SE 140 Structural & Materials Laboratory Senior Capstone Design Course

SE 140
ROBO-CRANE COMPETITION 2016 RULES

Table of Contents
1. Introduction .....................................................................................................................................................1
2. Problem Statement ........................................................................................................................................2
3. Schedule of Project: Milestones & Deliverables ...........................................................................................2
4. Grading of Project & Deliverables Description .............................................................................................4
Schematic Design Proposal Presentation ......................................................................................................4
Design Development Analysis Report .............................................................................................................4
Mechanical Systems Design Report ...............................................................................................................4
Initial RoboPro Design .....................................................................................................................................5
Design Development Analysis Validation Report ...........................................................................................5
Preliminary SolidWorks Motion Simulation ....................................................................................................5
FEA of Joints and Connections Report............................................................................................................5
Final Report & Presentation ............................................................................................................................5
5. Winning the Bid...............................................................................................................................................6
6. Performance Index .........................................................................................................................................7
7. Corporation Roles & Responsibilities ............................................................................................................8
8. Dimensions & Specifications ...................................................................................................................... 10
Functionality .................................................................................................................................................. 10
Usability ......................................................................................................................................................... 11
9. Materials and Components......................................................................................................................... 11
Rented versus Purchased ............................................................................................................................ 11
10. Preparation of Model Crane ..................................................................................................................... 12
11. Schedule of Competition .......................................................................................................................... 12
12. Competition Testing .................................................................................................................................. 12
Stage 1: Deflection Measurement ............................................................................................................... 12
Stage 2: Motion & Cargo Unloading............................................................................................................. 13
Stage 3: Structural Test ................................................................................................................................ 13
13. Penalties ..................................................................................................................................................... 13

Spring 2016

SE 140 Structural & Materials Laboratory Senior Capstone Design Course

1. Introduction
The Robotic Crane Competition is the UC San Diego Structural Engineering Departments Senior Capstone
Design Project for the Spring 2016 SE140 Structures and Materials Laboratory course. This document
contains the project schedule, grading criterion, rules, and competition details for the project.
The project asks groups of 910 individuals to work together in corporations to design and build a model
of a robotic crane. There will be a maximum of 18 corporations in total. Each group will be responsible for
completing various milestones and deliverables in the following main areas:

Project Management (Bill of Materials, Budget, Timeline/Schedule (Gantt Chart))

Structural Design (Conceptual Design, Component Design, and Final Design)
Structural Analysis (SAP 2000, Theoretical Hand Calculations)
Mechanical Design
Control (Programming of Crane UserInterface using RoboPro)
Construction (Fabrication of Model)
Integrated Design (Solidworks Models, Motion Control, AutoCAD Design Details, integrating
mechanical, structural, electrical, aesthetics, and construction disciplines together)
Precompetition testing of model
Competition
Technical Communication (Interim Reports, Final Report, and Presentation)

Each corporations project will be evaluated in the categories of aesthetics, stiffness, accuracy of deflection
prediction, cargo unloading speed, structural performance, and structural economy. The projects will be
judged and scored by the SE 140 teaching team, who has the authority to accept and reject proposals, and
alter and clarify these rules. If there is ever a question to a rule, the CEO/CFO of the corporation should
come ask the SE 140 teaching team. The final testing will include three stages:
Stage 1 Deflection: Measuring the deflection of the crane under a weight of 15N.
Stage 2 Motion: Actual unloading of cargo from dockside warehouse and placement, as
accurately as possible, of the cargo onto a cargo ship. This must be done autonomously
over a 10minute period using RoboPro (motion control software).
Stage 3 Structural Capacity: Measuring the peak load of the crane and the associated
deflection at peak load. The crane will be loaded to failure. Failure is defined by a drop in
peak load of 20% or deflection of 2 inches.
The rules of this competition allow and encourage creativity in design. Designers should compare the
advantages of different crane designs in order to present the best crane possible. Computer modeling of
proposed cranes using programs such as SAP2000 and SolidWorks is required (each team must include
information as to why the final design was chosen in the final report and it should be based on theoretical
and analytical results). Designers should also carefully consider how they program their crane, so as to
facilitate efficient transport of cargo. The Port Authority, who is the client, requires that proposed cranes be
fully autonomous.

