Mechanical Level 3 - Advanced System Design

Learning Objective

Design complex mechanical systems with multiple integrated mechanisms and motion paths, including four-bar linkages and cam-follower systems; perform dynamic analysis (inertia, vibration, resonance) and simulation-based optimization for moving systems; understand swerve drive design and kinematics as an advanced drivetrain option; apply geometric dimensioning and tolerancing (GD&T) when producing manufacturing drawings; and lead subsystem integration with electrical and programming teams. This level typically takes a full season and centers on a capstone project reviewed and signed off by a mentor -- this is where students move from following instructions to operating independently and making informed design tradeoffs.

Prerequisites

• Mechanical Level 2 - Mechanism Design & Analysis
• CAD Level 2 - Part Design & Assembly
• Manufacturing Level 2 - Power Tools, Machining & Digital Fabrication

Primary Resources

• Citrus Circuits (1678) Technical Training resources
• Citrus Circuits: A Shooter Mechanism -- From Concept to Competition (archived copy; Citrus has since reorganized their site)
• Swerve 101 (Jeremy Z, Team 694; archived copy via Citrus Circuits)
• ReCalc
• ILITE Drivetrain Simulator (Chief Delphi thread)
• Chief Delphi: Should FRC Students Use GD&T?

Tasks

1. Advanced Mechanism Design

   • Design a four-bar linkage for a specific required motion
   • Create a cam-follower system for a specific application
   • Analyze instant centers and velocity for a linkage
   • Design a manipulator with three or more degrees of freedom

2. Dynamic Analysis & Simulation

   • Calculate system inertia and dynamic loading for a moving mechanism
   • Analyze vibration and resonance risks in a design
   • Use CAD-integrated simulation tools to validate a design before building it
   • Perform a trade study between two or more design alternatives

3. Swerve Drive Design

   • Understand swerve drive kinematics and why it is more complex than tank or mecanum drive
   • Evaluate the tradeoffs of building versus buying a swerve module
   • Understand the control requirements (closed-loop PID, encoders) that swerve depends on

4. Manufacturing-Ready Design (GD&T)

   • Apply geometric dimensioning and tolerancing (GD&T) basics to a manufacturing drawing
   • Produce a drawing package that a machinist could build from without additional clarification

5. Cross-Functional Leadership

   • Lead mechanical development for a subsystem from concept through build
   • Coordinate directly with electrical and programming leads on subsystem interfaces
   • Resolve a real integration conflict between subsystems
   • Capstone project: independently design, build, and document a complete robot subsystem, reviewed and signed off by a mentor

Level 3 Completion Requirements

• Mentor-reviewed capstone subsystem project, independently designed, built, and documented
• Successfully lead a cross-functional integration effort with electrical/programming counterparts
• Produce a manufacturing drawing package that meets GD&T basics
• Complete a dynamic analysis and simulation-based design trade study

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