page i

Implementation
Products, Robotics, and Other Useful Things

Hugh Jack
Copyright, 2006


page 1

1.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1
1.2
1.3
1.4
1.5
1.6
1.7

2.

Introduction
Bloom’s Taxonomy
Examples
Summary
References and Bibliography
Problems
Challenge Problems

1.1
1.1
1.2
1.2
1.2
1.2
1.2

DRAFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.1

2.2

2.3

CONVENTIONAL DRAFTING
2.3
2.1.1
Manual Drafting
2.4
2.1.2
Turning Three Dimensions Into Two (Multi View Drawings)2.5
The Glass Box
2.5
2.1.3
Lines
2.8
2.1.4
Holes

2.10
2.1.5
Special Cases
2.11
Aligned Features
2.11
Incomplete Views
2.14
2.1.6
Section Views
2.16
Full Sections
2.16
Offset Section
2.17
Half Section
2.18
Cut Away Sections
2.19
Revolved Section
2.20
Removed Section
2.20
Auxiliary Section
2.22
Thin Wall Section
2.23
Assembly Section
2.23
Special Cases

2.24
Fill Patterns
2.26
2.1.7
Auxiliary Views
2.26
Secondary Auxiliary Views
2.30
Partial Auxiliary Views
2.30
2.1.8
Descriptive Geometry
2.30
2.1.9
Isometric Views
2.31
2.1.10
Special Techniques
2.31
NOTATIONS
2.32
2.2.1
Basic Dimensions and Tolerances
2.33
2.2.2
Geometric Dimensioning and Tolerancing (GD & T)
2.33
Feature Control Symbols
2.34
Symbols and Meaning

2.35
Datums
2.40
Modifiers
2.41
WORKING DRAWINGS
2.42


page 2

2.3.1

2.4
2.5

3.

Drawing Elements
Title Blocks
Drawing Checking
Drawing Revisions
Bill of Materials (BOM)
2.3.2
Drawing Types
Assembly Drawings
Subassembly Drawings
Exploded Assembly Drawings
Detailed Drawings
PRACTICE PROBLEMS

REFERENCES

2.42
2.42
2.43
2.43
2.44
2.44
2.44
2.45
2.45
2.45
2.46
2.46

METROLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
3.1
3.2
3.3

3.4

3.5
3.6

3.7

Introduction
3.1.1
The Role of Metrology

DEFINITIONS
STANDARDS
3.3.1
Scales
3.3.2
Calipers
3.3.3
Transfer Gauges
Instruments
3.4.1
Vernier Scales
3.4.2
Micrometer Scales
The Principle of Magnification
The Principle of Alignment
3.4.3
Dial Indicators
3.4.4
The Tool Makers Microscope
3.4.5
Metrology Summary
Surfaces
3.5.1
Measures of Roughness
Measuring Surface Roughness
3.6.1
Observation Methods
3.6.2
Stylus Equipment
3.6.3

Specifications on Drawings
3.6.4
Other Systems
3.6.5
Roundness Testing
Intrinsic Roundness Testing
Extrinsic Roundness Testing
Gage Blocks
3.7.1
Manufacturing Gauge Blocks
3.7.2
Compensating for Temperature Variations
3.7.3
Testing For Known Dimensions With Standards
3.7.4
Odd Topics
3.7.5
Limit (GO & NO GO) Gauges

3.47
3.47
3.48
3.49
3.49
3.50
3.50
3.51
3.51
3.52
3.53

3.54
3.55
3.57
3.58
3.59
3.60
3.63
3.63
3.63
3.68
3.69
3.72
3.73
3.76
3.78
3.82
3.85
3.85
3.86
3.87


page 3

3.8

3.9

4.


