ENGR 102: Computer Aided Design Project 5 Fall 2019 Worth 400 project points INCLINED SAND VEHICLE CHALLENGE (Work in Progress) Design for Three Dimensional Printing Due electronically via CANVAS Students shall be arranged into groups of four. Construction will be held in Scholes Library OBJECTIVE: 3D Printing Project: Design of a Car for carrying load on an sand inclined surface Your task is to design a Sand Vehicle (SV) able to carry a load that is in the shape of a cuboid along a sand slope incline. . L1 L2 Load Figure 1: Sample schematic of the sand ramp challenge Figure 2: Sample car sketch For your design, you will receive the following components: 1. Mini Electric DC Motor 2. Gear Box 3. Motor mounting bracket 4. Boat Rocket Switch to turn on and off the motor. 5. Battery Holder (2 x AA) with batteries 6. Set of Plastic Gears 7. Two shafts (2mm or 3mm diameter) that can be used as axle for the car 8. Super Glue 9. Wires DESIGN CONSTRAINTS: · Maximum number of wheels = 4 · Design Chassis of the car · Design the tires of the car that will carry the load on the sand surface (Not allow the additional materials such as rubber, spikes, etc.) · Minimum diameter: 25mm, maximum diameter 70mm. · Design for carrying a box of size 50mm X 50mm X 50mm with a maximum weight of 200 grams. · The vehicle must be able to carry the load on the flat and the inclined surface. · Your designs must minimize the overall weight and volume of the 3D printing material used in the construction of this project. · Must not use more than 100 cm3 of material · Must not be more than 75 mm wide. · No bearings or other materials other than what is included in the kit. Phase 1: Group Formation · A group of four students will be assigned by your instructor. · Share the names and contact information of the students for each group · The instructor will also assign you a group number. Phase 2: Initial Sketch and Brainstorming (This is an individual contribution) · Each student must come up with a sketch for how the components are to be laid out and come up with approximate dimensions of the overall design. Make sure that your overall design is not bigger than the given design constraints. · You must submit on Canvas. Your design must be original. Phase 3: Design in SolidWorks · Design all parts in SolidWorks including battery holder, motor switch etc · Minimize the material required for 3D printing the chassis and the wheel · Assemble in SolidWorks · Generate drawing files for the chassis and the wheels Phase 4: Get your design approved · Make an appointment with your instructor to go over the dimensions and clearances for the parts · Make an appointment with the Digital Fabrication Supervisor to make sure that your parts have all the required settings and clearances for your design. Afterwards you can schedule 3D printing. Phase 5: 3D-print your design · Collect your printed parts from your instructor when they are ready · Any issues or concerns, plea ...

1. ENGR 102: Computer Aided Design
Project 5 Fall 2019
Worth 400 project points
INCLINED SAND VEHICLE CHALLENGE
(Work in Progress)
Design for Three Dimensional Printing
Due electronically via CANVAS
Students shall be arranged into groups of four. Construction
will be held in Scholes Library
OBJECTIVE: 3D Printing Project: Design of a Car for carrying
load on an sand inclined surface
Your task is to design a Sand Vehicle (SV) able to carry a load
that is in the shape of a cuboid along a sand slope incline. .
L1
L2
Load
Figure 1: Sample schematic of the sand ramp challenge
Figure 2: Sample car sketch
For your design, you will receive the following components:
1. Mini Electric DC Motor
2. Gear Box
3. Motor mounting bracket
4. Boat Rocket Switch to turn on and off the motor.

2. 5. Battery Holder (2 x AA) with batteries
6. Set of Plastic Gears
7. Two shafts (2mm or 3mm diameter) that can be used as axle
for the car
8. Super Glue
9. Wires
DESIGN CONSTRAINTS:
· Maximum number of wheels = 4
· Design Chassis of the car
· Design the tires of the car that will carry the load on the sand
surface (Not allow the additional materials such as rubber,
spikes, etc.)
· Minimum diameter: 25mm, maximum diameter 70mm.
· Design for carrying a box of size 50mm X 50mm X 50mm with
a maximum weight of 200 grams.
· The vehicle must be able to carry the load on the flat and the
inclined surface.
· Your designs must minimize the overall weight and volume of
the 3D printing material used in the construction of this project.
· Must not use more than 100 cm3 of material
· Must not be more than 75 mm wide.
· No bearings or other materials other than what is included in
the kit.
Phase 1: Group Formation
· A group of four students will be assigned by your instructor.
· Share the names and contact information of the students for
each group
· The instructor will also assign you a group number.
Phase 2: Initial Sketch and Brainstorming (This is an individual
contribution)
· Each student must come up with a sketch for how the
components are to be laid out and come up with approximate
dimensions of the overall design. Make sure that your overall

3. design is not bigger than the given design constraints.
· You must submit on Canvas. Your design must be original.
Phase 3: Design in SolidWorks
· Design all parts in SolidWorks including battery holder, motor
switch etc
· Minimize the material required for 3D printing the chassis and
the wheel
· Assemble in SolidWorks
· Generate drawing files for the chassis and the wheels
Phase 4: Get your design approved
· Make an appointment with your instructor to go over the
dimensions and clearances for the parts
· Make an appointment with the Digital Fabrication Supervisor
to make sure that your parts have all the required settings and
clearances for your design. Afterwards you can schedule 3D
printing.
Phase 5: 3D-print your design
· Collect your printed parts from your instructor when they are
ready
· Any issues or concerns, please let your instructor know about
it
Phase 6: Assembly and Testing
· Assemble your car
· Test your car
Phase 7: Competition for the sand ramp challenge
· Come up with a name for your group
· Get ready for competing with other groups
Competition scoring
· Finish L1(Flat) : 20 point
· Finsh L2 (Slope) : 30 points

