Project: Mars Lander

March 2017

Contents:
 1. Client brief
2. Specifications:
- Bill of materials
- Method
- Tools
3. Drawing package:
- Cover page
- Front view
- Top view
- Side view
4. Risk management
5. Tender evaluation
6. Gantt chart

Client Brief:
Problem Statement:
Your client, EMPACT, has approached you to design a prototype Mars
Lander/Rover, for an upcoming bid to be a part of an international space
exploration consortium. You have been approached to provide an innovative
solution to the final deployment stage of a rover, and therefore you must design,
construct and test a small scaled vehicle that is capable of deployment and
withstanding a vertical drop. The client brief is outlined in Sections 2.1 through to
2.3. The client can be contacted through a discussion board on blackboard,
though remember that although the client aims to respond to any
communication within two (2) working days, this may not always be attainable.

Design statement:
EMPACT requires a vehicle to be constructed such that it is capable of being
tested by rolling down a slope between 30-45 degrees for 2 metres, and falling
through a vertical drop of 1 metre without sustaining any significant damage.
The prototype must conform to constraints given in Section 2.2, and will be
evaluated according to the variables given in Section 2.3.

Design constraints:
1. Conceptual: The prototype must be designed to travel in a self-
guided straight line for 2 metres, down a slope set to not less than 30
degrees. Following this free roll, the prototype will be subject to a
vertical drop of 1 metre, and must land and stay on its wheels. Due to
the nature of the project, the final design will be required to carry a lot
of heavy equipment. This has been scaled down to require the
prototype to carry a weight, in the form of 600ml water bottle. This
cargo must be loaded onto the top of the prototype, with no complex
assembly required (i.e. closing a box flap is acceptable, screwing a
panel is not). The condition of the cargo must be easy to assess
without directly accessing the prototype (i.e. visual inspection from
~1m distant).
2. Dimensional: The entire footprint of the prototype vehicle must fit
within an A3 sheet of paper (420mm x 297mm), with no portion of the
assembly overhanging the boundary. The maximum height of any
portion of the prototype is 210mm. There must be at least two axles on
the prototype, and the wheels (or tracks) must allow the prototype to
move down a slope of 30 degrees minimum.
3. Materials: The prototype must be designed to cost less than $30
when pricing materials using the spreadsheet provided on blackboard.
3D printed components are permitted provided that the total 3D cost is
less than 25% of the theoretical prototype cost (as determined by the
spreadsheet). 3 Recycled materials may be used in lieu of purchased
materials at the construction stage, and this may result in a higher
performance level (Appendix A). The actual cost is calculated by
considering the cost incurred by the contractors (e.g. if a pack of 4
items is bought for $1, but only one is used, the actual cost is still $1).
Recycled materials can be accounted for with a cost equivalent to 50%
of the spreadsheet cost
 4. Impact & Cushioning: The prototype must be designed such that
no manual control is required between the release onto the slope, and
the end of testing (after the impact on the floor). The prototype must
end testing with at least one set of wheels in contact with the ground,
and without damage or spilt cargo.

Specifications:
Bill of materials:
Item Dimensions/ Size Purpose Cost
Wood (MDF) 1200*450*16mm Acting as the $9
wooden base, and
bottle necking
mechanism.
Wood (Pine) 1000*70*35mm This will be acting $2.80
as the supporting
structure under
the MDF base.
Pool noodle 1500*70mm This will form the $2
wheel of the
rover.
Steel rod 1000*6.3mm This will be acting $2.60
as the axle.
3D printed Rims 5*50mm These will be
used in order to
support the wheel
shape and
structure.
Velcro tape 25*1000mm This will be used $3.00
to hold down and
secure the water
bottle throughout
its journey.
Water bottle 205*70mm This will be used N/A
for testing the
rover
Ball bearings 7mm This will reduce $1.5*4
the friction and
inevitably allow
the smooth
rotation of the
axle.
Construction Method:

Base of body:

Collect materials needed for body and inspect for faults.

Ensure materials fit measurements shown in drawings 3 and 4.
Glue both side planks to the body as shown in drawing 3.
Leave aside for 24 hours to allow glue to dry.
Drill 2 screws, per side through the top of the body and into side lengths
8mm from edge and 40mm in from the front and the back of car.