Basic Concepts
GO & NO GO Gauges Using Gauge Blocks
Taylor’s Theory for Limit Gauge Design
Gauge Maker’s Tolerances
3.7.6
Sine Bars
Sine Bar Limitations
3.7.7
Comparators
Mechanical Comparators
Mechanical and Optical Comparators
Optical Comparators
Pneumatic Comparators
Measuring Aparatus
3.8.1
Reference Planes
Granite Surface Plates
Cast Iron Surface Plates
3.8.2
Squares
Practice Problems

3.87
3.89
3.90
3.91
3.93
3.95
3.96
3.97

3.98
3.99
3.99
3.101
3.101
3.102
3.102
3.103
3.106

CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.119
4.1

4.2

4.3

4.4

Drilling
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
Milling
4.2.1

Drill Bits

Reamers
Boring
Taps
Process Parameters
The mrr For Drilling

Types of Milling Operations
Arbor Milling
4.2.2
Milling Cutters
4.2.3
Milling Cutting Mechanism
Up-Cut Milling
Down-Cut Milling
Feeds and Speeds
4.3.1
The mrr for Milling
4.3.2
Process Planning for Prismatic Parts
4.3.3
Indexing
Lathes
4.4.1
Machine tools
Production Machines
4.4.2
Toolbits
4.4.3
Thread Cutting On A Lathe
4.4.4

Cutting Tapers
4.4.5
Turning Tapers on Lathes
4.4.6
Feeds and Speeds

4.119
4.122
4.125
4.126
4.127
4.128
4.130
4.131
4.131
4.133
4.133
4.133
4.134
4.135
4.136
4.139
4.139
4.139
4.142
4.145
4.146
4.147
4.150
4.152

4.153
4.155


page 4

4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12

5.

Introduction
ADHESIVE BONDING
ARC WELDING
GAS WELDING
SOLDERING AND BRAZING
PLASTIC WELDING
Examples
Summary
References and Bibliography
Problems
Challenge Problems

5.182

5.183
5.184
5.186
5.187
5.188
5.193
5.193
5.193
5.193
5.194

ROTATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.195
6.1
6.2
6.3
6.4

6.5
6.6
6.7
6.8
6.9

7.

4.156
4.157
4.158
4.159
4.164

4.164
4.164
4.164
4.164
4.165

JOINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.182
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11

6.

4.4.7
The mrr for Turning
4.4.8
Process Planning for Turning
Cutting Speeds, Feeds, Tools, and Times
Cutting Power
Examples
Summary
References and Bibliography

Problems
Challenge Problems
Practice Problems

Introduction
Rotational Masses and Inertia
Motor Models
6.3.1
Basic Brushed DC Motors
Tachometers
6.4.1
Angular Displacement
Potentiometers
6.4.2
Encoders
Tachometers
Examples
Summary
References and Bibliography
Problems
Challenge Problems

6.195
6.195
6.203
6.203
6.210
6.210
6.210
6.211

6.215
6.216
6.216
6.216
6.216
6.216

FEEDBACK CONTROL REVIEW . . . . . . . . . . . . . . . . . . . . . 7.217
7.1
7.2

Introduction
OpAmps

7.217
7.221


page 5

7.3
7.4
7.5
7.6
7.7

8.

7.225
7.225

7.225
7.225
7.225

MECHANICAL POWER TRANSMISSION . . . . . . . . . . . . . . 8.226
8.1

8.2
8.3

8.4
8.5
8.6
8.7
8.8
8.9

9.

Examples
Summary
References and Bibliography
Problems
Challenge Problems

Mechanisms
8.1.1
Locking/Engaging
8.1.2
Motion Transmission/Transformation

8.1.3
Four Bar Linkages
8.1.4
Reciprocating
8.1.5
Six Bar Linkages
Mechanical Advantage
Gears
8.3.1
Spur Gears
8.3.2
Involute Profiles
8.3.3
Design of Gears
8.3.4
Design Issues
Undercutting and Contact Ratios
Changing the Center Distance
8.3.5
Helical Gears
Design of Helical Gears
Perpendicular Helical Gears
8.3.6
Bevel Gears
Design of Bevel Gears
8.3.7
Other Bevelled Gears
8.3.8
Worm Gears
8.3.9

