructions

[This is the end of Design Report 3;

Design Review Instructions

Design Report 3 Resubmission Instructions

[This is the end of D.R.3 Resubmission;

Changes / Corrections in the Prototyping Phase

Competition Paperwork Submission Instructions

Appendix I: Meeting Minutes (all members completed meeting minutes)

Prototype Development and Testing

Design Report 4 Submission Instructions

Appendix A: Decision Matrix Calculations & Justification Data

LEAVE THE REST OF EACH

Common Report Errors & Weaknesses

Links to Project Templates and Reference Documents

MAIN PROJECT DOCUMENTS

CONCEPTUAL DESIGN GENERATION (D.R.1)

TIPS FOR WORKING EFFECTIVELY

SELECTION OF DESIGN CONCEPT (D.R.2)

DETAILED DESIGN (D.R.3)

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