Bottle Constrainer:

Collect materials needed for bottle constrainer and inspect for faults.
Ensure materials fit measurements provided in drawing 3 and 4.
Glue both bottom ends of wood in position with the main body as
displayed in diagram 4.
Leave aside for 24 hours to allow glue to dry.
Apply screws to both ends of Velcro strap, and place on either side of the
main body, aligned with the middle of the bottle holding mechanism.
Leave aside for 24hrs to allow glue to dry.

Wheels:

Collect material needed for wheels and inspect for faults.

Cut four wheels with thickness of 25mm from the pool noodle.
Drill a hole through the middle of the pool noodle, directly in the center
with a width shown in drawing 5.
Drill four holes in each pool noodle with diameter and placement shown in
drawing 5.
Design the outer rims of wheel displayed in drawing 5.
Design the inner rim of the wheel shown in drawing 5.
Use 3D printer to print off the outer and inner rims for each wheel.
Assemble the wheel by putting the outer rim through each foam wheel
and joining them by connecting the inner rim.

Axles:

Obtain the steel rod with dimensions given in the material list.
Cut off two pieces with the length of 280mm.

Wheels to Axles:
At the ends of both axles wrap tape to ensure it will not move within the
wheel.
 Pass the axles through the bottom of the main body.
Place the wheels onto the axles and use super glue to fix them into place.
Leave for 24hrs to allow glue to dry.

Caution when gluing, if glue gets inside the bearing will not run smoothly.

Techniques:
Gluing technique:
Ensure glue is spread evenly over wood. This can be achieved by using a
notched trowel to spread the glue. When drying apply weight upon the
freshly glued wood, this will ensure no air bubbles in the glue thus making
the join stronger. This can be achieved through either putting weights e.g.
bag-o-lead, or clamping together the two pieces of wood being glued.

Tools:
1. Drill: with the drill bit size as small as 3mm diameter.
2. Saw: this will be used for cutting the metal axle and wooden base to the
required dimensions throughout the construction.
3. Screws: This tool will be used throughout the construction, for example
screw will be required in order to attach the Velcro straps to the rover.
4. Wood glue: This will act as an adhesive that will hold together the structure
of the rover, providing the rover with great structural integrity.
Drawing package:
Cover page
Drawing package:
Front View
Drawing package: Top
View
Drawing package:
Side View
Drawing package:
Wheels
Drawing package:
Wheels (Exploded
View)

Risk Management:
Design Phase:
Hazards Risks Likelihood and Mitigation Residual Risk
Consequence
Poor May not depict a Possible: This is These risks can be There is still a risk
Formatt product that was a possibility, as avoided by ensuring that the design w
ing envisioned: during the that the person not meet the
Therefore, this designing designing the rover is expectations of th
might inhibit the process it is both familiar and client, hence this
rover to be difficult for the capable of designing a a risk that simply
designed to the designers to try very coherent model must be accepted
liking of the client, and picture and of the rover. This can as regardless of th
hence resulting in speculate what be achieved by using a selection process
an unwanted the client has in design program that is that you go throu
financial loss. mind in regards familiar with the to pick a preferred
Furthermore, due to the outcome designers. Ensure that designer, there is
to being unable to of the design the format is clear by still a possibility t
meet the wants of from simply a offering multiple views design will be
the client it may string of and angle of the poorly formatted
impact the conversations design, whilst through human
reputation of the that have taken implementing the use error and hence
designers. place between of different line poorly interpreted
client and techniques in order to
designers. indicate particular
Hence, the areas of the design. i.e
construction and dashed lines, dotted
formatting of the lines, bold lines etc.
design isnt
always
necessarily
going to please
the clients
expectations.