Harmonic Drives
8.3.10
Design With Gears
Gear Trains
Examples - Fixed Axis Gears
Examples - Moving Axis Gears
Epicyclic Gear Trains
Differentials
8.3.11
Gear Forces and Torques
Cams
8.4.1
Using Cams in Mechanisms
Examples
Summary
References and Bibliography
Problems
Challenge Problems

8.226
8.227
8.230
8.230
8.232
8.234
8.236
8.238
8.238
8.243
8.245

8.248
8.248
8.250
8.250
8.251
8.254
8.255
8.257
8.258
8.258
8.261
8.261
8.262
8.263
8.267
8.267
8.270
8.272
8.274
8.287
8.287
8.287
8.287
8.287
8.290

MECHANICAL ISSUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.291


page 6


9.1
9.2
9.3
9.4

9.5
9.6
9.7
9.8
9.9
9.10

10.

9.291
9.291
9.293
9.294
9.295
9.296
9.299
9.299
9.300
9.301
9.301
9.301
9.301
9.301
9.301


SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.302
10.1
10.2

10.3

10.4
10.5
10.6
10.7

11.

Introduction
Friction
Friction
Contact Points And Joints
9.4.1
Switching
9.4.2
Deadband
9.4.3
Saturation and Clipping
9.4.4
Hysteresis and Slip
9.4.5
Delays and Lags
Wheeled Vehicles
Examples

Summary
References and Bibliography
Problems
Challenge Problems

INTRODUCTION
SENSOR WIRING
10.2.1
Switches
10.2.2
Transistor Transistor Logic (TTL)
10.2.3
Sinking/Sourcing
10.2.4
Solid State Relays
PRESENCE DETECTION
10.3.1
Contact Switches
10.3.2
Reed Switches
10.3.3
Optical (Photoelectric) Sensors
10.3.4
Capacitive Sensors
10.3.5
Inductive Sensors
10.3.6
Ultrasonic
10.3.7
Hall Effect

10.3.8
Fluid Flow
SUMMARY
PRACTICE PROBLEMS
PRACTICE PROBLEM SOLUTIONS
ASSIGNMENT PROBLEMS

10.302
10.302
10.303
10.303
10.304
10.311
10.312
10.312
10.312
10.313
10.320
10.324
10.326
10.326
10.326
10.327
10.327
10.331
10.337

ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.339
11.1
11.2

11.3
11.4
11.5
11.6

INTRODUCTION
SOLENOIDS
VALVES
CYLINDERS
HYDRAULICS
PNEUMATICS

11.339
11.339
11.340
11.342
11.344
11.346


page 7

11.7
11.8
11.9
11.10
11.11
11.12
11.13


12.

11.347
11.348
11.348
11.348
11.349
11.349
11.350

PROJECT MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 12.351
12.1
12.2
12.3

12.4
12.5
12.6
12.7
12.8
12.9

13.

MOTORS
COMPUTERS
OTHERS
SUMMARY
PRACTICE PROBLEMS
PRACTICE PROBLEM SOLUTIONS

ASSIGNMENT PROBLEMS

Introduction
An Academic View of Design Revisited
Project Management
12.3.1
Timeline - Tentative
12.3.2
Teams
12.3.3
Conceptual Design
12.3.4
Progress Reports
12.3.5
Design Proposal
12.3.6
The Final Report
12.3.7
Gantt Charts
12.3.8
Drawings
12.3.9
Budgets and Bills of Material
12.3.10
Calculations
Examples
Summary
References and Bibliography
Problems
Challenge Problems

Forms

12.351
12.351
12.355
12.355
12.355
12.356
12.356
12.357
12.358
12.359
12.359
12.359
12.360
12.360
12.360
12.360
12.361
12.361
12.361

MOTION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.363
13.1
13.2
13.3

1.4
1.5
1.6

1.7
1.8
1.9

INTRODUCTION
MOTION PROFILES
13.2.1
Velocity Profiles
13.2.2
Position Profiles
MULTI AXIS MOTION
13.3.1
Slew Motion
Interpolated Motion
1.3.2
Motion Scheduling
PATH PLANNING
CASE STUDIES
SUMMARY
PRACTICE PROBLEMS
PRACTICE PROBLEM SOLUTIONS
ASSIGNMENT PROBLEMS