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

2. Problem Statement
The Port Authority intends to replace an aging crane used to unload cargo ships. Proposals are requested
for a replacement crane, which will meet the Port Authoritys requirements as follows:
1. The Port Authority prefers designs that are as efficient and stiff as possible (fatigue has been an
issue with existing cranes), and that are able to unload cargo in the shortest amount of time.
2. Crane designs must be able to safely, carefully, and accurately transfer the cargo from a ships hold
to an existing warehouse while meeting dimensional requirements necessary to not impinge on the
neighboring cruise ship terminal property. The crane can only bear on an existing footing. See
Appendix 1 for site layout.
3. Cranes must be fabricated from a limited selection of permissible components and materials.
4. Any attempt to circumvent the intent of the competition will be grounds for rejection of the model
and termination of the companys eligibility.

3. Schedule of Project: Milestones & Deliverables

The Port Authority is enforcing the timeline of milestones and deliverables listed in Table 1 and shown in
calendar form. All assignments will be due in PDF form on TritonED unless specified otherwise.
Table 1: Milestones and Deliverables

Week
1

2
3
4
5
6
7
8
9
10
Finals

Deliverable
Form Teams on TritonED
Register Corporations
Sign up for Schematic Design Presentation
Schematic Design Proposal PowerPoint
Schematic Design Proposal Presentations
Team Logo Due (jpeg format)
Design Development Analysis Report
Materials Store Opens; Fabrication Begins
Mechanical Systems Design Report
Initial RoboPro Design
Bonus Practice Testing
Analysis Validation Report
Free Practice Testing
Preliminary SolidWorks Motion Simulation
Charged Practice Testing
FEA of Joints and Connections Report
Expensive Practice Testing
Final Construction Documents
Sign up for Competition
Ridiculously Expensive Practice Testing
Impound Completed Cranes
Pre-Test Report
Competition
Final Report
Final Presentation PowerPoint
Delivery of Final Presentation

Spring 2106 | pg. 2

Deadline/Submission
Thursday March 31st 5:00 PM
Friday April 1st 5:00 PM
Monday April 4th 5:00 PM
Wednesday April 6th 12:00 PM
Wednesday April 6th 2:30 PM 6:00 PM &
Thursday April 7th 1:00 PM 4:00 PM
Friday April 8th 5:00 PM
Friday April 15th 5:00 PM
Monday April 18th
Friday April 22nd 5:00 PM
Monday April 25th 5:00 PM
Tues April 26th Thurs April 28th during lab
Friday April 29th 5:00 PM
Tues May 3rd Thurs May 5th during lab
Friday May 6th 5:00 PM
Tues May 10th Thurs May 12th during lab
Friday May 13th 5:00 PM
Tues May 17th Thurs May 19th during lab
Friday May 20th 5:00 PM
Monday May 22nd 5:00 PM
Tues May 23rd Thurs May 25th during lab
Friday May 26th 12:00 PM in SME 145
Monday May 29th 5:00 PM
Tues May 30th Thurs June 1st during lab
Monday June 5th 5:00 PM
Monday June 5th 5:00 PM
Tuesday June 6th 11:30 AM 2:30 PM

