1.0 - Introduction
Welcome to the UW Robotics Mechanical Team! This training is designed to teach you the skills required to take on tasks within the team. It will teach you about SolidWorks design, GrabCAD, part fabrication/manufacturing techniques and more. The training is designed to challenge your skills and encourage self teaching. However, if you are having trouble with any parts of the training please feel free to contact anyone on the mechanical team! We are more than happy to help you work through it 
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2.0 - The University Rover Challenge
Currently, our team designs Mars Rover Robots to compete in the annual University Challenge in Utah. In this competition, we have to design a rover capable of completing four missions - Science, Autonomy, Equipment Servicing and Extreme Retrieval and Delivery.Please read the rules for URC 2022. The rules change slightly every year, but generally remain very similar. To compete in URC, our team needs to submit a System Acceptance Review (SAR) package. Part of this submission involves creating a 5min video to showcase our rover.
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3.0 - Machine Shop Training
If you plan to work on the rover on campus, mechanical members are required to complete their Machine Shop Training. Completion of this training will give you access to the Engineering machine shops on campus and will be essential for the fabrication of most mechanical projects. The training will also teach you about machining! The training is available in the ‘Self Registration’ section of LEARN.
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You also need to complete the WHIMIS2017 training as a prerequisite of the machine shop training. If you are part of MME, this is the same training course you need to complete for any lab.
4.0 - Installing SolidWorks
SolidWorks is the CAD software used by the team for mechanical design. Our team currently uses SolidWorks 2020-2021, so please update your software if you are running an older version. If you are part of the MME department, feel free to use the student licenses provided by the University of Waterloo. However, if you do not have access to an educational license through our school please see the steps below:
To get access to SolidWorks, follow the steps at: Downloading SOLIDWORKS.
5.0 - Setting Up GrabCAD
UW Robotics uses GrabCAD workbench to store and share our CAD files. It's like GitHub for CAD - all files are stored on an online cloud and you push your changes to update the cloud and pull from the cloud to update your local files. To get started with GrabCAD, first you need to create an account on their website. https://grabcad.com/
5.1 - Installing the GrabCAD Workbench App
GrabCAD consists of two components - a web page, and desktop app. The webpage tracks all project changes, file revisions and new users.
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Download and install the desktop application:https://workbench.grabcad.com/workbench/downloadSend your email address to the current mechanical team leads(Winter 2023: Thomas Valer & Josh Harper)on discord and ask to be added to the GrabCAD.Once you have been added to our GrabCAD, log into your GrabCAD account in Workbench, access settings and click "Manually Connect Project"
Navigate to the projects for UWRT, and click "Link to Folder"
Create a GrabCAD folder somewhere in your computer's Documents folder. This will help prevent file errors with your uploads.Sync your folder to download the current files from the cloud. I'd recommended you sync two separate folders for our 2020 and 2022 rover build.
5.2 - GrabCAD Usage Instructions
GrabCAD Workflow Overview
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If you've accidentally made a change to a part that you didn't intend, you will an upload prompt in GrabCAD. You can easily undo the change if you need to!Click the upload window and select the files you would like to revert.Click the dropdown arrow next to "upload" and you will see a button that says "Undo My Changes..."
Accept the deletion prompt
6.0 - Getting Started with SolidWorks
As mentioned in Section 5.0 of this training, our team uses SolidWorks to define create models of parts used in our rover. CAD is a critical part of our workflow, as it lets us visualize parts that we want to create, virtually assess form, fit and functions of designs, assists with creating manufacturing documentation and much more. This section of the training will get you up to speed with using the software.
6.1 - Tutorials for Beginners
If you have never used a 3D CAD software, getting started with SolidWorks may seem a bit intimidating. Don't worry though, there are lots of online resources that can teach you how to use SolidWorks!
LinkedinLearning: University of Waterloo students have access to LinkedinLearning for free. Gabriel Corbett has an excellent series on how to learn SolidWorks, so if you are complete beginner I highly suggest you watch his series.
https://www.linkedin.com/learning/learning-solidworks/design-your-world-with-solidworks?u=55034593SolidWorks Tutorials: SolidWorks also hosts some great tutorials right inside of the software. To access these tutorials, click on the search bar and select "Tutorials"
Complete all of the tutorials in the "Getting Started" tab (although feel free to skip the AutoCAD and SOLIDWORKS tutorial as the team does not use AutoCAD on a regular basis).
I would also suggest you watch the "Pattern Features, Revolves and Sweeps and Assembly Mates" tutorials in the "Basic Techniques" tab.
6.2 - Team Templates
Our team uses various for parts and drawings. You should use these templates as applicable when you are designing something for the team. Below are the instructions for setting up and using the templates.