4. · The wining team – Finish L1 & L2 with fastest time (In case
the time is same, low weight car is win)
· Winning team will get the bonus credits
Phase 8: Peer Evaluation Submission
· You will evaluate your team members for their contribution
for this project
· A sample evaluation form will be uploaded on CANVAS
SCHEDULE
Week 1 Tasks:
1) Submit individual design sketches (ink) as per Phase 2.
2) Meet with your group and utilize a systematic design process
to generate alternative vehicle designs from individual deisgns
in Phase 2. Refer to Appendix A for details.
3) Create a functional solid model of the vehicle you have
chosen
4) Write Progress report due week 2.
Week 2 Tasks:
5) Complete design Phase 3.
6) Attend an introductory lecture from the digital fabrication
laboratory supervisor.
7) Finish creating assembly of your design rendered in
Solidworks:
a. Each part should include your group number as an identifier
(e.g., as extruded lettering) to unambiguously identify your part
from amongst other submissions.
b. Be mindful of 3D printing limitations. Features below 1/16”
cannot be printed, and features below 1/8” (or greater,
depending on application) will likely not have sufficient
strength to perform any load bearing function. The printer over
sizes by approximately 0.01”, so you must offset your
dimensions in order to fit shafts/holes, etc. If in doubt, please
consult The digital fabrication supervisor.
8) Create properly dimensioned part and assembly drawings of

5. the SV. Be sure to label the sheet scale, units, title, and author
names.
9) Submit solid model files of the SV in the proper format for
3D printing for approval.
10) submit parts for 3D printing
11) Prepare progress report for due week 3.
Week 3 Tasks:
12) Complete the Sustainability tutorial found under Design
Evaluation and Simulation tab.
13)Perform a sustainability analysis on the SV. Refer to
Appendix B for details.
14)Prepare sustainability report for week 4.
15Assemble and test vehicle for SV competition.
Week 4 Tasks:
13) RACE DAY
14) Write up and submit your final report. Refer to Appendix D
for details.
Grading
Grading:
Final Report with drawings: 200 points
Progress Reports: 100 points
Contest: 50 points
Self Study: 50 points.
Appendix A. The Engineering Design Process (Design Intent)
There is no singular method that engineers must follow when
designing a system, component, or process to meet desired
needs within realistic constraints. However, many engineers in
professional practice utilize a systematic design process
involving at least the following steps (note: many ancillary

6. considerations have been omitted for this introductory
document):
1. Problem Identification
a. What is the main goal of the engineering project?
b. Ask ‘what’ is needed to solve the problem
i. Do off-the-shelf solutions already exist? If not, what is
inadequate about the current state of the system, component, or
process?
ii. What new features would be desirable and most relevant?
c. Develop specifications in as much detail as possible
i. What objective(s) must each system, component, or process
achieve?
ii. What design constraint(s), if any, exist?
An objective-constraint tree can be used to summarize design
requirements:
<SYSTEM, COMPONENT, OR PROCESS>
1. <OBJECTIVE CATEGORY 1>
a. OBJECTIVE 1
b. CONSTRAINT 1
c. CONSTRAINT 2
2. <OBJECTIVE CATEGORY 2>
a. OBJECTIVE 1
i. SUB-OBJECTIVE 1
1. SUB-SUB-OBJECTIVE 1
2. SUB-SUB-OBJECTIVE 2
ii. SUB-OBJECTIVE 2
b. OBJECTIVE 2
c. CONSTRAINT 1
Broad objective categories may be broken down into objectives
and/or constraints of increasingly detailed specification. An
objective-constraint tree is an evolving document that can
change throughout the design process as the engineers (and

7. clients!) learn more about the problem.
2. Concept Generation
a. Perform a function decomposition analysis by asking what
function(s) (i.e., work or specific actions) must each system,
component, or process perform?
i. Analogous to an objective-constraint tree, a function
decomposition tree can be used to delineate the most basic
functions of each system, component, or process:
<SYSTEM, COMPONENT, OR PROCESS>
1. <FUNCTION CATEGORY 1>
a. FUNCTION 1
i. SUB- FUNCTION 1
1. SUB-SUB- FUNCTION 1
2. SUB-SUB- FUNCTION 2
ii. SUB- FUNCTION 2
b. FUNCTION 2
2. < FUNCTION CATEGORY 2>
a. FUNCTION 1
i. SUB- FUNCTION 1
1. SUB-SUB- FUNCTION 1
2. SUB-SUB- FUNCTION 2
ii. SUB- FUNCTION 2
b. FUNCTION 2
ii. At this stage, do not worry about how these functions will be
implemented. The purpose of function decomposition analysis is
to develop a fundamental understanding of required design
functionalities.
b. Brainstorm multiple approaches to the problem. Do not reject
any ideas out of perceived impracticality: ideation and
evaluation should be handled as separate exercises.
i. Research the state-of-the-art to know what has been done.
ii. Focus primarily on how to implement the most basic

8. functionalities identified in the function decomposition tree.
iii. Work collaboratively. Consider each other’s ideas and build
upon them.
iv. Whenever possible, communicate visually. Utilize sketches
to convey and modify ideas.
3. Concept Selection
a. A decision matrix is a rubric that applies a weighted set of
evaluation criteria to a number of candidate solutions. An
example decision matrix is provided below:
Weighting Factor
Candidate
Solution
s (relative ranking 1 being best, 4 being worst)
Criteria
1 = high importance, 5 = low importance