SE 140 Structural & Materials Laboratory Senior Capstone Design Course

SE 140 Project Calendar

Sun

Mon
Tue
Wed
PROJECT INTRODUCTION PHASE
28
29
30

27
WEEK 1

3
WEEK 2

SCHEMATIC DESIGN (SD) PHASE

4
5
Sign-up for
Presentations

10
WEEK 3

11

31

Deadline to
Form Teams on
TirtonED

Deadline to
Register
Corporation

SD Proposal
Presentations

SD Proposal
Presentations

Team Logo Due

13

14

15

16

DD Analysis
Report

17
WEEK 4
24
WEEK 5

12

Thu

April 2016
Fri
Sat

18

DESIGN DEVELOPMENT (DD) PHASE

19
20
21

22

23

Mechanical
Systems Design

25

26

27

28

29

Initial RoboPro
Design

Bonus Practice
Testing

Bonus Practice
Testing

Bonus Practice
Testing

DD Analysis
Validation Report

30
May 2016

1
WEEK 6

8
WEEK 7

15
WEEK 8

16

Free Practice
Testing

Free Practice
Testing

Free Practice
Testing

SolidWorks
Motion
Simulation

CONSTUCTION DOCUMENTS (CD) PHASE

10
11
12
Charged
Practice Testing

21
WEEK 9

Charged
Practice Testing

Charged
Practice Testing

13

14

FEA Joints &

Connections
Report

17

18

19

20

Expensive
Practice Testing

Expensive
Practice Testing

Expensive
Practice Testing

Final Construction
Documents

22

23

24

25

26

Sign-up for
Competition

Ridiculously
Expensive
Practice Testing

Ridiculously
Expensive
Practice Testing

Ridiculously
Expensive
Practice Testing

Impound
Completed
Cranes

21

27

June 2016
28
WEEK 10
4
FINALS
WEEK

29
Pre-test
Report

PROJECT COMPLETION PHASE

30
31

Competition

Competition

Competition

Final Report &

PPT Slides

Final
Presentations

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

4. Grading of Project & Deliverables Description

The project will be graded based on the deliverables found in Table 2.
Table 2 Project Deliverables and Weighted Percentages

Deliverable
Schematic Design Proposal Presentation
Design Development Analysis Report
Mechanical Systems Design Report
Initial RoboPro Design
Design Development Analysis Validation Report (Hand Calculations)
Preliminary SolidWorks Motion Simulation
FEA of Joints and Connections Report
Final Construction Documents
Final Report (Pretest report & Final report)
Final Presentation

Percentage
of Grade
5%
7.5%
7.5%
5%
7.5%
5%
5%
7.5%
25%
25%

Each deliverable has its own separate document with guidelines and explanation for the expected content.
This document gives a brief description of each deliverable below.

Schematic Design Proposal Presentation

The project proposal is an opportunity for each corporation to present their initial proposal for a
replacement crane. Proposals should demonstrate a proficient understanding of the problem statement.
In this proposal, do not spend time restating the problem statement, but rather how your proposed design
addresses it. Include an initial budget estimate for your design and very preliminary SAP2000 analysis of
the crane for one load case that identifies critical connections and members and approximates the load
path. This is not a detailed analysis, but should show that you thought about the structural integrity of the
crane for your proposed design and feel confident you can design and analyze it to meet the specifications.
Each corporation will be expected to present a 10minute oral presentation of their conceptual design to
the Port Authority. The use of PowerPoint and/or other visual aids is encouraged.

Design Development Analysis Report

The Design Development Analysis Report should include a more refined design based on feedback from
the Schematic Design Proposal Presentation. This includes a more refined SAP2000 analysis of your
proposed crane that incorporates multiple load cases (including calculating influence lines for a dynamic
load), identifies critical connections and members, reports preliminary results, and presents a detailed load
path. This is still a preliminary analysis of the crane so you should identify potential sources of error in the
model and future work.

Mechanical Systems Design Report

The Mechanical Systems Design should summarize the final design details (including a schematic) of the
mechanical systems. This should include the location of motors and/or sensors, force calculations for
pulleys (demonstrating mechanical advantage and taking into consideration differential friction on various
pulleys to ensure that the cargo is balanced when raised), detailed analysis showing reasons behind
selecting a motor size/configuration, and range of motion of the lead screw, etc. Furthermore, the
mechanical engineer should analyze (using hand calculations) the dynamics of the cargo swinging like a

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

pendulum when the crane moves (i.e., how does the cargo oscillate and how does that impact the
mechanical design and overall performance of the crane during testing).

Initial RoboPro Design

Teams will be required to submit initial RoboPro programs that demonstrate how varying motor
configurations (WormDrive setup, Chain Drive, Pulley System, etc.) will be properly controlled. Teams
should refresh themselves with the Lonnies garage assignment completed in SE 120. The Control Engineer
must describe in detail the process by which the crane will be controlled in addition to providing a graphic
that demonstrates the proposed RoboPro logic and configuration.

Design Development Analysis Validation Report

Teams are required to perform detailed hand calculations predicting the response of their crane in order
to verify their analytical models, in addition to the data presented in the first analysis report. These include
expected truss forces, stresses, checks for buckling, fatigue analysis, and other theoretical calculations
from past courses. Hand calculations should be used to determine if the analytical models are reasonably
accurate. The validation report should include a comparison between hand calculations and analytical
results for critical members, factor of safety calculations as appropriate, and a discussion of potential
sources of error. The report should indicate how the team used or plans on using the results of the hand
calculations to improve the model.

