2016 Warman Competition

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29thWARMAN

DESIGN & BUILD COMPETITION

2016

Project RAVINE

Restore Access Via Independently Navigated Equipment

CONTEXT

The inhabitants of Gondwana, a small planet on the outer fringes of our Galaxy, have recentlyexperienced a number of significant quakes. These seismic events have resulted in significant damage toessential infrastructure, including roads and bridges, leaving many of the Gondwanan people isolated andcut-off from food and general supplies.

DILEMMA

A huge Gondwana quake has destroyed a bridge that originally crossed a narrow deep ravine. The bridgewas used to transport food and general supplies to a crucial community. Fortunately, supplies are pre-

packaged in robust spherical containers. Strong and gusty winds through the ravine means transport byaircraft is not suitable. Additionally, there is also a danger the banks on each side might suddenlydisintegrate, so replacing the bridge in the short-term is not possible.

CHALLENGE


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CHALLENGE

Competition Guidelines

Version: 1.0 Released: 5 February 2016

ELIGIBILITY

G 1. Teams that are eligible to represent their campus in the National Final will consist ofstudents from a first or second year engineering design course/subject/unit in an Australasian(or other countries, by arrangement) mechanical-based BE or 3+2 ME programme. Teamsshall consist of at least two students, with teams of three or four strongly recommended, but itis recognised that larger teams may be educationally appropriate at some universities. If analternative team structure is envisaged, the National Organiser should be consulted to ensurethat other teams are not unreasonably disadvantaged.

SAFETY

G 2. Safety is of paramount importance when participating in this competition. Allengineers should know that injury and damage to equipment and the environment occurswhen the control of energy in a system is lost.

G 3.

As appropriate, protective clothing, footwear, safety glasses or full face masks shouldbe worn by students working on systems during construction, testing, and competitions.

G 4. Students are encouraged to carry out a risk assessment for their system prior to

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COMPETITION TRACK, EQUIPMENT AND ENVIRONMENT

G 7.

The competition track shall be fabricated using primarily two sheets of MediumDensity Fibreboard (MDF), each with nominal dimensions 2400 x 1200 x 18 mm, arrangedas shown in Figures 1 and 2 with detailed drawings included as Appendix A. The supportingframe for these sheets may be fabricated by any convenient method.

NOTE: The MDF sheets as supplied in the ACT are slightly larger than the nominal 2400 x1200 dimensions. They are 2420 x 1210 and do not need to be cut down.

G 8.

The two MDF sheets and relevant attached features shall be identified respectively as

Track Segments 1 and 2 as shown in Figures 1 and 2. The attached features shall include;DAR 12 x 12 mm timber, the MDF panels defining the shed walls that form the StartingZone, the MDF panels defining the ravine walls and supports for each end of the tube, a 50mm Outside Diameter (OD) aluminium tube with a collar to prevent it sliding. Collectively,Track Segments 1 and 2, the shed, the ravine walls and the MDF panels supporting each endof the aluminium tube, the aluminium tube and its collar shall be identified as theCompetition Track.

G 9.

The upper surfaces of the two MDF sheets of Track Segments 1 and 2 shall define thecompetition base plane which is nominally horizontal. The heights of the Track Segmentsshall be adjusted so that the height difference between the track segments at the positionwhere the track segments overlap longitudinally (as detailed in G11) does not exceed 5 mm.

G 10.

The competition base plane shall be no less than 300 mm above the supporting floorat the National Final.

G 11.

Track Segments 1 and 2 shall be orientated parallel to each other along their long

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G 18.

The vertical surfaces (2 off) defining the ravine walls shall be formed with 18 mmMDF and be flush with the top surface of the track segment as shown in Appendix A.

G 19.

A 50 mm OD x 3 mm wall thickness aluminium tube shall be supported at an angle tothe horizontal by 18 mm MDF attached to the edges of Track Segment 1 and Track Segment2. The tube shall be located in oversize holes, and prevented from sliding and rotating by asuitable collar fixed to the end of the tube at its highest end, as shown in Figure 1 andAppendix A.

NOTE: 50 mm OD x 3 mm wall thickness aluminium tube can be purchased from a number

of suppliers. For example, a 6.5 m length can be purchased from Ullrich Aluminium for less

than $100 (see:http://www.ullrich.com.au/extrusions/extruded-round-tube).

