Corporation 4 – NASA

Project Manager – Phillip Young

Presenting – John-David Jenkins and Jack Becker

Outline Electrical Engineer Progress Report

EE Interface Diagram

Project Management

Systems Engineering (SE) – Mission Objectives

SE – Concept of Operation

SE – Architecture and Design

Overall Dimensions

Frame Subsystem

Linkage Subsystem

Bucket Subsystem

Bearing Selection

Bolt Selection

Wheel Geometry

Gator Interface

SE –Verification and Validation

EE Progress Report Progress has gone as planned and on schedule (We have a

working demo)

All components are mounted

Xbox 360 controller

Joystick controls actuator

A Button turns motor ON/OFF

Power system was overheating

Add heat sink to voltage regulators

Add a cooling fan

EE Interface Diagram

Project Management

Presentation Goals1. To present a detailed design of hardware (i.e. drawings and

specifications to fabricate)

2. Establish the basis for proceeding with manufacture

- Show that the correct design option has been

selected

- Dimension all parts and prepare for manufacture

- Prepare Manufacture and Assembly plan

-Verification methods have been established

Project Management (cont)

Program Manager (Dr. Beale)

Frame Subsystem (Lead Alan Gaskins)

Subsystem Member

(Jack Becker)

Bucket Subsystem (Lead JD Jenkins)

Subsystem Member

(Joe Bryant)

Linkages Subsystem (Lead Bryant Hains)

Force Analyst

(Luke Weniger)

Project Manager (Phillip Young)

Systems Engineer

(John Andress)

Management Structure

Project Management (cont)

Milestones

Project Management (cont)

NASA Lunar HarvesterCorporation 4

Project Lead: Phillip Young

Today's Date: 12/5/2008

[42] Start Date: 8/18/2008 (Mon) 0

WBS Tasks Task Lead Start End Du

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1 Frame Subsystem Alan 10/02/08 12/15/08 75 100% 53 75 0

1.1 Frame 10/02/08 10/21/08 20 100% 14 20 0

1.2 Wheel Structure 10/15/08 10/21/08 7 100% 5 7 0

1.3 Subsystem Interface 10/20/08 11/08/08 20 100% 15 20 0

1.4 Gator Interface 11/09/08 11/28/08 20 100% 15 20 0

2 Bucket Subsystem John-David 10/02/08 12/15/08 75 75% 53 56 19

2.1 Bucket 10/02/08 10/18/08 17 100% 12 17 0

2.2 Blade 10/02/08 10/18/08 17 100% 12 17 0

2.3 Front Door 10/02/08 11/09/08 39 0% 27 0 39

2.4 Subsystem Interface 10/02/08 10/29/08 28 100% 20 28 0

3 Linkage Subsystem Bryant 10/02/08 12/15/08 75 98% 53 73 2

3.1 Mechanical Links 10/02/08 10/18/08 17 100% 12 17 0

3.2 Actuator 10/02/08 10/18/08 17 90% 12 15 2

3.3 Joints 10/02/08 11/07/08 37 100% 27 37 0

3.4 Subsystem Interface 10/02/08 10/30/08 29 100% 21 29 0

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HELP

- Modify the GREEN cells and the WBS, Tasks, and Task Lead columns. The rest of the columns are formulas.- The number of weeks shown in the gantt chart is limited by the maximum number of columns available in Excel.- The Start Date that you choose determines the first week in the gantt chart, starting on a Monday.- Use the slider to adjust the range of dates shown in the gantt chart.- Only 48 weeks can be shown/printed at one time, because each week uses up 5 columns.

Q: The Working Days column shows "###". How do I fix that?You need to install the Analysis ToolPak add-in that comes with Excel. Go to Tools > Add-ins, and select Analysis ToolPak.

Q: How do I make Task 2 start the day after the end of Task 1?

Gantt Task Chart

SE – Mission Objectives Mission Statement

“Create a tele-operated lunar harvester prototype targeting less than 150 W power usage and weighing less than 100 kg for studies on the earth fulfilling environmental requirements of the moon.”