Preliminary SolidWorks Motion Simulation

Using SolidWorks Simulation (Motion), each team must create a video showing their structure in motion.
One of the Integrated Designers is responsible to not only create the motion simulation, but to conduct a
dynamic analysis of the detailed mechanical system highlighting its dynamic response. File format for video
submission will be clarified further in class.

FEA of Joints and Connections Report

Working with the Structural Analyst, the Structural Designer must identify the most critical connections in
the crane and run a thorough FEA analysis on the integrity of the connection. Utilize the data provided on
the strength of JB Weld or aluminum shear/tension strength to optimize the design of the connections to
avoid failure. This report summarizes the final connection design including detailed design drawings. The
report should summarize the iterative design process used to come up with the final design details.

Final Report & Presentation

The Final Report is the summary report for the crane model. It is strongly recommended that corporations
begin work on their report as early on in the design process as possible. The Final Report will be divided
into two sections:
PreTest section that is a detailed document of the crane design process (discusses the iterative
design approach, the final design details, and justifies design decisions). The final design selection
should detail why the final design for the structural, mechanical, and foundation design was
chosen. Detailed connection designs should be provided. Also a discussion of construction and
how the asbuilt structure deviates from the structural design due to challenges in construction
should be included.
Performance section that contains a complete analysis of your final structure, including analysis of
the mechanics. It should describe results from testing and compare the analytical predictions with

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

the actual response of the crane (discusses the performance of the crane under given testing
conditions).
A PDF of the PreTest section must be submitted by the required deadline or your team will forfeit the
competition.
The Final Report will also include a section where teams discuss the holistic building of the crane and how
functional relationships between individual components affect the structure as a whole. How do design
intentions, performance requirements, process of manufacture and assembly, and systematic organization
of various parts of your crane project integrate together?
The suggested format for the Final Report, as well as detailed instructions, will be distributed in a
supplementary handout.

Lab Factor
Final grades for the entire SE 140 course are multiplied by the Lab Factor. This factor represents your
involvement, engagement, and attention in the lab sessions throughout the quarter. The Lab Factor is
assigned individually at the end of the quarter by the TAs and lab staff, and could range from 0.7 to 1.1.
Elements that determine your Lab Factor include, but are not limited to:

Attendance If an absence is anticipated for any required lab session, email Dr. VDE, the TAs, and
lab staff ahead of time.
Preparedness It is expected that all students read the lab instructions and documentations
posted on TritonED.
Involvement Every member of each group must be involved in the lab course. Do not sit and
watch your teammates complete the entire lab task. In contrast, students who are actively
engaging in the labs and using these opportunities to advance their understanding of engineering
concepts (as is the purpose of this course) may receive a factor bonus.
Clean up All lab stations in SME 145 & 147 and equipment must be thoroughly cleaned at the
end of any work session. Leave everything better than when you found it.
Follow all lab rules There will be no exceptions to students who do not follow the signed Lab Code
of Conduct.

5. Winning the Bid

In order to win the bid for the crane proposal competition, corporations must not only perform well on the
final competition days, but win the various milestones throughout the project. The Port Authority is
awarding competition points to the top three corporations for all the items listed in Table 3. The
corporation who wins the highest amount of competition points will be granted the bid proposal for the
crane.
Table 3 does not display the quantity of points awarded, but instead demonstrates which categories are
worth the most on a scale where 5 is worth the most points, and 1 is worth the least points. Corporation
point totals will remain confidential and will be revealed at the end of the competition.
As detailed in the course syllabus, the top three corporations in the bid proposal placing will receive extra
credit points for the entire course grade.