I.T Hardware Likely: The risk This issue can quite Again, no matter
Issues malfunction: A of hardware simply be avoided how many
hardware malfunction, and through the use of an preventative tacti
malfunction could ultimately data external hard drive / that you take in
very well result in loss can be seen USB that would enable order to retain an
a complete loss of as a possibility to designers to save hold your design
data/ design work. throughout the their work to after data securely the
This would result design phase of each session of their is always a chanc
in a financial loss a project as it is designing phase. This that I.T issues will
and could lead to not uncommon will ensure that the cause a failure an
unwanted conflict for computers to designers arent corruption of data
and tension experience simply just relying on Therefore, again
between the difficulties with the integrity of the this is simply a ris
designers, client retaining computer being used that must be
and constructors information. The to retain their design accepted by the
due to being issue is that it is work, hence avoiding designers.
unable to meet hard to detect any major loss of data
the required when these throughout the entire
deadlines. errors may design phase.
 occur, so it is Furthermore, this will
often the case ensure that the design
where designers is ready and available
are caught off for presenting on time,
guard when meeting the schedule
cases like this and demands of both
occur. the client and the
constructors.
Ultimately this will
retain a good working
relationship and
uphold the reputation
of the designing team.

Financial deficit: Likely: This can This can be mitigated The risk of going
Going This may be be considered as through giving the over budget may
over caused due to the a likely designers a more still be present, th
budget underestimation possibility due to flexible budget, or is due to the fact
of the time it will the fact that it is ensuring that the that the budget
take to build/put often difficult to designers are very given to the
together the find materials strict when it comes to designers by the
design, hence the that meet the what is actually client may be
client may require quality and fall necessary to have unrealistic, hence
paying the within the implemented in the could be near
designing team budget of the design. Therefore impossible to
more for their client. It is also there can be a process design a project
work. This risk hard to gauge of elimination that can within the given
could also be how long the take place where the cost constraints.
apparent due to designing designers decide what Therefore, the risk
the designers process will take. is/isnt actually needed will remain, and in
inability to specify for the design in order this case must be
and find materials to meet the specified accepted.
that meet the budget.
discussed budget
and expectations
of the client,
hence resulting in
the client having
to spend more
than desired on
the product to
build the design.
Construction Phase:

Hazards Risks Likelihood and consequence

Client Designers Contractors Client Designers Contr
1 Use of The risk for The risk for Electrocution, The likelihood of The likelihood See pa
Tools/Powe the client the cutting of this happening is for this below
r Tools: is that designers limbs, drilling low as the tender happening to
they may is that yourself application the designers is
get a they may completed by the low as they
2 Wood/ product have their Eyes getting contracting team would be able
Super glue that is not reputation stuck should have to to pick those
up to their damaged if together, meet the who they
standards the final toxic, standards of the believe will be
because of product is appendages designers who able to produce
the faulty not up to getting stuck get their the best final
workmans the together standards from product. The
hip of the standards the client, but the consequence is
3 Working contractin of the Splinters, consequence is also low as
with wood g company client. nails in high as they will they can claim
and sharp hands, cut get a product that that they were
materials hands or they are not not the ones
appendages happy with. who made the
on sharp final product
materials. and they
passed the
tender
evaluation
Mitigation Residual risk
Client Designers Contractors A risk that you cannot get rid
1 To mitigate In order to Introduce a set of rules. Only completely or mitigate, is th
the risk of protect their people with experience malfunction of a power tool
getting a reputation, should use power tools and leading to injury of the user,
product that the designers less experienced people example a saw blade snappi
they are not need to make should only use them in the and a piece of the blade
happy with, sure that the presence of those will puncturing the skin of the us
the client contractors considerable experience. The extent of the injury can
needs to understand Power cords need to be kept but it is extremely unlikely th
make sure the designs, away from water. this will occur so the residua
that the and that the Safety glasses need to be is low.
designers contractors worn at all times
that they are
2 hire for the supervised If glue is splashed onto The residual risk is minute fo
project are while hands, wash them use of wood glue and super
able to constructing immediately. Gloves can be as the mitigation techniques
make the product worn to prevent it getting on highly effective in reducing t
designers hands risk
that are Do not touch any part of
easy to your face whatsoever when
understand using glue
3 and that the Gloves can be worn to Splinters are unpredictable,
contractors prevent splinters. Sharp despite the fact they are com
are materials should be handled the severity of the injury is l
supervised with care and steel cap therefore the residual risk is
during the boots can be worn to to none.
construction prevent injury to feet
process