G 20. All exposed surfaces of the MDF and timber shall be brush coated with one coat ofWattyl Water Based Estapol Clear Satin followed by two coats of Wattyl Estapol Matt.

G 21.

The payload used for the competition will be a regulation 12 inch softball.

NOTE:As defined in the Official Rules of Softball, a 30.5cm (12 in) ball shall be between30.2cm (11 7/8 in) and 30.8cm (12 1/8 in) in circumference, and shall weigh between 178.0g

(6 1/4 ounces) and 198.4g (7 ounces).

G 22. Teams must accept that the presence of bright lighting and photography includingflash and infrared systems are part of the competition environment.
http://www.ullrich.com.au/extrusions/extruded-round-tubehttp://www.ullrich.com.au/extrusions/extruded-round-tube


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FIGURE 4 50mm angle brackets (available at Bunnings for $4.54 per pkt of 4 see:

http://www.bunnings.com.au/zenith-50mm-zinc-plated-angle-brackets-4-pack_p2760232).

PROTOTYPE SYSTEM

G 23.

The system shall deliver the payload on the defined competition track in accordancewith the rules.

G 24 Th t h ll t ti ll d b d l ti f ti ti t k


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Competition Rules

RULE WORDING

R 1. The language of the rules is tiered. Those clauses expressed as SHALL aremandatory and failure to comply will attract penalties which in the extreme could lead todisqualification at the National Final. Those expressed as SHOULD or MAY reflectsome level of discretion and choice.

MATERIALS AND MANUFACTURE

R 2. Students SHALL manufacture and fabricate their prototype system themselves usingcommonly available materials, components and methods.

NOTE:At the National Final Campus Organisers may be required to confirm that the system

presented has been appropriately manufactured in keeping with the spirit of the competition.While students may purchase components off-the-shelf, it is not intended that they

purchase systems / major subsystems as solutions directly.

R 3. In keeping with the spirit of the competition, teams SHALL NOT use LEGOMindstorm or similar comprehensive kitted systems at the National Final.

R 4. In keeping with the spirit of the competition, teams MAY use Arduino or similar PICbased components.

R 5 I k i i h h i i f h i i MAY d / dif / i


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Zone. The Start Zone includes the internal faces of the MDF front and side walls, 50 mmangle brackets, inside edges of the two 400 mm square openings, and the competition surface

bounded by the external faces of the front and side wall.R 12.

The Team SHALL indicate to the appropriate official when their setup is complete.

R 13. After initial setup and prior to running, everything placed and left on the competitiontrack SHALL be considered to be part of the system.

R 14.

During final setup, the payload SHALL be presented to the team for placement on orin the system. The payload SHALL NOT be modified in any way and SHALL be setup on orin the system so that it is clearly visible when viewed from above at completion of the run in

order to measure its position.

R 15. The team SHALL be allowed a maximum of 10 seconds for final setup, the additionof the payload.

R 16.

After setup, and prior to running, the system SHALL be subject to volume constraints.The system SHALL be wholly contained within the start zone as defined by the size of theshed, i.e.; the height and projected plane of the external faces of the front and side wall, andthe edges of Track Segment 1. The volume and positioning conditions SHALL be physicallychecked by an official.

R 17. After set up and prior to running, the system SHALL NOT be held or supported orcontacted by anything other than the competition base plane and must be ready to start. Thesystem SHALL NOT be in contact with or be restrained by the walls of the shed. The systemSHALL NOT be restrained by personal contact by team members. Systems SHALL becapable of remaining in the set up condition indefinitely.

R 18

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R 26.

At the completion of the run, the system SHALL cease translation on the competitionsurface and remain in this state indefinitely relative to the competition surface. Mechanisms

and items above the surface supporting the system MAY continue to move but no furtherfunctions can be executed.

R 27. The team MAY indicate to the timekeepers when they declare their run to becomplete. However, the time keepers SHALL make the final judgment as to when thesystem ceases translation and all functions have ceased and the recorded time MAY exceedthe teams declaration.

R 28.