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

Table 3 Scale Representing Points Awarded by the Port Authority

Deliverable
Schematic Design Proposal Presentation
Design Development Analysis Report
Mechanical Systems Design Report
Design Development Analysis Validation Report (Hand Calculations)
Preliminary SolidWorks Motion Simulation
FEA of Joints and Connections Report
Final Construction Documents
Pre-Test Report
Aesthetics
Performance Index
Final Report
Final Presentation

Point Worth Scale

1
2
2
1
1
1
3
4
1
5
4
4

6. Performance Index
Each team must submit one model crane for review and testing. The categories of competition are
aesthetics, stiffness, deflection prediction, unloading speed, virtual cost, peak load (with associated
deflection), structural performance, structural economy weight of the structure, and structural capacity.
Overall performance will also be rated. A crane that catastrophically fails during the Motion Stage of the
competition is not eligible for awards in any category.
The crane model should adequately address the need to transfer cargo from the ship hold to the warehouse
in a completely autonomous manner. A minimum level of competence in addressing this need must be
demonstrated.
Crane models will be graded based on their absolute performance, quality of structural system, and
demonstration of engineering competence. Relative rankings between corporations will hold little weight in
grading. However, groups should recognize that there will be a strong correlation between the quality of
their models and the performance cost and economy of their crane.

Scoring Categories
Aesthetics

Elegance
Quality of Workmanship
Originality
Form meeting function

Stiffness
Least deflection wins this category. Deflection () is measured as the vertical displacement of the cranes
cargo lifting mechanism that is positioned by the crane at one of the cargo bays as a result of a 15N force
(Stage 1).

Deflection Prediction
Best Analysis Prediction Score (APS) wins this category. APS is based on the accuracy of the predicted
deflection for the model crane supporting a 15N force suspended over the ship (Stage 1).

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

= 1 + |
|
2

Unloading Rate
Crane with highest unloading rate will win this category.
Unloading rate will be the ratio of cargo safely transferred over total transfer time (Stage 2). Cranes will be
given 10 minutes to unload as much cargo as possible. Total transfer time will be 10 minutes. Cargo safely
transferred will be defined as per Section 13: Penalties.

Peak Load and Peak Deflection

Peak Load and Peak Deflection will be measured. A 20% reduction in load or 2 deflection will be grounds
for failure. Peak Deflection is measured at the Peak Load.

Weight
Total weight of the structure measured in grams on test day.

Virtual Cost
Virtual Cost will be the total cost of all materials, components, and connectors as described in Section 8:
Material and Components, plus penalties as defined in Section 13: Penalties.
Lowest cost wins this category.

Structural Performance
Structural performance will be rated as:
= () $80,000/

Structural Economy
The most economic crane design will win this category. Economy will be determined as:
= ($) +

40,000 ($ /)
+ 40($/) ()
(/)

Structural Capacity
Structural Capacity will be determined as:
= ()/ () $60,000 (/)

Overall Performance Index: The Overall Winner

Lowest overall Performance Index wins.
PI = SP + SE + SC

7. Corporation Roles & Responsibilities

Corporations must have 910 team members designated with the following roles and responsibilities:
1. CEO/CFO: Primary point of contact with the Client (Port Authority) and conducts overall project
management including oversight of a detailed Gantt chart. Financial responsibilities include overall

Spring 2106 | pg. 8

SE 140 Structural & Materials Laboratory Senior Capstone Design Course

2.

3.

4.

5.

6.