Mission Level Requirements

Shall be designed to conduct studies on earth but be able to operate in a Lunar environment

Shall interface with Gator utility vehicle

Shall be designed to integrate Electrical Engineering subsystems into the mechanical design

Shall collect and hold at least 50 kg soil per hour

SE – List Concept of Operations

i) Lunar Prototype to harvest position, “scrape” soil from behind Gator in lane-like fashion until bucket reaches capacity

ii) Lunar Prototype to transport position, Gator returns to collection point with Lunar Prototype pulled behind, only surface contact is Lunar Prototype wheels

iii) Gator drives up and over soil ramp to position Lunar Prototype over hopper opening

iv) Lunar Prototype to dump position, empty bucket contents into hopper

v) Lunar Prototype to transport position, Gator returns to harvest area

vi) Lunar Prototype to harvest position, begin “scrape” process

Harvesting Position

Transporting Position

Dumping Position

SE – Graphical Concept of Operations

SE – Mechanical Architecture and Design

Lunar Harvester Prototype

Bucket

Blade

Container

Welded Bucket

Sealed Bearings

Socket Cap Screw

Frame

Wheel Structure

Tire

Wheel Bracket

Wheel Axle

Gator Interface

Hitch

Frame Mount

Frame Bracket

Bucket/Linkages/

Frame Interfaces

Sealed Bearings

Socket Cap Screw

Washers and Spacers

Linkages

Linear Actuator

Interface Bracket

Slider Base

Slider

Pivot Bar

Sealed Bearings

Socket Cap Screw

Transfer Bar

Sealed Bearings

Socket Cap Screw

Linkage Actuator Connection Rod

Rotational Bar

Sealed Bearings

Socket Cap Screw

Overall Dimensions

Total Prototype Dimensions

Weight: 121.5 lbs (55.23 kg)

Length:72 inches

Width:28.5 inches

Frame SubsystemSwitch was made from standard

square metal tubing to 80/20 Square

Tubing for ease of manufacture and

assembly

Standard brackets for frame are

provided by 80/20

Non-standard brackets and tabs will

be manufactured in house

Requirements:•Shall interface with a Gator utility

vehicle

•Shall maintain horizontal orientation of

harvester frame for optimal harvesting

and dumping positions

•Shall maintain or enhance structural

rigidity/strength of frame subsystem

•Shall accommodate yaw motion required

for “trailing” Gator

Frame Isometric View

Linkage Subsystem

Derived Requirements

Shall be able to move bucket into the three desired mechanical

positions

Shall be powered by motorized actuator

Shall provide mechanical advantage in operating bucket

Shall constrain bucket movement to safe bounds

Shall allow variable digging depth that includes the range of 1-

5cm

Linkage Subsystem (cont)

At 1.25” Digging Depth (In inches)

Provides variable 1-5 cm

cutting depth

Linkage Subsystem (cont)

70˚ angle achieved to ensure dirt removal Bumper stop could be implemented to restrain

linkages from obtaining toggle position

Dumping Position

Linkage Subsystem (cont)

Linkage Interface Rod

Linkage Interface Rod allows 1 linear actuator

to use both sets of mechanical linkages

½” Diameter Alloy Steel

Link Subsystem Cont.

General Description

Tolomatic mxe32s Linear Slide

High degree of customizability

Critical Review Update

Single Actuator with Linkage Interface Rod

Brackets integrated with actuator

Can handle extremely large vertical forces

Maximum Forces the MXE-S can handle

Shock Load Information

Worst case scenario shock load for FEA was 500 lb

Calculated using impulse

For Normal Traveling Velocity:

If traveling just above the required velocity of

2.2 cm/min (3.67x10-4 m/s) and a maximum

mass of 150kg stopping nearly instantaneously

(.001s), the impulse average force is calculated

to be 12.36lb-force. If this force were translated

through the linkage system, the actuator would

experience a force of about 26lbs acting

vertically and about 8lbs acting along the axial

direction.