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If you are having problems with team templates, contact Caleb (team lead). You should also record any bugs noticed in the Template Bug Tracker.
6.3 - Creating Parts
The UW rover robotics team has established a universal naming scheme for all files. This is a mandatory naming convention that must be used for ALL SolidWorks files. The intent of the naming convention is to ensure all files properties are recognizable from the name and to ensure that all files have unique names to avoid SolidWorks errors. The naming scheme for different types of files are shown below. All files from your project must follow this convention before a design review is conducted. Please see these files for the naming convention of UWRT and OTS components.
7.0 - Manufacturing: A Brief Overview
Knowledge of manufacturing processes is critical when designing a successful part. "DFM" (design for manufacturing) refers to designing a part for a successful manufacturing operation. This can extend to a number of critical success factors, such as low manufacturing cost, quick production time, high part quality/dimensional accuracy, to name a few. Understanding DFM (as well as design for assembly, design for excellence, etc.) takes time, but a good baseline for DFM is understanding what manufacturing methods our team has available.
7.1 - Additive Manufacturing
Additive manufacturing is a blanket term that for the most part is used to describe 3D printing (material is added to a surface to create a part, waste is very low). Our team 3D prints a number of components when prototyping, and as quick fixes or light parts on our main rover that won't experience a large amount of stress. Currently, our team mainly can make use of three types of additive manufacturing - FDM, SLA and SLS. Additionally, our current additive manufacturing capabilities are mostly limited to plastics or plastic composites.
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(compared to metal)SLA/SLS Printing
Our team does not have a dedicated SLA printer, but one of our sponsors offers free SLA and SLS printing services!
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7.2 - Subtractive Manufacturing
Subtractive manufacturing refers to any process in which material is removed from a piece of stock to create a part. Most traditional metalworking processes (laser cutting, lathe, mill, sawing, cutting, drilling, you name it) are forms of additive manufacturing. Typically, any part we make from metal is created using some form of subtractive manufacturing. Before we get into types of subtractive manufacturing done by the team, it is worth discussing the difference between CNC and manual machining. See the video below!
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Our team also has access to CNC laser cutting, milling and lathe operations through our sponsors. Machining sponsors are the experts when it comes to making parts, and will be able to create complex parts within our specified tolerances! We typically use our machining sponsors to make complex parts with tight tolerances, as they are reliable and create great quality parts. The only downside with sponsors are long lead times, as parts typically come back in 2-3 weeks.
8.0 - SolidWorks Project
In this section of the training, you will be recreating one of the prototype end effectors designed for the 2022 Mars Rover. This project is intended to ensure that all members are comfortable with the basics of SolidWorks, however it is not intended to teach you to use SolidWorks if you are a new user. If you are struggling to complete any sections of the training, try looking at the additional SolidWorks resources mentioned in the comment section. Also, spend some time trying to google what you are stuck on! I have found random Google and YouTube searches to be one of the best ways to learn SolidWorks. That being said, please always feel free to ping any of the mechanical leads or mechanical members if you are experiencing issues with SolidWorks - we would be more than happy to help you figure things out .
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To provide some context as to what you will be making, below are some pictures of the end effector prototype in SolidWorks and real life:
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8.1 - Folder Creation
First, go to Mars Rover 2022 / Member Training and create a folder with your name. This folder will store all of your files for the training. Review the confluence pages linked in Section 7.3, as well the CAD folder structure page linked in Section 6.2. All of the files you create should emulate the folder structure shown within the CAD folder structure for "Sub-system without Children". Try to create the skeleton for the file structure on your own. It should like something like this:
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8.2 - Training Naming Conventions and Base Part Downloads
When creating parts within this training, a modified version of the standard naming conventions will be used:
Parts: "<MR+Year>-<Sub System Initials>-<ID Number><Revision>-<(InsertName)>.SLDPRT"
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8.3 - Lead Screw Bracket - Part Creation Walk Through
A detailed walk-through will be provided for the first part to be created for the SolidWorks project.
Click "File → New → Templates → 6061-MMGS"
Go to the Feature Manager. Right click the material, and select "Edit Material"
Search up "6061-T6 (SS)", select the material and click "Apply". This is a grade of 6061 aluminum.
Select any plane, and create a new sketch.
Start by creating a 40mm by 26mm rectangle. Extrude the rectangle to a width of 10mm.
Create a new sketch on one of the 40mm x 10mm faces of the rectangle. Create another rectangle aligned to the center bottom edge of the face, and create an extruded cut to the opposite side of the rectangle as shown in the image below.
Next, we will be creating a bushing hole. On the "Features" bar, select "Hole Wizard", and navigate "Hole Type → Legacy Hole → Type: Counterbore". Fill in the fields as shown below, and position the hole in the center of cutout face.