accounting for the project, purchasing materials, and budgeting. The CEO/CFO is the only
representative from the team that can address legal matters with the Port Authority, in addition to
attending weekly meetings with a representative from the Port Authority to receive updates on
critical information and go over all budgetary matters. They are also the primary representatives
that will sign their corporation up for all testing and competition. This person should have good
people skills, be organized and professional, and someone who can motivate and encourage the
team to perform. Responsible for tracking team member time sheets.
Technical Writer: Primarily responsible for all documentation and reports submitted on behalf of
the corporation such as the Schematic Design PowerPoint (week 2), the Design Development
Analysis Report (week 3), the Mechanical Systems Design Report (week 4), the Design
Development Analysis Validation Report (week 5), the FEA of Joints and Connections Report (week
7), the Pre-test Report (week 10), and the Final Report (Finals week). This person should be a strong
technical writer, be organized and be able to consolidate various sections provided by other team
members into a cohesive document.
Structural Designer: Responsible for the overall Schematic Design concept (week 2), refinement of
the design for the Design Development Report (week 3), and the Final design (week 4). This
includes working with the Structural Analyst to identify the most critical joint(s) in the crane, and
conduct a detailed connection design and checks for this critical member using SolidWorks FEA
analysis and hand calculations (week 7). The Structural Designer should work with the SolidWorks
and AutoCAD Designers (described below) to produce design details for the report (Finals week).
Structural Analyst: Preliminary analysis for the Schematic Design presentation (week 2), which
includes the preliminary design concept and identifies critical connections or members and an
understanding of the load path. This analysis is further refined for the Design Development Analysis
Report (week 3), which beyond load path and critical members must include results from a variety
of load cases. Supporting hand calculations that verify/validate the analytical model must be
provided in the Design Development Analysis Validation Report (Hand Calculations) (week 5) to
help identify assumptions in the model that could be incorrect such as connection details, boundary
conditions, applications of loads, and material properties. Fully refined analyses and predictions
for the test phases including fatigue analysis will be required (week 10). This person should be
proficient in SAP2000 and finite element analysis strategies as well as technically sound in
structural analysis theory (for hand calculations).
Mechanical Designer: One engineer dedicated to develop the mechanical systems for the crane
and submit the Mechanical Systems Report with a schematic of mechanical design (location of
motors and/or sensors), screenshot of the RoboPro program, and description of the logic for the
RoboPro controlling the crane (week 4). This person must have a good mechanical sense,
understand RoboPro and work closely with the Control Engineer, and have good statics and
dynamics skills to be able to predict and demonstrate through hand calculations forces in the pulley
systems and the pendulum motion of the structure during dynamic loading. This person must also
be able to utilize SolidWorks to visualize and design a working mechanical system. Also work
closely with the SolidWorks Designer on the final construction documents to detail the final
mechanical design.
Control Engineer: Responsible for controlling the mechanical systems and developing the required
RoboPro programs to operate the crane during testing and competition. Development and
submission of Initial RoboPro Design (week 5). Responsible for orchestrating all required testing
(weeks 59) to fine tune the control program and meet the specifications and goals for the project.
Coordinates the competition (week 10). Responsible for providing schematics of the RoboPro
programs to the Technical Writer for the Final Report and Presentation. In addition to being

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

proficient in RoboPro, the control engineer must be a very calm, patient person who can solve
problems on the fly. The control engineer should be able to delegate tasks to teammates in a
constructive manner in the heat of the moment.
7. Construction Engineer: The Construction Engineer is responsible for the entire fabrication of the
crane. Work with the CEO/CFO to identify materials necessary for purchasing (week 3 and as
needed). Responsible for coordinating fabrication (throughout weeks 48) and asking the
CEO/CFO to schedule other members of the corporation to assist with fabrication as the Gantt chart
allows. The Control Engineer must document when asbuilt changes deviate from the original
design details due to construction challenges or material limitations, communicate this to the
SolidWorks and AutoCAD Design Engineers (see below) to ensure final SolidWorks/AutoCAD
models are accurate, and provide information to the Technical Writer for the Final Report. This
person needs to be very good at hands on construction, have patience to produce high quality
products, and work well delegating tasks to all members of the corporation in conjunction with the
CEO/CFO.
8. SolidWorks Design Engineer: Communicates with structural designer and mechanical designer to
ensure final design can accommodate structural loads and mechanical systems. Develop a
preliminary Solidworks model for the Schematic Design Proposal Presentation (week 2). Develop a
more refined Solidworks model for the Design Development Analysis Report (week 3), develop the
Preliminary SolidWorks Motion Simulation (week 6), and work with the Structural Analyst to use the
model to assess dynamic response of the mechanical systems. Finalize Motion Simulation and all
drawings/marketing materials for final predictions in the PreTest report (week 10) and for the
Final Report and Presentation (finals week). Work with the Structural Designer, Mechanical
Designer, and Construction Engineer to finalize the Final Construction Documents using SolidWorks
for the submittal (week 8).
9. AutoCAD Design Engineer: Communicates with structural designer and mechanical designer to
ensure final design can accommodate structural loads and mechanical systems. Preliminary
AutoCAD drawings for the Schematic Design Proposal Presentation (week 2), refined AutoCAD
drawings for the Design Development Analysis Report (week 3). Work with Structural Designer to
produce detailed design drawings for the critical connection (week 7). Finalize all AutoCAD detailed
design drawings for the Final Report and Presentation (finals week). Responsible for Integrated
Design section of final report that discusses how all components and disciplines work together and
require synergy for project to come together (details will be provided in Final Report guidelines).
10. Project Engineer: If you have a 10th person it is recommended that you have an engineer assigned
to various tasks as needed. This is the best job of all because you get exposure to all aspects of
the project. This persons tasks will be assigned by the CEO/CFO depending on where additional
support for the project is needed. Project Engineer must track hours spent on each task. This
person must have a flexible personality and be willing to be the jackofalltrades.

