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 .

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. 

Extra Information on URC

If you'd like to learn more about the URC competition, please check out their website. If you have time, this video also does a great job to showcase what the competition is all about! 

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.

After enrolling, the course should appear on your homepage. Completing the online course will grant you a Machine Shop access. Additional training for more advanced machining techniques are available from the Engineering Student Machine Shop staff. It is highly recommended to complete your lathe and mill training as soon as possible, although the completion of additional training is not required for joining the mechanical sub-team.

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.

The desktop app, called "GrabCAD Workbench" is used to sync your local CAD files to the project cloud. To Install GrabCAD Workbench,

1. Download and install the desktop application: https://workbench.grabcad.com/workbench/download
2. Send 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. 
3. Once you have been added to our GrabCAD, log into your GrabCAD account in Workbench, access settings and click "Manually Connect Project"
   
   
4. Navigate to the projects for UWRT, and click "Link to Folder"
   
5. Create a GrabCAD folder somewhere in your computer's Documents folder. This will help prevent file errors with your uploads.
6. 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

• Before you start adding files to the GrabCAD, make sure you are saving things in the correct spot. Please read File Structure and File Naming to understand how we organize our files.
• Whenever you begin designing, start by checking GrabCAD for updates to the cloud and download them. If someone has made changes to your file without asking, do not download those files; contact Max Apitz-Grossman on discord to get it fixed.
  • If you are working on a task/project with multiple active collaborators, ping other collaborators working on your project on discord to notify your teammates that you will be making changes to the CAD. This will help prevent conflicts in the long run. 
    
• Once you are done making your design changes, make sure that you haven't accidentally broken any higher level assemblies. For example, say you are working on a linkage for the gripper assembly. After you are finished working on the linkage, open up the gripper assembly to ensure none of the mates have broken.
• After double checking any higher level assemblies you are involved with, upload your changes to the cloud. Only upload files that are in your project (the ones that you should be designing). 
  • If you are working on a task/project with multiple active collaborators, please push your CAD immediately once you are done working with it. The longer you hold onto GrabCAD changes, the higher the chance for file conflicts. 

Undoing Changes in GrabCAD

• 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=55034593
• SolidWorks 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.

1. Click the ‘System Options’ menu from the menu bar. (the gear)
2. Select ‘File Locations’ from the left side menu. 
3. Select ‘Document Templates’ from the drop down menu.
4. Click the ‘Add’ Button.
5. Navigate to the templates folder in the GrabCad folder. (\GrabCAD\Mars Rover 2022 Mechanical\Documentation\Templates)
6. Click ‘Select Folder’. Windows might ask for admin access to the folder. Allow access.
7. The templates folder is now linked and will be available when making a part.

Using the templates for file creation:

1. Select ‘New…’ from the file menu (Ctrl + N)
2. Click advanced on the pop up screen (bottom left corner).
3. The next screen will have tabs at the top. Select ‘Templates’ to use team templates.
4. Select the appropriate template.
   1. The following templates are used for defining parts. 5052 refers to a part made from 5052 aluminum, 6061 refers to a part made from 6061 aluminum and ABS refers to a 3D printed part. 
      
      
   2. The follow templates are used for defining drawings. A0, A1, A2, A3 and A4 refer to the sheet size of the drawing. When defining a drawing, you typically want to choose a template where you can apply a reasonable scale (1:2 or 2:1) and fill up majority of the white space within the drawing template. 
      
      

Please also see this page for a quick overview of additional fields to fill in when defining parts or drawings: Creating a Standard Part / Drawing

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.

• File Naming Standard/Number Registration (2021-2022)
• OTS Component Etiquette

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. 

We don't really do DLP printing, but still might be worth a watch

FDM Printing

FDM printing is one of the most accessible types of manufacturing methods available to our team. We currently have a Prusa i3 printer in the bay, and many team members have their own 3D printers. 

SLA/SLS Printing

Our team does not have a dedicated SLA printer, but one of our sponsors offers free SLA and SLS printing services!

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!

On Campus Resources - Manual Machining

The engineering machine shop is available to all students who complete the training. Since you have completed the shop training as part of being a mechanical member, you should know what is available! Mills, drill presses, lathes, bandsaws, etc. Below is a list of the machines available.

- https://uwaterloo.ca/engineering-machine-shop/equipment

Here are some pros and cons to manual machining on campus.

CNC Resources - On Campus

Waterloo has a CNC mill in the machine shop, but it requires training to use and is not easily accessible for new members. However, the RPC in E5 and student machine shop have CNC C02 laser cutting and waterjetting services available to design team members! These services are very useful in a pinch. 

https://uwaterloo.ca/engineering-student-shops/cnc-resources

https://uwaterloo.ca/3d-print-centre/laser-cutting-request-form

https://www.flowwaterjet.com/Learn/How-Waterjet-Works.aspx#pure

Laser cutters and water jet cutters are quite precise, but typically are reserved for cutting parts from sheet metal - i.e. parts with uniform thickness. Some additional finishing processes may be required when working with laser cut or water jet parts. 