1.363
1.364
1.364
1.373
1.376
1.377
1.378

1.379
1.381
1.383
1.385
1.385
1.386
1.387


page 1

1. INTRODUCTION

Topics:
•

Objectives:
•

1.1 Introduction
1.2 Bloom’s Taxonomy
1. Knowledge: remembering of previously learned material; recall (facts or whole theories);
bringing to mind.
Terms: defines, describes, identifies, lists, matches, names.
2. Comprehension: grasping the meaning of material; interpreting (explaining or summarizing);
predicting outcome and effects (estimating future trends).
Terms: convert, defend, distinguish, estimate, explain, generalize, rewrite.
3. Application: ability to use learned material in a new situation; apply rules, laws, methods, theories.
Terms: changes, computes, demonstrates, operates, shows, uses, solves.



page 2

4. Analysis: breaking down into parts; understanding organization, clarifying, concluding.
Identify parts: See Related Order; Relationships; Clarify.
Terms: distinguish, diagrams, outlines, relates, breaks down, discriminates, subdivides.
5. Synthesis: ability to put parts together to form a new whole; unique communication; set of
abstract relations.
Terms: combines, complies, composes, creates, designs, rearranges.
6. Evaluation: ability to judge value for purpose; base on criteria; support judgment with reason.
(No guessing).
Terms: appraises, criticizes, compares, supports, concludes, discriminates, contrasts, summarizes, explains.

1.3 Examples
1.4 Summary
1.5 References and Bibliography
1.6 Problems
1.7 Challenge Problems


page 3

2. DRAFTING
• Drafting was previously a set of techniques (using compasses, angles, T-squares, etc.) for creating drawings that could be understood and used in manufacturing.
• More recently drafting is focusing less on techniques and more on conventions, because of CAD
systems.
• The conventions of drafting are very important because they allow us to define parts in a way
that they will be understood by any engineer, machinist, technologist, etc.

2.1 CONVENTIONAL DRAFTING

• The purpose of drafting is to present technical ideas in precise and concise forms.
• A properly drafted drawing should be understood by any engineer.
• A sample of a drafted drawing is given below.


page 4

Ø0.25

Ø0.006

1.750

M

Ø1.62

Ø2.00

A

A

0.25
2.50
Ø1.0005/0.9995
section A-A
Notes:
1. Break sharp edges to 0.01 max.
2 Drill Ø0.985 ream to spec.


2
part: bushing
date:
etc....

2.1.1 Manual Drafting
• This is the use of drafting boards, pencils, pens, and a number of specialized tools for drafting.
While this method is still very popular, the techniques used in manual drafting are quickly
being displaced by CAD (Computer Aided Design) systems.
• I will not cover some of the manual drawing topics list below, but more information on them
appears in a large number of drafting books.
- lettering
- hand sketching
- drawing ellipses
- etc


page 5

2.1.2 Turning Three Dimensions Into Two (Multi View Drawings)
• The problem with drafting is that the paper is flat, while the object drawn is not.
• To get around this we can develop a number of views to work with.
- Front View
- Top View (Plan View)
- Right Side View
- Left Side View
• This method of developing views is known as Orthographic projection
• This method eliminates the perspective distortion in real vision, thus making it easier for technical depiction.
• In this method, object faces that are parallel to the viewing plane are shown as actual size, but

objects that are not parallel are foreshortened.
• The number of views used is a function of the geometry. For a simple object such as a washer,
only one view is needed. A more complicated object, such as a piston, would require at least
two views.