Force Transfer Bar Force Load Case

Force Transfer Bar FEA (stress)

Pivot Bar Load Case

Pivot Bar FEA (stress)

Rotational Bar Load Case

Rotational Bar FEA (stress)

Linkage Interface Bar

2

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F=250 lbs F=250 lbs

F=250 lbsF=250 lbs

Bucket Load Case

Bucket FEA (Stress)

Blade Load Case100 lbs distributed across the front of the blade

Blade FEA (stress)

Bearings

Manufacturer: Daemar Bearings Inc Dry slide self-lubricating bearing with PTFE coating

Bearings (cont)Bearing Specs

(in) Max. Load (N/mm 2̂) (psi)

Outer dia. 0.375 Static Load 250 36250

Inner dia. 0.3125 Very Slow Speed 140 20300

Width 0.75 Rotating/Oscillating 60 8700

Shaft Diameter (in) Width (in) Load on Bearing (lbs) P (psi)

0.3125 0.75 100 426.6667

200 853.3333

300 1280

400 1706.667

500 2133.333

600 2560

700 2986.667

800 3413.333

900 3840

1000 4266.667

Radial Load (lbs. to psi)

Bolts•Bucket and Linkage Bolt

•5/16” -18 socket cap screw

•1-1/4” long

•Linear Actuator Interfacing Bolt

•¼” – 20 socket cap screw

Wheel Geometry•Tires have built in bearing

•Axle is stationary

•Wheel Diameter – 13.5”

Tire Type Pneumatic

Rim Size (in.) 6

Tire Size 13.5 x 400 x 6

Diameter (in.) 3/4

Bearings Included Yes

Hub Width (in.) 6

Load Capacity (lbs.) 300

Rim Included Yes

Tubeless Tire Yes

Tread Type Ribbed

Shipping Weight (lbs) 7Aluminum Bracket

Gator Interface

•Hitch will be purchased off the shelf

•Brackets will be manufactured in house using .25 inch thick aluminum

plate

•Will be replaced by interfacing plate on final lunar design

Bill of MaterialsItem # Part Item Quantity Material Part # Cost Supplier

1 Frame Rail Square Tubing - 28.5" 2 80/20 9701 $10.55 BA

2 Cross Beam Bracket 80/20 2 Hole Bracket 12 80/20 4302 $35.40 BA

3 Frame Bracket 80/20 4 Hole Bracket 8 80/20 4303 $35.20 BA

4 Straight Tongue Style Coupler 2 " Ball with 2" Channel Coupler 1 21128 $15.90 AAC

5 Gator Interface Beam 2" square tubing (.25" thick), 24" long 1 Al 6063 T52 - $28.00 OM

6 Hitch Ball 2" Regular Duty, Zinc Trailer Hitch Ball 1 Zinc 63831 $7.45 TPS

7Hitch Mount

Adjustable Quick Release 2" sq. Hitch Ball

Mount 1 Black Powder Coated Al 5223026 $69.95 TPS

8 Extruded Aluminum Rectangle 1.5" x 3" x .25" 1 Al 6061 T6 - $7.00 OM

9 Linear Slider Actuator MXE32S BN08 SK17 LMI Actuator 1 - - $1,212.36 TI

10 Carrier Bracket 3 X 3 X 12 inch Aluminum Square 1 Al 6061 SQ33 $81.00 MD

11 Actuator Grounding Bracket Included with Actuator 4 - - $0.00 TI

12Wheel

Wheelbarrow Assembly, 3/4in. Bore — 13.5

x 400 x 62 - 121024 $49.88 NTE

13 Wheel Structure Bracket 1/4" thick sheet aluminum 12" x 12" 2 Al Alloy 6061 9246K13 $23.46 MCC

14 Wheel axle 3/4" diameter steel rod 6' in length 1 4140/4142 Alloy Steel 8935K39 $29.97 MCC

15 Bucket Sides 24" x 24" x 1/2" Square Sheet 2 1018 Steel 1388K181 $462.24 MCC

16 Bucket Rear Plate " - " - - MCC

17 Bucket Bottom Plate " - " - - MCC

18 Blade 5/8" x 3.5" x 24" 1 ASTM A36 9517K38 $70.70 MCC

198 1/4" Pivot Bar

Rectangular Bar 1/2" Thick, 4" Width, 3'

Length2 4140/4142 Alloy Steel 6554K323 $147.12 MCC

20 18 3/4" Force Transfer Bar " " - - MCC

21 7 1/4" Rotational Bar " " - - MCC

22 Rotational Bar Bracket " " - - MCC

23Linkage Interfacing Rod

1L40 Alloy Steel Rod 1/2" Diameter, 3'