CNC Resources - Sponsors

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 . 

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:

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:

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"

• The year represents the current year that the part is made.
• The sub system initials are used to describe what part of the rover the components are located on. Normally, all of the parts in the end effector would be labelled under subsystem "EE" (for end effector), however for the parts you make in the training, please use subsystem initials "MT" (for member training). 
• The ID number represents the number of the part. Normally, when we design our parts all designers will register a unique part number in the part number registration page. However, for the sake of this training please name your files in in numerical order starting from the provided base part downloads. Although this does not reflect the team practices for numbering parts, it makes tracking the training parts much easier .
• The revision is a letter (starting from A) that describes the version of a part. If you design a part, then make  changes to it's geometry you would change the part numbers revision from A to B. 

Assemblies: "<MR+Year>-<Sub System Initials>-<ID Number><Revision>-<(InsertName)>.SLDASM"

• Same idea as for parts but for assemblies.

Drawings: Drawing of a part or assembly shall have the same name as the part number or assembly

Please download these three components, rename them accordingly and save them in the correct location in your training folder. 

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. 

1. Click "File → New → Templates → 6061-MMGS"
2. Go to the Feature Manager. Right click the material, and select "Edit Material"
   
3. Search up "6061-T6 (SS)", select the material and click "Apply". This is a grade of 6061 aluminum. 
4. Select any plane, and create a new sketch.
5. Start by creating a 40mm by 26mm rectangle. Extrude the rectangle to a width of 10mm. 
   
   
   
6. 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. 
   
7. 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.
   
8. 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.
9. Add a 2.5mm 45 degree chamfer to the 4 corners of the part using the chamfer tool. 
   
   
10. 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. 
11. Add a 45 degree 2mm chamfer to the interior cutouts of the part.
    
12. Save the part and name it appropriately. Make sure the part is saved in the correct location within your training folder. 
13. 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. 

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. 

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:


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

When you source OTS components, you will almost always know what supplier you will buy the part from, and generally either know the part number, or know the specifications of the part you want. This example will cover search methods for both scenarios. You will source a "Precision Acme Round Nut with M10 x 2mm Thread for Lead Screw" from McMaster, a large supplier of fasteners and other various mechanical related parts. 

1. Known Part Specifications
   1. Go to https://www.mcmaster.com/
   2. Go to the search bar, and search "acme round nut"
   3. The nut has an M10 thread, which is a metric designation. Select metric precision acme lead screws and nuts.
      
   4. 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.
      
   5. 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.
      
   6. 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.
      
      
2. Known Part Number
   1. If you know the part number, searching for parts is much easier. Once again, navigate to the McMaster search bar. 
   2. This time, search the part number. The search bar should take you right to the part. 

Once you have downloaded this file, save it in the correct OTS component folder in your training. Please note that typically, within the "OTS Components" folder, there will be sub folders that vary by supplier. 

OTS Components for Training
When downloading OTS components and saving them in your folder, make sure you follow this guide! OTS Component Etiquette. In this section of the training, you will be sourcing a wide variety of OTS components.

McMaster Parts:

• Black-Oxide Alloy Steel Socket Head Screw, M5 x 0.8 mm Thread, 12 mm Long
• Black-Oxide Alloy Steel Hex Drive Flat Head Screw, 90 Degree Countersink, M5 x 0.80 mm Thread, 12 mm Long
• Clevis Pin with Retaining Ring Groove, Zinc-Plated Steel, 3/16" Diameter, 5/8" Usable Length
• Headless Clevis Pin with Retaining Ring Groove, Zinc-Plated Steel, 3/16" Diameter, 1-1/4" Usable Length
• Medium-Strength Class 8.8 Steel Hex Head Screw, M6 x 1.00 mm Thread, 16 mm Long
• Zinc-Plated Steel Hex Nut, Medium-Strength, Class 8, M6 x 1 mm Thread
• Oil-Embedded Flanged Sleeve Bearing, for 6 mm Shaft Diameter and 10 mm Housing ID, 6 mm Long
• Aluminum Unthreaded Spacer, 5/16" OD, 7/16" Long, for Number 10 Screw Size
• Clevis Pin with Retaining Ring Groove, Zinc-Plated Steel, 3/16" Diameter, 3/8" Usable Length

KHK Parts:

• Part Number: DSF0.5-120
• Part Number: SSG0.5-30B

Polulu Parts:

• Part Number: 4753 (note that when downloading the CAD for this motor, the 50-70 with encoder step file will be a good choice for the assembly)

Once you have downloaded all of the OTS components, make sure you adjust the files appropriate as discussed in OTS Component Etiquette and save the files in the correct folder location. 

ALSO: Although it goes against our naming convention, please end all OTS parts with your name in brackets. Once again, this is just to make it easier to track training files in the long and and avoid conflicts. An example is shown with the two files posted below, please also download these files in preparation for the next section of the training. Thanks!

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:

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:

• Lead Screw Bracket (Part made in section 9.3)
• All "SCHEMATIC" parts

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