Risks explained:
1. Power tools and manual tools cause the largest amount of injuries
annually in the tool category that includes garden tools, lawnmowers,
snow removal tools and medical equipment according to the National
Electronic Injury Surveillance System (1). Power tools were responsible for
217,393 injuries in 2015 (1) and Non-Power Tool were responsible for
200,803 injuries in 2015 (2).
Electrocution is always possible when power tools are in use, and therefore
precautions need to be taken to reduce this risk. Electrocution can lead to
heart failure and possibly death and needs to be taken seriously. If water is
around any of the power points or extension cords, if they are being used,
there is potential for the user to be electrocuted.
When saws (electric or manual) are being used, caution must be taken. It
is quite easy to cleave off a finger or gash an arm with the incorrect use of
a saw. When using power tools
Though a highly irregular risk it is possible to end up drilling a hole through
your own hand if correct technique and safety precautions are not used.
Full concentration is required when using power tools as it is to go too far
through a hole and end up going through your hand on the other side.
2. Super glue and wood glue are very strong adhesives and can be quite
dangerous if not handled correctly and with caution. It is easily possible to
 get wet glue on your hands when using these glues and then touching
sensitive areas on your body, for example, rubbing your eyes when you
have glue on your hands, leading to getting glue stuck in your eyes or
gluing your eyelids together leading to immense irritation and possible
damage to your eyes. Even just getting your fingers stuck together could
be an issue as the adhesive is quite strong and could take off layers of skin
which, while not serious harm, can be quite painful.
3. Sharp Materials and splinters are always a risk when using sharp materials
and when working with wood. The injuries sustained can vary from
someone getting a splinter while holding a piece of wood, someone
sustaining a small cut from a sharp edge to someone opening a large gash
on an arm or foot from mishandling a sharp tool or material.

Likelihood and consequence in depth:

1. Injuries with tools and especially power tools quite common place, but
with a wide range of severity. For example it is not rare that a person
might give them self a small cut from a knife or a file or a burn from a belt
sander. There are low severity injuries but are quite likely, on the other
hand, electrocuting yourself, drilling a hole through your hand or cutting
open an arm are injuries that are highly unlikely but are higher severity
injuries. According to the National Electronic Injury Surveillance System,
42.87% of power tool injuries were to fingers (1) , while only 19.43% of non-
power toll injuries were to fingers (2) . Extra caution needs to be given when
using power tools as 14,176 injuries involving power tools were to eyes (1),
and only 3,474 injuries caused by non-power tools were to eyes (2). The
eyes are an extremely delicate part of the body and need to always be
protected, so extreme caution must be used when using power tools.
People have died when using power tools incorrectly, even though this is
highly unlikely, full attention must be given to the task at hand to avoid
any sort of injury.
2. Glue is a very tricky substance to work with, and can lead to minor
injuries. Wood glue and epoxy are both extremely sticky and hard to pull
apart once set. If the glue gets accidentally applied to fingers and they are
placed together while the glue is drying, attempts wo pull the fingers apart
could pull off multiple layers of skin which is quite painful. Though this is
likely to happen it is only of a minor severity as it will not impact the user
in any way.
On the other hand, if glue ends up near the eyes it is slightly more
dangerous. If glue gets on the users fingers and they touch their eyes in
any way, the glue has the potential to get into the eye or become stuck on
the eyelids leading to severe irritation and sometimes vision impairment.
This is a highly unlikely situation but is of a mild severity as it can affect
the users vision which can lead to other risks as the ability to see clearly
and focus becomes impaired.
3. Sharp materials are an ever present risk in construction and if poor safety
standards are used along with incorrect procedure. Splinters and minor
cuts are highly likely when using wood and other sharp materials but are
of low severity as they will not permanently damage you. Dropping
materials on feet can bruise or cut feet and quite possibly break some of
the smaller bones in the foot, but it is unlikely that any bones will be
 broken and it will mostly be a low severity bruise that will be worn if a
material is dropped on a foot.