To ensure that judging has been completed teams SHALL NOT retrieve their system

or assist in gathering other items until directed by an official.R 29. The system SHALL NOT damage or contaminate the competition track. Teams

presenting a system that damages or is deemed to have potential to damage the track may bedisqualified from the competition.

EXPLANATORY NOTE:A component of the system left simply on the competition trackdoes not constitute contamination but may be subject to a score penalty as detailed in R35.

An example of contamination would be a sticky residue requiring significant effort to remove

it, with the possibility of permanent change occurring to the surface finish.

R 30. As directed, teams MAY attempt two runs.

R 31. The system MAY be modified between runs but the mass, volume and timeconstraints must be satisfied for a run to achieve a valid non-zero score.

R 32. Violations of procedural rules SHALL result in a zero run score being recorded.

R 33. The judges decisions on all matters pertaining to the competition SHALL be final.


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SCORING

R 34.

Better systems will achieve the objectives of negotiating the track and transporting thepayload with greater accuracy and efficiency whilst adhering to the timing, volume andpositioning constraints. A valid run score SHALL be calculated using the following formulaand is based on the end state of the payload.

R 35. The run score is based on the following formula:

= +

Calculated to one decimal place, where at the end of the run:

= 80

10

=600

30 +

Where:

If the payload at the end of the run remains on, or in a plan view

above Track Segment 1, then:

= 360 +


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R 36.

For the payload and system to be considered fully supported by the aluminium tube

during the ravine crossing, at some instant during the transition from track segment 1 to tracksegment 2, the system SHALL be in contact with the tube and be fully supported by the tube.

R 37. PAYLOADmeas SHALL be based on horizontal measurements from one of threedatum lines as defined by furthest most position of the payload on the competition base plane.

If the payload is:

- fully in the finish zone then PAYLOADmeas is zero;

- on or above track segment 2, then PAYLOADmeas is the shortest distance measured fromthe finish zone boundary to the furthest point of the payload in cm or part thereof (where themaximum value of PAYLOADmeas recorded is 180);

- suspended above the gap between track segment 1 and track segment 2 (known as theravine), then PAYLOADmeas is the shortest distance measured from the vertical surfacedefining the ravine wall attached to the edge of track segment 2 (extended upward) to thefurthest point of the payload in cm or part thereof (where the maximum value of

PAYLOADmeas is 60);- on or above track segment 1 and fully outside the Start Zone, then PAYLOADmeas is theshortest distance measured from the corner of track segment 1 (closest to the Finish Zone) tothe furthest point of the payload in cm or part thereof (where the maximum value ofPAYLOADmeas recorded is 240);

- lost (see R23) or not fully outside the start zone (see R38), then PAYLOADmeas is notmeasured and the RUNscore is zero.

R 38 F th l d t b id d f ll t id th St t Z it SHALL b h ll


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Frequently Asked Questions

1. Does the system have to stay in contact with the competition track at all times?No. However the scenario is for essentially a ground based system (see G24). The guidelinesand rules do define what can be legally contacted (see G25, R17, R22, R23 and R24).

2. Can part of a system be discarded off the track without penalty?

No. If the system, or part of the system, is discarded off the competition track this would leadto a zero run score (R23).

3. Can part of the system or payload overhang the extremities of the track withoutpenalty when negotiating track segments 1 and 2?

Yes. Provided volume and positioning constraints of the system and payload are met prior torunning (see R16) and the system and payload are fully inside the Finish Zone at thecompletion of the run (as detailed in R39). The position of the payload at the completion ofthe run will be measured in accordance with R35.

4. Can part of the system or payload overhang the extremities of the track without

penalty when crossing the ravine?

No. Systems shall not overhang the projected extremities of the track when transitioning fromtrack segment 1 to track segment 2 (see R25). Furthermore see R25 for the definition of the

projected extremities of the track.

5. Can part of the system or payload contact the inward face of the MDF sheet

supporting the aluminium tube without penalty?

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10. Can off-the-shelf items be used?

Commonly available components such as toy and machine parts are able to be used. The

spirit of the competition is that students manufacture and fabricate their system themselves,meaning that professionals are not engaged to do it for them. It is possible for someassistance to be obtained (e.g.; for a weld) but this should be minimal or where possible bedone by the students themselves. The production of major components should not beoutsourced.