8. Dimensions & Specifications

Functionality
The crane must be able to be attached to the playing field within the designated footprint (see
Appendix 1 for location and dimensions). No part of the crane will be allowed to bear on any part
of the playing field other than the footprint.
Information about how the crane will be attached to the playing field will be discussed further.
Cranes must incorporate electromagnet technology for picking up and releasing the cargo.

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

Usability
No part of the crane shall exceed 36 inches in height at its tallest expanded configuration.
Expanded implies the tallest configuration that will be reached during the course of the entire
unloading sequence. Height will be measured from the top of the footing (a surface on the playing
field). See Section 13: Penalties.
No part of the crane shall extend beyond the vertical plane that separates the Port Authority
property from the land owned by the Cruise Ship Terminal during any portion of the unloading
sequence. See Section 13: Penalties.

9. Materials and Components

Cranes must be designed and fabricated from members, connectors, and components only.
Members are defined as any part used in the structural system of the crane that is longer than 1 inch in
any linear dimension. Members must be purchased or rented from the provided catalog. Cranes shall not
incorporate members that are not purchased or rented from the catalog. Purchased members may be
modified in any way, and do not have to be returned. Rented members must not be modified, and must be
returned following the competition.
A connector, as defined by these rules, is any part of the cranes structural system that is smaller than 1
inch in any linear direction; that is, connectors must be able to fit within a 1inch diameter sphere.
Connectors can be purchased from the catalog, fabricated from purchased members, or fabricated from
material obtained elsewhere. A $200 cost will be assessed to each connector that is fabricated from
material not purchased from the catalog. Adhesives that are used to connect members are not considered
connectors. Aesthetics should be carefully considered with the use of adhesives. The use of tape will be
limited to only blue masking tape and only for securing electric wires.
Components are the wires, motors, and switches that are used to control the motion of the crane. Wires,
electrical leads and their connectors shall be purchased from the catalog, and use only as power and
control. Motors and switches are rented, and cannot be altered.

Rented versus Purchased

There is a distinction between rented and purchased components. Crane elements that are rented from
the catalog cannot be modified in any way. Purposeful violations of this restriction will result in ineligibility.
Accidental violations will be penalized as follows:

Corporations will be required to buy the altered part for the full virtual purchase price. If the item in
question cannot be purchased, but is rentable only, teams will be assessed the purchase cost of
renting that part for 1 quarter. This cost will be added to the virtual crane cost. The cost of the initial
rental will not be refunded, nor will it be credited towards purchase.
No rented member that has been altered or modified in any way will be allowed in any portion of
the crane.

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

10. Preparation of Model Crane

Impound of Crane Models
On the due date established in the project schedule, completed crane models must be delivered by each
corporation to the Laboratory Manager. No modifications or alterations to the models will be allowed after
this date and time. No corporation will have further access to their model after that date and before the
competition. Impounded crane models must be completely dry (no wet glue, paint, etc.).

Assembly of Rented Components

On the day of the competition, groups will have a limited amount of time to attach rented motors and/or
other components, which are rented the day of the competition. See the catalog for rental durations. The
Port Authority requires that cranes be fully constructed and wired for components before this assembly
period takes place. Teams should be able to mount rented components onto their crane in as efficient a
manner possible.

11. Schedule of Competition

The following events will occur during competition, which will take place during 10th week.
1. Cranes will be displayed for everyone to view.
2. The cranes, in a predetermined order, will be tested consecutively, with the following procedure:
a. Assembly of rented components must be completed within a limited amount of time. See
Section 13: Penalties.
b. Mounting of crane to playing field.
c. Deflection test.
d. Cargo unloading.
e. Structural Test.
f. Removal of crane from the dock and disassembly/return of all rented components from
each crane.
3. Winners of each category, and the overall winner, will be announced following completion of all
testing.

12. Competition Testing

Fully assembled cranes will be transported to the testing location and bolted to the testing site by the team
and with help from the TAs or Laboratory Manager. Teams will be responsible for connecting the crane
wiring to the USB controller unit. Teams are required to provide their own laptop for controlling their
structure.