Testing Phase:
Risk Hazard Likeliho Consequen Mitigation Residual Risk
od ce
Small Not lining Possible Minor Ensure the model If the model is
scratches up the vehicle is lined up poorly designed
and cuts: model straight facing and/or constructe
Injury from vehicle in down the ramp to then there is still
broken correct guarantee that it risk of it being
pieces to straight rolls in a straight damaged on impa
those orientation/ line and falls off with the ground.
involved in vehicle the end of the This therefore doe
the testing veers of the ramp. not eliminate the
stage. ramp/break Have any people risk of debris or
Injuries s after involved with the materials injuring
sustained landing testing stand people involved.
can vary model several metres The residual risk i
from a small vehicle falls away from the reduced overall a
scratch to a and breaks. landing area. people are a safer
larger cut or distance away fro
wound. any potential deb
or material comin
off the model.

Loss of Not lining Possible Moderate Take time and If the design and
marks: up the consideration in construction
Loss of model the design process is done
marks can vehicle in process, choosing carefully and
result from correct materials, adequately then t
not lining up straight techniques and risk of damage to
the model orientation/ specifications that the model/load or
properly or vehicle will keep the not satisfying the
from poor veers of the model from client brief is
design ramp/break getting damaged reduced.
and/or s after while satisfying The risk of losing
construction. landing the client brief marks will be
As the model and therefore the reduced with the
model was vehicle falls clients needs. more care put into
not and breaks. Ensure the model the design proces
successful vehicle is lined up The more adequa
and was straight facing the construction,
damaged, down the ramp to the more significa
not guarantee that it the decrease in ri
completing rolls in a straight of marks being los
the clients line and falls off
needs leads the end of the
to a lesser ramp.
overall mark
for the
project
assessment.
Unsuccessful Testing a Possible Moderate In order to The more thought
design model that complete the time and research
Clients has not (in a real life needs of the that goes into the
needs not been project the client the design design process, th
met: designed to severity process needs to less likely that the
withstand would be be thoroughly model will be
Client is left the fall/drop major to thought through unsuccessful in
with an required, or extreme and each aspect keeping the load
unsuccessful testing a depending of the model undamaged when
design that model that on the needs to be dropped.
does not has not projects considered so This significantly
fulfil their been importance) that the design reduces the risk o
needs as per constructed works properly. the clients needs
their brief. appropriatel The designers not being met and
y or that and contractors therefore is more
has not need to likely to guarante
been completely and design that is
constructed understand the successful.
in client brief and
accordance the clients needs.
to the The model needs
specificatio to fit the client
ns. brief entirely to
guarantee its
success.
 Tender Evaluation
Criteria:

Client: EMPACT

Project: Mars Lander/Rover

Engineering Foundations Principles and Communications

 Contents:
1.0
Introduction.................................................................................................................
............................................3
- Tender Evaluation Criteria Introduction
2.0 Criteria
Summary......................................................................................................................
.............................3
- Criteria Titles, Details and Mark Allocation
3.0 Criteria
Explained.....................................................................................................................
.............................4
- In Depth Explanations of Criteria
 1.0 Introduction

This document outlines the summary and explanation of each criteria that will be
used by MARS CARS to evaluate the three potential companies bidding to
construct EMPACTs Mars Rover/Lander. The successful tenderer for the
construction will be the company that satisfies the most criteria that follows,
hence by being awarded the most marks.

Marks are awarded on a scale basis. M.A.R.S. Cars will consider the criteria and
the groups abilities in that area, and determine where they rank on the scale for
each aspect. Any half marks will be rounded down.

Example: The below will be awarded 4 marks instead of 4.5.

0 Marks Available 5

2.0 Criteria Summary

Criteria Details Marks Total Weighting

Professionalism Trustworthiness
Organisation
Time Management
Respect
Communication
Team Work
Previous Experience Construction Experience
Past Performance
Construction Technical Skills
Support Resources
Access to Required Tools and Resources
Understanding of Design

2.0 Criteria Explained

 The contracting company bidding fo the design of the Mars Lander/Rover must
be able to provide sufficient evidence to MARS CARS relating to these criteria to
support their bid for construction.