11. Is there a requirement on the end state of the system at the completion of the

run?

No. However R40 defines the state of the system that satisfies a completed run.

Further Competition Details

NATIONAL FINAL

It is planned that the Warman National Final will be held on Friday 23 - Sunday 25September 2016 in Sydney at a location to be determined.

Prizes for Campus Winners and National Podium Places will be awarded at the NationalFinal. A National Final Judges Prize and an NCED Design Prize may also be awarded.

The planned format will have students gathering on Friday morning in Sydney. Lunch,

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Spirit of the Competition

Although the rules may look rigid you will find that they have been written in a way whichallows, and in fact encourages, creative and innovative solutions. This is not always the casein real-world engineering projects. In this project and competition, the rules are there becausewe have tried to be very clear on points which will be important when student groups cometogether for the National Final. For this reason, it is essential to work with your campusorganiser from an early stage, and for the campus organiser to verify decisions with the

National Organisers so that everyone has the same understanding of the meaning of the rules.

If you think you see a loophole, clear it with your campus organiser before you rely on it incompetition. Even if it is accepted at the local level, you might be in for a shock at thenational level where the interpretation might be different. Provision will be made forconfidentiality, so your idea will not be passed on to other students.

It is highly recommended that all students communicate with their campus organiser and thatif a ruling is required by the National Organisers, this is sought by the campus organiser.

Students SHOULD NOT contact the National Organisers directly for an individual ruling.

The competition tracks, both at the Campus Competitions and the National Final, will bemade with reasonable care but because it is a real engineering object it may well be wrongin various small ways. For example the surface might have a slight longitudinal slope. Yourteam is expected to consider these possibilities in your design, and develop a system that canfunction even if the competition track has slight imperfections and inaccuracies. In otherwords, you are not allowed to blame failure of your system on some minor imperfection with

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DETAIL ASCALE 1 : 10

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NOTE: (1)COLLAR MUST PREVENT MOVEMENT IN THE AXIAL DIRECTION AND ALSO PREVENT

ROTATION OF THE ALUMINUIM PIPE.

ITEM QTY DESCRIPTION1 1 50ODx3WTx3250 ALUMINIUM TUBE2 2 1200x2400x18 MDF SHEET3 2 600x500x18 MDF SHEET4 5 50X50 ANGLE BRACKETS5 2 1200x300x18 MDF SHEET6 1 1200x800x18 MDF SHEET7 1 LOCKING COLLAR8 1 120x45 TIMBER9 18 12x12 DAR

10 1 200x750x18 MDF SHEET

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CAD GENERATED DRAWINGDO NOT MANUALLY UPDATE

THE TECNICAL INFORMATIONCONTAINED HEREIN ISCONSIDERED THE UNIVERSITY OFNEWCASTLE PROPERTY AND SHALLNOT BE USED, REPRODUCED,RELEASED OR DISCLOSED INWHOLE OR PART WITHOUT WRITTENPERMISSION.

RELEASED FOR CHECKING

RELEASED FOR CONSTRUCTION

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PROJECT NO: DRAWING NO:

SIGNATURE

APPV'D

NAME

CHK'D

DATE

DRAWNDATEDESCRIPTIONREV BY APPV'D

NOTICETHE UNIVERSITY OF

NEWCASTLE AUSTRALIA

FACULTY OF ENGINEERINGAND THE BUILT ENVIRONMENT

SCHOOL OF ENGINEERING -

DEPARTMENT OF MECHANICAL ENGINEERING

ENGINEERING CLOSE, CALLAGHAN NSW 2308

DRAWN TO AS1100-1992ALL DIMENSIONS IN MILLIMETERS

UNLESS OTHERWISE STATEDDO NOT SCALE

SIZE:SHEET:

SCALE:

A3

DEBUR ALL SHARP EDGESALL ROUNDS ARE R1mm UNLESS OTHERWISE STATED

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(1)

NOTE: (1)THIS DIMENSION WILL BE GREATER THAN OR

EQUAL TO 300mm AT THE NATIONAL FINAL.

ITEM DESCRIPTION1 START ZONE2 END ZONE

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2016 Warman Competition

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