Stage 1: Deflection Measurement

After the crane is mounted to the site, each group will be allowed a maximum of five minutes to operate
their cranes to ensure that the cranecontroller program is working correctly. When each team is satisfied
with the setup of their crane, the testing will begin.
Teams will be allowed to use manual or programmed controls to position their lifting mechanism so that it
is positioned 5.5 inches vertically above the bottom of cargo bay #1 (lower left bay as shown in Appendix 1

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

Plan View). A deflection measurement device will be positioned at this location, 15N of force will be applied
and deflection will be recorded.

Stage 2: Motion & Cargo Unloading

Teams will be allowed to calibrate their crane to a starting position. It is strongly recommended to develop
one or more setup programs for this operation. Time will begin when the Laboratory Manager signals for a
team to begin their autonomous unloading sequence. During the unloading, cranes or cargo cannot be
touched or altered in any way. If a crane becomes uncalibrated and/or inoperable, teams will be allowed
to stop the unloading sequence and recalibrate to their starting position. However, time will not be
stopped, and penalties as per Section 13 apply.
The mass of each weight (cargo) to be transferred should be determined by each team prior to the
competition. Below is a summary of the available cargo weights that teams may choose to move. Each
cargo is worth a different score for the PI, as determined by the unloading rate (kg/min).
Red Cargo
1830 grams

Green Cargo
2295 grams

Gold Cargo
2760 grams

Cargo is rectangular shaped, dimensions of the cargo is approximately 6 by 3 in plan and 4 in height.
There are nine different cargos in total, three of each color weight class as listed above. Each of the nine
cargos are unique in the placement of the center of gravity. Corporations must perform calculations of the
center of gravity for each cargo that is chosen to be lifted and then design the crane to accommodate the
chosen cargo. Corporations must lift and move at least three different cargos. There are no restrictions to
which weight class(es) are chosen.
The cargo unloading will begin when the Laboratory Manager presses the start button and begins the time.
After 10 minutes, the unloading sequence will be stopped, and the amount of safely and accurately
transferred load will be recorded.
The Laboratory Manager reserves the right to stop time and interrupt the unloading sequence in order to
make any necessary rulings regarding technical difficulties or safety.

Stage 3: Structural Test

After the 10minute Cargo Unloading test, the cranes will be repositioned at the original starting position
over the ship. A testing cable will be placed at the center of the unloading feature of the crane (this will vary
from crane to crane). This cable will be pulled vertically down, slowly with an increasing force until the crane
fails. Failure is determined by a drop in peak force of 20% or a 2inch displacement of the crane.

13. Penalties
Penalties will be assessed as follows:

Catastrophic failure of any part of the crane during the testing procedures will result in
disqualification and ineligibility for awards in any category.
Encroachment into Cruise Ship Terminal property will be penalized as a dimensional violation, see
the Site Map in the Appendix 1, and Section 7: Dimensions and Specifications. Penalty is $50,000
per incident, added to the Virtual Cost.

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SE 140 Structural & Materials Laboratory Senior Capstone Design Course

Failure to comply with the crane height maximum (see Section 7: Dimensions and Specifications)
will result in a $25,000 one-time fine added to the Virtual Cost.
Any cargo unit that touches any part of the playing field other than the ship and storehouse will be
penalized by adding $5,000 per incident to the Virtual Cost.
Any load that does not land standing in the ship will be considered damaged cargo and will not be
counted.
As per the discretion of the Laboratory Manager, cranes that damage the walls of the storehouse
will be subject to a onetime fine of $75,000, added to the Virtual Cost.
Failure to fully assemble the cranes rented components within the 10-minute assembly limit during
the testing schedule will result in a penalty of $1,000 per half minute, to be added to the cranes
Virtual Cost.
If a team member touches any part of the crane or cargo, or must restart because of miss
calibration, a $5,000 penalty will be added for each occurrence to the Virtual Cost.
Accuracy in placing the cargo into the ship is important to the Port Authority. Any portion of the
cargo transferred that is placed outside of the bulls eye, will be subject to reductions in terms of a
percentage of the cargo successfully placed on the target.
o Bulls Eye (Red): 100%
o Yellow: 90% (10% reduction)
o Blue: 80% (20% reduction)

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