2002 Course Notes

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Introduction to Engineering Design

GEEN 1400 Course Notes

Spring 2002

John K. Bennett

"Genius is one percent inspiration and ninety-nine percent perspiration."

Thomas A. Edison, 1932

"Give me the political economist, the sanitary reformer, the engineer; and take your saints and virgins, relics and miracles. The spinning-jenny and the railroad, Cunnard's liners and the electric telegraph, are to me ... signs that we are, on some points at least, in harmony with the universe."

Charles Kingsley, 1848

"For `tis the sport to have the engineer
Hoist with his own petar;"

W. Shakespeare, Hamlet III iv, 206

Copyright © 1994-2002 by John K. Bennett

Seventh edition, January 2002.

Permission is hereby granted to reproduce and to distribute verbatim copies of this document in whole or in part, provided that no fee is collected for its distribution (other than reasonable reproduction costs) and this copyright notice is included.

Other than verbatim copies with copyright notice intact, no part of this document may be reproduced in any form without written permission of the author. For example, the right to make derivative works based on this document is not granted, and requires written consent.

Substantial portions of this document are derived from The 6.270 Robot Builder's Guide, Copyright © 1992 by Fred G. Martin, with the permission of the author.

To contact the author, write to:

John K. Bennett
Department of Computer Science
CB 430
University of Colorado at Boulder
Boulder, CO 80309

This document may also be obtained in electronic form via the World Wide Web at URL:

http://www-csl.cs.colorado.edu/LegoRobots

Section 2.1, "`Electronic Assembly Technique," is based on a previous version written by Pankaj Oberoi of M.I.T..

Chapter 8, "LEGO Design," was originally co-authored by Fred Martin and Randy Sargent, both of M.I.T..

Chapter 4, "Basic Electronics," was originally co-authored by J. Patrick Frantz and David Hindman, and was extensively revised by Jim Young.

Chapter 3, "Basic Mechanics," was originally written by David Hindman, and revised by Brendan Daly.

This document was typeset by the LATEX text formatting system. The psfig macro was used for including PostScript figures in LATEX documents. dvips was used to create final PostScript output.  Latex2html was used to create the html version, which was then edited using Microsoft Frontpage.

Many diagrams were created with the idraw X-windows-based drawing program, distributed by the M.I.T. Athena computer network. The commercial program IslandDraw was used to edit postscript figures from other sources.

Electrical circuit schematics were drawn using the the Viewlogic Systems PowerView CAD suite of tools.

Printed circuit board artwork was created using the PADS Perform PCB design suite.

