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After successful completion of the course, students are able to independently develop, build and test mechatronic systems. In doing so, the students can predict the characteristics and interactions of the various mechatronic components and software aspects as well as adapt them accordingly for the development and integration of the required systems. In addition, students will have in-depth practical knowledge and skills in the development of mechatronic systems. Students are able to develop and commission an autonomous wheel-based mobile platform, which fulfils a defined spectrum of tasks. Furthermore, they have further developed their skills regarding problem-solving and teamwork in the context of interdisciplinary problems.

The Intelligent Machine Design Lab course aims to enable students to develop and build complex and powerful mechatronic systems with high social/economic relevance. The goal of this course is the design and implementation of a small mobile robot with “capabilities” of field rescue forces support in mass accidents/ catastrophes. The students are divided into teams, and each team will build its own robot. All teams will compete to see which robot has the best performance based on key indicators.

The students design the robot based on their knowledge through the online materials and tutorials as well as the materials and production methods available in the MUC Maker Space. The robot will comprise the following modules: master processing unit, locomotion, low-level controller, gripper, IR localisation, light beacon and obstacle avoidance.

Master processing unit:

- This module comprises the SBC (Raspberry Pi 4B). Its role will be the wireless communication of the robot to the central PC, main functionality, and communication with the locomotion module and low-level controller via ROS.

Locomotion module:

- This module allows the platform to move and rotate along the arena. Students will be allowed to use the Actuators and actuator drivers from the iCreate 3 robot used in lab assignment #2.

Low-level controller.

This controller is based on the SAME54 Xplained Pro development board used in lab-assignments #4-6. It communicates to the main controller via ROS and generates the necessary signals for the following modules.

Gripper:

- This module will be comprised of a gripper mechanism and its actuation drive. Control signals will come from the low-level controller. The gripper should be able to grasp and lift a 4x4 wooden block (representing the tools).

IR localisation:

- This module allows the robot to localise itself within the arena based on the IMDL IR localization protocol. It is based on exercises from Lab-assignment #5. Specialised details can be found in the annexe.

Light Beacon:

- This module allows the robot to provide a light beam (Power LED) into a position it is commanded to. It should be able to redirect the light beam within 180°.

- Programming (C )
- Basics of electrical engineering (analogue circuits, ...)
- Basics of electronics (microcontrollers, bus systems, ...)
- Basics of machine elements
- Actuator and sensor systems

During the course, students are instructed in project work with team distribution.

- Tutorials and Lectures (for direct transfer of theoretical knowledge)

- Project tasks (to evaluate whether students can transfer the methods they have learned during the tutorials and applied to real-life complex task)

Grade Calculation
Each team member’s grade is based on:

Project Work (same for all):
15% Design & Production Quality
15% Basic Functionality
15% In-Field Challenge

Individual Performance:
15% Daily Work Log (What did I do today? What will I do tomorrow?)
15% Weekly Milestone Meetings
10% Final Presentation
15% Self-Evaluation

Basic Functionality:
Robot must report status, move, detect position, navigate, detect/grasp objects, rotate beacon, control light, and drop cube in box A or B.

In-Field Challenge:
Robot executes a sequence of commands while navigating the arena.

Milestone Meetings:
Each member must understand all project areas, not just their own.

Final Presentation:
10-minute overview of system concept, design, and decisions.

Self-Evaluation:
After the project, each member evaluates their teammates.

- Paul Scherz and Simon Monk, ‘Practical Electronics for Inventors’, 4th rev. ed McGraw-Hill Education
- Eric S. Roberts, ‘The Art and Science of C’, Pearson Education
- Robert l. Norton, ‘Design of Machinery’, Mcgraw-Hill Europe; 3rd Revised edition
- Clarence W. De Silva, ‘Mechatronics: Fundamentals and Applications’, Apple Academic Press Inc.
- Shimon Y. Nof, ‘Springer Handbook of Automation’, Springer; 2009. Edition
- Jan Awrejcewicz, ‘Mechatronics: Ideas, Challenges, Solutions and Applications’, Springer; 1st ed. 2016 Edition

- Rochdi Merzouki, ‘Intelligent Mechatronic Systems; Modeling, Control and Diagnosis’, Springer; Softcover reprint of the original 1st ed. 2013 Edition
- Paul Horowitz, ‘The Art of Electronics’, Cambridge University Press; 3. Edition