Next, on one of the top or bottom faces of the part, we will be adding some M5 tapped holes. Add the tapped holes with the same condtions as shown in the image below. Ensure to add cosmetic threads with a thread callout when defining the hole specification.
Note that the positioning of the holes is symmetric.Add a 2.5mm 45 degree chamfer to the 4 corners of the part using the chamfer tool.
Add a 6mm rectangular cut out of the center of the part that is aligned to the previous cutout made in step 6.
Note: This cut should be symmetric about the center of the bushing hole.Add a 45 degree 2mm chamfer to the interior cutouts of the part.
Save the part and name it appropriately. Make sure the part is saved in the correct location within your training folder.
Click File → Properties → Summary Information and enter your name as the author of the part.
8.4 - Creating a Part from a Drawing
Next, you will be creating a part from a drawing. Download the drawing below, make the part, name it appropriately and save it within the same part of your folder.
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8.5 - Creating your Own Parts
In this section of the training, you will be creating your own parts from a solid body. Download the SolidWorks files below. Take note of the material specified in each file, take dimensions of the parts using the measure tool, and try to recreate each part using your own sketches, extrudes, cuts, etc. Name the parts appropriately, and save them within the correct location in your training folder.
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Please note that when SolidWorks generates imported bodies, it automatically adds lines on rounded features or curved radii, as shown below. You do not need to include these lines within your models.
8.6 - Creating Drawings
After you have created your own parts from the schematics provided above, please make a fully dimensioned engineering drawing for each part using the team's templates and an appropriate scale. If you have never created an engineering drawing before, check out these videos:
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Creating good engineering drawings is one of the most difficult parts of mechanical design, and takes a lot of practice to get good at. Feel free to take a crack at your drawings, then contact a mechanical member or post it to the drafting channel on discord to get some feedback!
Note: If you are experienced with SolidWorks, try to make SCHEMATIC2 using the SolidWorks sheet metal feature as an added challenge
8.7 - Sourcing OTS Components
Whenever you design something, there will be multiple parts you buy and use as-is, such as motors, gears, fasteners, bearings, etc. These are referred to as OTS (off the shelf) parts. Typically, suppliers will provide CAD data for these types of parts and you will not need to model them yourselves. This training will cover one quick example on sourcing an OTS part, and then will challenge you to find the rest.
Example: Acme Round Nut from McMaster
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Known Part Specifications
Go to the search bar, and search "acme round nut"
The nut has an M10 thread, which is a metric designation. Select metric precision acme lead screws and nuts.
In this case, we want a round nut with a right hand internal thread. Select the available option with the correct thread pitch, as shown below.
Select the product page and navigate to wherever CAD data is available. Please note that not all suppliers will provide 3D CAD data for SolidWorks. Instead, it is much more common for suppliers to provide STEP type files. STEP files are generally a good pic if a SolidWorks file is unavailable.
Identify the part number listed on the product page. This will generally be displayed explicitly on the part's PDF drawing, or somewhere else on the web page. In this case, the part number is 7549K32 - see if you can find it.
Known Part Number
If you know the part number, searching for parts is much easier. Once again, navigate to the McMaster search bar.
This time, search the part number. The search bar should take you right to the part.
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8.8 - Assembling the End Effector
In this section of the training, you will be making an assembly of the end effector in SolidWorks. This section of the training will be pretty hands-off, so if you don't have too much experience with SolidWorks, be sure to review the resources posted in Section 7.1 or the additional resources posted in the comments. Also, when structuring your assemblies, please review this document: CAD Etiquette/Tips for Large Assemblies.
Please download this parasolid file to use as a reference for your assembly:
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As a bonus activity, try to get a moving assembly working for the end effector, as shown in the gripper below.   Here are some tips to get you started on this bonus.
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When you are finished the assembly, save it in the correct spot and name it appropriately. If you are having any troubles with the mates in the assembly, feel free to reach out for help! This part of the training is given with loose direction as a challenge, but if you need assistance we are more than happy to provide some .
8.9 - Manufacturing Quiz
The last part of this training is designed to get you thinking on how you would actually make the parts you are designing. This may be challenging if you have never made any parts, but don't worry; just gather some ideas and be ready to discuss them when you complete your training. Be sure to read up on section 8, and take a careful look at the material and geometry of each of the parts you designed in the SolidWorks project. Please generate some ideas as to how you would manufacture the following parts:
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Hint: There are often a number of ways to manufacture the same part 
9.0 - End of Training
Congratulations on completing the mechanical training! Hopefully this was useful, you learned something new or were able to brush up on your existing knowledge. Please notify one of the mechanical leads once you have read through and completed all the tasks within this training, and push your SolidWorks project to GrabCAD. If you have any ideas on how to improve the training, please feel free to share them as well! Happy CAD'ing