Length1 41L40 Alloy Steel 6776T132 $18.21 MD

24 Frame/Bucket/Linkage Nut 5/16" 18 nut (100 per box) 1 Steel 90499A030 $3.78 MCC

25 Actuator Nut 1/4"-20 (25 per box) 2 Steel   90630A110 9.78$ MCC

26

All Purpose Washer

Zinc & Yellow Stl SAE HI-Strength Flat Washer

5/16" Screw Sz, 11/32" ID, 11/16" OD, .055"-

.080" Thk (50 per box)

2 Zinc 98023A030 $8.40 MCC

Bill of Materials (cont.)27 Actuator Bolts 1/4"x1"-20(100 per box) 1 Steel 91251A542 14.72$ MCC

28 Frame/Bucket/Linkages Bolts 5/16"id 1 1/4" socket cap screw 1 Steel 901284586 10.49 MCC

29 Bearing 5/16" i.d. Self Lubricating Bushing 30 Steel/Bronze/Teflon 05TH06 $67.50 ABI

30

Bucket/Linkage Ream

Solid-Carbide Fractional Chucking Reamer

3/8" Dia (.3750"), 3-1/2" L O'all, .3745"

Shank Dia

2 HS Steel 3026A37 122.58 MCC

31Bucket/Linkage Drill Bit

Jobbers Twist Drill Bit Black-Oxide, 3/8" Size,

5" L Overall, 3-5/8" L Flute8 HS Steel 2931A34 27.52 MCC

32

Bucket/Linkage Center BitSolid-Carbide 2 in 1 Countersink Trade Size 2,

5/64" Drill Size, 3/16" Body Diameter1 HS Steel 2925A54 19.55 MCC

33Bucket/Linkage Bottom Tap

Bright Finish High-Speed Stl Spiral Point Tap

1/4"-20, H3 Pitch Diameter, 2 Flute1 HS Steel 2523A411 $5.05 MCC

34 Layout Fluid Blue 16 oz. Layout Fluid 1 - 2131A17 $7.61 MCC

35 NA Cold Saw Blade (180) 1 - 4190A61 $92.97 MCC

36 NA Vert. Band Saw Blade 1 - 4179A316 $43.26 MCC

37 NA Horz. Band Saw Blade 1 - 4179A979 $55.05 MCC

38 End Mill 5/8" 2-Flute 4 HS Steel 2782A77 22.05$ MCC

39 End Mill 1/2" 4-Flute 1 HS Steel 8912A45 $26.12 MCC

40

Total $2,840.82MCC - Mc Master Carr

BA - Bertelkamp Automation

AAC - Automotive Accessories Connection

OM - OnlineMetals.com

TI - Tolomatic, Inc.

TPS - Trailor Parts Superstore

NTE - Northern Tool + Equipment

MD - MetalsDepot.com

ABI-Alabama Bearing Inc.

Manufacturing Plan

Linkages will be purchased as close to final design as possible

Linkage machining will be carried out using mills

Brackets will be made out of sheet metal

Bracket machining will also be carried out using mills

All machining will take place in the Design and

Manufacturing Lab

All parts will be measured to insure correct tolerances

before being approved

Bucket will be manufactured out of sheet metal and welded

Assembly Plan Frame will be assembled using pre-existing bolt pattern and

brackets purchased from 80/20

All brackets and attachment points will be connected to the frame

Linkage sub-assembly will be attached to their respective mounting points

Bucket will be attached to rotational and pivot bars

Actuator will be mounted to frame

Actuator and force transfer bar will be connected

Tire axle will be attached to frame

Tire will be attached to tire brackets

Trailer hitch will be attached

SE – Verification and Validation Phase C Verification:

Determine forces acting on individual links.

Verify linkage/frame construction by performing FEA using ALGOR.

Total picture verification

Plan for Phase D Verification:

Assemble linkages separately to test effectiveness.

Assemble total system for manual proof of concept testing. This could consist of manual movement of bucket positions, manual pushing of bucket through pseudo-regolith.

Conduct proof of concept testing at USDA facility using all components and interfacing to the Gator vehicle

Summary Electrical Engineer Progress Report

EE Interface Diagram

Project Management

Systems Engineering (SE) – Mission Objectives

SE – Concept of Operation

SE – Architecture and Design

Overall Dimensions

Frame Subsystem

Linkage Subsystem

Bucket Subsystem

Bearing Selection

Bolt Selection

Wheel Geometry

Gator Interface

SE –Verification and Validation