3.1 Professionalism [30

marks]

i) Trustworthiness (5 marks)

The contracting company must be able to provide evidence for their responses to
the criteria and tasks that are laid out in this document and in the design
package. The evidence given must be true and honest. Any information given to
MARS CARS by the bidding company that is deliberately misleading or not
accurate will be considered an act of dishonesty and will affect the bidding
companys mark.

ii) Organisation (5 marks)

The company must show skills of organisation and must display the capabilities
of structure and preparation. These skills will be assessed during any meetings
taking place, as well as through communication via email, text etc.

iii) Time management (5 marks)

All meetings are attended by the specified members on time and all work
submitted by the contracting company is on time without issues. This can be
evaluated by the punctuality of the contracting company at the meetings
between M.A.R.S Cars and the contracting company. Time management will also
be assessed on communication via other methods such as email and text.

iv) Respect (5 marks)

All members of the contracting company must show signs of respect towards
each other and towards members of M.A.R.S. Cars. All members of the
contracting team speak in turn and do not speak over other members of the
meeting. All language, verbal and bodily, should show signs of respect and be of
a professional standard. Offensive/abusive language will not be tolerated or
accepted.
v) Communication (5 marks)

This includes communication between M.A.R.S. Cars and the contracting

company, as well as communication between team members of the bidding
company. This criterion will be evaluated during any meetings that take place
where MARS CARS will assess the companys communication skills.

vi) Teamwork (5 marks)

The team bidding must display the ability to work together as a team throughout
the tendering process. Skills associated with teamwork that will be judged
include but are not limited to communication, cooperation, problem solving and
organisation as a group.

3.2 Previous experience [15 marks]

i) Construction Experience (5 marks)

The company must provide evidence of experience that any members have in
construction. Construction includes models and prototypes, wood and metal
work, electrical work, as well as constructions during high school careers etc.
Past experience is seen as a necessity by M.A.R.S. Cars in this project and is
considered an important aspect of the criteria.

ii) Past Performance (10 marks)

Another aspect considered of high importance is past performance in similar

projects or assessments. These can include high school assessments as well as
assessments taken previously in the engineering course.

3.3 Construction [35

marks]

i) Technical Skills (10 marks)

 Power tools are dangerous when used by someone with no experience and
limited knowledge. Knowledge of correct techniques needs to be shown by a
simple test. A block of wood will be provided along with a power drill and a hole
is to be drilled through this block of wood in an efficient and safe way.

ii) Support Resources (5 marks)

The company must provide evidence of any supporting resources they have that
will aid them in the construction process. These resources include access to
supervision, teaching, instructors, equipment, internet etc. that will

iii) Access to Required Tools and Resources (10 marks)

The Contacting company need to provide evidence of owning a drill or having

easy accessibility to one. One way this can be proven is if we give a piece of
paper with a code on it and they must provide a photo of the code

iv) Understanding of Design (10 marks)

During meetings, the contractors must demonstrate their knowledge and

understanding of the M.A.R.S. Cars Mars Lander design. This criterion is vital
towards the construction process as a good understanding will ensure that all
methods and specifications are followed precisely, leading to a model that will
satisfy the clients needs.
 Jake Dubois Designer Yatin William Power Khan John Other EFY EFPC Deadlines
s Patel Deadlines

Assignment 1- Lab Report- Stage 1 Design Package Wk 5

ASTR1002 MAEN1000

ASTR1001 Visual Diary ASTR1001 Visual Diary Wk 6

1a- 1a-

TFW
Gantt Chart:

Tender Application Stage 2 Contractors TFW

Essay 1b & Assignment 2- Essay 1b & Lab Report- Wk 7

2A maths- ASTR1002 2A maths- MAEN1000 Quiz 2
ASTR1001 ASTR1001 Online- COMP1004

Mid Sem Test- Stage 2 Designers Wk 8

MAEN1000

MAEN1000 Lab Report- Wk 9

COMP1004 Mid Sem Test- Handover Wk 10

In-class Essay Lab Report- Engldentity Reflection Wk 11

test- ASTR1002 MAEN1000
Contractor Keanu Radford Hong-yi
s Wang

COMP1004
Assessment 2

MINE1002
Assessment 2