 Table of Contents

bulletContents
bulletList of Figures
bulletForeword
bulletPreface
bulletAcknowledgements
bulletCourse Notes Overview
bulletLego Robots Course Organization
bulletLego Robots Contest Rules
bulletObject
bulletBlocks
bulletPeriod of Play
bulletControl
bulletInfrared Beacon
bulletThe Contest Playing Table
bulletStructure
bulletThe $20 Rule
bulletScoring
bulletArbitration
bulletRule Changes
bulletParts List
bulletAssembly Manual
bulletElectronic Assembly Technique
bulletSoldering Technique
bulletDesoldering Technique
bulletComponent Types and Polarity
bulletComponent Mounting
bulletComponent Value Markings
bulletThe Lego Robots RoboBoard (See User's Manual and Developer's Manual)
bulletThe Battery System
bulletThe Battery Charger
bulletWiring the Battery Cable
bulletWiring the 12 VDC Adaptor
bulletThe Infrared Transmitter
bulletAssembly Instructions
bulletCable and Connector Wiring
bulletSensor Wiring
bulletTouch Sensors
bulletPhotocell Light Sensor
bulletMercury Tilt Switch
bulletInfrared Reflectance Sensor
bulletSharp Infrared Sensor
bulletPotentiometer
bulletSlotted Optical Switch
bulletHall effect sensor
bulletMagnetic Switches
bulletMounting Sensors
bulletSwitches
bulletIR Reflectance Sensors
bulletSlotted Optical Switches
bulletPhotocells
bulletPotentiometers
bulletMounting the RoboBoard
bulletMotor Wiring
bulletLEGOizing the Round Johnson and Mabuchi Motors
bulletLEGOizing the Oblate Johnson Motor
bulletAlternate Motor Mounting
bulletWiring a Cable and Plug to a Motor
bulletStepper Motor
bulletComputer Cable Wiring
bulletBasic Mechanics
bulletForces
bulletFriction
bulletTorque
bulletSimple Machines
bulletThe Inclined Plane
bulletLevers
bulletThe Wheel and Axle
bulletCams and Cranks
bulletPulleys
bulletThe Screw
bulletInertia
bulletSprings
bulletRubber Bands
bulletCounterweights
bulletBasic Electronics
bulletWhat is Charge?
bulletCharge exists.
bulletCharge comes in two styles.
bulletCharge is conserved.
bulletVoltage
bulletCurrent
bulletBatteries
bulletCircuit Elements
bulletResistors
bulletCapacitors
bulletInductors
bulletSemiconductor Devices
bulletThe Truth About Charge
bulletSilicon
bulletDiodes
bulletLego Robots Hardware (See User's Manual and Developer's Manual)
bulletMotors
bulletDC motors
bulletStepper motors
bulletServo motors
bulletDC Motors
bulletRatings and Specifications
bulletMeasuring Motor Torque
bulletSpeed, Torque, and Gear Reduction
bulletPulse Width Modulation
bulletStepper Motors
bulletStepper Motor Control
bulletServo Motors
bulletServo Motor Control
bulletBatteries
bulletCell Characteristics
bulletVoltage
bulletCapacity
bulletPower Density
bulletDischarge Curve
bulletInternal Resistance
bulletRechargeability
bulletCost
bulletBattery Packs
bulletLego Robots Battery Charger
bulletLEGO Design
bulletFundamental LEGO Lengths
bulletLEGO Gearing
bulletGear Reduction
bulletChain Drives
bulletDifferentials
bulletTesting a Geartrain
bulletLow-Force Geartrains
bulletRack and Pinion Steering
bulletMulti-tasking Motors
bulletSensor Design
bulletSensors as Transducers
bulletAnalog and Digital Sensors
bulletSensor Inputs on the RoboBoard
bulletReading Sensor Inputs
bulletConnector Plug Standard
bulletSensor Wiring
bulletThe Voltage Divider Circuit
bulletTactile Sensors
bulletLimit Switch
bulletSwitch Circuitry
bulletMercury Tilt Switch
bulletPotentiometer
bulletLight Sensors
bulletPhotocell
bulletInfrared Reflectance Sensor
bulletInfrared Slotted Optical Switch
bulletModulated Infrared Light Detector
bulletOther Sensors
bulletMagnetic Field Sensors
bulletMotor Current Sensor
bulletRobot Control
bulletBasic Control Methods
bulletFeedback Control
bulletOpen-Loop Control
bulletFeed-Forward Control
bulletSummary
bulletSensor Calibration
bulletManual Sensor Calibration
bulletDealing with Changing Environmental Conditions
bulletUsing Persistent Global Variables
bulletRobot Control
bulletSensor Unreliability
bulletTask-Oriented Control
bulletCoordination of Tasks
bulletHints from the Past
bulletRobot Structure
bulletGearboxes
bulletWeight Considerations
bulletGeneral Structure
bulletMiscellaneous Parts
bulletProgramming
bulletSize of Code
bulletRobot Queries
bulletNested Loops and Statements
bulletProgramming Modules
bulletProgramming Style
bulletGroup Dynamics
bulletPatrick Frantz:
bulletDesign Time-Line
bulletWeek 1
bulletWeek 2
bulletWeek 3
bulletWeek 4
bulletWeek 5
bulletWeek 6
bulletWeek 7
bulletWeek 8
bulletWeek 9
bulletWeek 10
bulletWeek 11
bulletWeek 13
bulletWeek 14
bulletWeek 15
bulletPrinted Circuit Board Documentation
bulletBattery Charger Board
bulletInfrared Beacon Board
bulletResources
bulletIntroduction
bulletRetail Suppliers
bulletSurplus Suppliers
bulletOrdering Catalogs
bulletThe Surplus Companies
bulletSurplus Company Listing
bulletThe Retail Companies
bulletComparing Rice and M.I.T. Hardware
bulletHardware
bulletSoftware
bulletSummary
bulletGlossary
bulletFor Further Reading
bulletIndex
bulletAbout this document ...


jkb
9/19/1998