2.1.2.1 - The Glass Box
• The views are developed as if a glass box was placed over the object. The view from each direction was frozen, and when the box is unfolded, the resulting views are seen.
• Imaging the case below of a small tetrahedron (a three pointed triangle),


page 6

freeze the view
through each
side of the glass
box

cover with
a glass box
the part

Unfold the sides to get
a set of views

• The drawings are layed out with certain conventions. The example above is continued below for
illustration, In the figure extra construction lines are added to show how the drawings in the
different views are related.Note that the top view is related to the side view using a 45° line.
These properties are a result of the ‘glass box’ concept. The folding lines are often shown on
drawings (they have two dashes and one long). Also note that in the figure shown below, the
points in the top view will be the same distance from the folding line as they are in the side

view.


page 7

T
F

F R-S

• The layout of the drawings is done by convention. In this drawing the right side view is to the
right of the front view. If this drawing observed european standards, the right side view would
be on the left hand side.
• A useful method for keeping the large number of points in a drawing sorted is to number them.
For example,


page 8

3

2

1

4
T
F
1


1

F R-S

2,3
3

4

2

4

• The view that is selected as the front is arbitrary, but it should
- be a natural front to the object.
- be the most important view
- appear stable
- chosen to minimize hidden lines in other views
- contain most of the detail

2.1.3 Lines
• The number of lines on drawings will become confusing, therefore this calls for some method
for differentiating between lines.
• Hidden lines are dashed lines used to show lines that not visible.


page 9

• Centre lines are used to show the axis of rotation for an object surface. These lines have long/
short dashes.

• Construction lines are drawn on to help locate final drawing lines. These lines are so light that
they are often not even erased when the drawing is complete.
construction line
centre line
hidden line
phantom line
drawing line
break line
dimension line
leader
cutting plane

• Some objects have disproportionate dimensions. As a result, it may be necessary to ‘break’ them
to show any reasonable level of detail. There are three types of breaks commonly used,
- S breaks - for round objects
- Z breaks - for thin long/wide objects
- freehand breaks - for long rectangular objects


page 10

S break

Z break

freehand break

2.1.4 Holes
• There are a number of holes commonly depicted in drawings,



page 11

Through Holes - these are cut all the
way through an object

Blind Holes - these holes stop part way
through an object

Tapered Holes -

Counterbored Holes -

2.1.5 Special Cases
2.1.5.1 - Aligned Features
• Aligned features - in some cases, features are revolved, and shown at a consistent radial distance, but not necessarily in the correct position.
• Holes are commonly rotated to simplify views


page 12

preferred

• Ribs and wings are commonly rotated to simplify views

Preferred


page 13


• Large features on parts may be rotated to simplify views. small features, such as slots may also
be rotated between views for clarity.
Part is imagined in this
position, but drawn
correctly in the top view

But the part can be drawn, and
correctly dimensioned in the front
view with the bend artificially
removed
• Sheet metal parts start out flat, but are deformed to new useful shapes. Therefore it is common to
draw sheet metal parts in the deformed, and the undeformed state.


page 14

2.1.5.2 - Incomplete Views
• Incomplete views - certain details can be omitted to simplify the view. This method produces
drawings that are not correct, but they are commonly used in practice.
• Some views will end up having an excessive number of hidden lines. To combat this problem,
we may sometimes just leave them out.


page 15

• Large radial/cylindrical parts are often cropped to save space. But, enough is shown to make the
remainder of the geometry obvious.

use half circles


or use a break


page 16

2.1.6 Section Views
• when there are complicated internal features, they may be hard to identify in normal views with
hidden lines. A view with some of the part “cut away” can make the internal features very easy
to see, these are called section views.
• In these views hidden lines are generally not used, except for clarity in some cases.
• The cutting plane for the section is,
- shown with thick black dashed lines.
- has arrows at the end of the line to indicate the view direction
- has letters placed beside the arrow heads. These will identify the section
- does not have to be a straight line
• sections can be lined to indicate,
- when the section plane slices through material
- two methods for representing materials. First, use 45° lines, and refer to material in title
block. If there are multiple materials, lines at 30° and 60° may be used for example. Second, use a conventional set of fill lines to represent the different types of
materials.

2.1.6.1 - Full Sections
• Full sections - generally a straight section line cuts through a part to give a complete view of the
inside. This section typically replaces one of the views that is confusing.


page 17

A


A

A section view
can clarify a view
appreciably

SECTION A-A

2.1.6.2 - Offset Section
• Full sections will experience difficulties when the features do not lie along a single line.