Session 1: Introduction to CAD and Initial Sketching
Objective: Understand CAD basics and sketch a robotic component with precise measurements.
Topics:
Overview of CAD in robotics: Designing robotic arms (e.g., grippers, joints) and AGVs (e.g., chassis, wheels).
Introduction to FreeCAD: Interface, workbenches (Part, Sketcher), units (mm precision).
Importance of measurements: Tolerances, scale, and real-world application (e.g., motor mounts).
Sketching principles: Orthographic views (top, front, side), dimensioning rules.
Activity:
Students sketch a robotic arm (e.g., base, arm, gripper) or AGV (e.g., frame, wheels, sensor mounts) on paper.
Specify exact measurements (e.g., arm length: 150 mm, wheel diameter: 50 mm) with ±0.1 mm tolerance.
Assignment: Submit a hand-drawn sketch with labeled dimensions (strictly enforced).
Session 2: 2D Drafting in FreeCAD – Base Components
Objective: Translate sketches into precise 2D CAD drawings.
Topics:
FreeCAD Sketcher workbench: Creating 2D profiles (lines, circles, constraints).
Applying constraints: Geometric (parallel, perpendicular) and dimensional (length, angle).
Robotics focus: Drafting base plates for arms (e.g., 100x100 mm) or AGV chassis (e.g., 200x150 mm).
Embedding electronics: Adding mounting holes for microcontrollers (e.g., ESP32: 51.5x28 mm).
Activity:
Create a 2D sketch of the robotic arm base or AGV chassis in FreeCAD.
Example: Arm base with 4x M3 holes (3 mm diameter, 40 mm apart); AGV chassis with wheel slots (50 mm wide).
Enforce precision: Check all dimensions against sketch (±0.1 mm).
Assignment: Export 2D sketch as PDF with dimension annotations.
Session 3: 3D Modeling – Robotic Structure
Objective: Build 3D models of robotic components with accurate measurements.
Topics:
FreeCAD Part workbench: Extruding 2D sketches into 3D solids (e.g., base thickness: 5 mm).
Robotics components: Arm segments (e.g., 150 mm long, 20 mm wide) or AGV body (e.g., 30 mm high).
Boolean operations: Cutting holes for motors (e.g., servo: 40x20x36 mm) or sensors (e.g., ultrasonic: 45x20 mm).
Precision checks: Using measurement tools to verify dimensions.
Activity:
Extrude the 2D base into a 3D model, adding arm segments or AGV wheel mounts.
Example: Robotic arm with a 50 mm pivot joint; AGV with 10 mm wheel axles.
Strict measurement enforcement: All parts must match sketch specs.
Assignment: Submit a 3D model file (.FCStd) with a screenshot showing key dimensions.
Session 4: Assemblies and Embedded Systems Integration
Objective: Assemble robotic parts and integrate microcontroller/electronics housings.
Topics:
FreeCAD Assembly workbench (or A2plus addon): Combining parts (e.g., arm base + segments, AGV chassis + wheels).
Robotics focus: Joints for arms (e.g., servo mounts) or AGV wheel alignment (e.g., 100 mm wheelbase).
Electronics integration: Designing enclosures for microcontrollers (e.g., STM32: 44x22 mm, Raspberry Pi: 85x56 mm).
Tolerances for fit: Clearance for screws (e.g., 0.2 mm), motor shafts (e.g., 5 mm diameter).
Activity:
Assemble the robotic arm (base, arm, gripper) or AGV (chassis, wheels, sensor mounts).
Add a microcontroller housing (e.g., ESP32 slot with 2 mm walls, 10 mm height).
Verify alignment and measurements (e.g., joint spacing: 50 mm ±0.1 mm).
Assignment: Export assembly as .FCStd and provide an exploded view screenshot.
Session 5: Final Detailing and Real-World Application
Objective: Finalize CAD models with details for fabrication and embedded functionality.
Topics:
Adding fillets/chamfers for strength (e.g., 2 mm radius on edges).
Detailing for robotics: Cable routing slots (e.g., 5 mm wide), sensor mounts (e.g., 20x20 mm platform).
Exporting for manufacturing: STEP files for 3D printing, DXF for laser cutting.
Simulation preview: Basic stress analysis (FreeCAD FEM workbench) for motor loads.
Activity:
Finalize the robotic arm (e.g., gripper with 10 mm finger gap) or AGV (e.g., sensor tower 30 mm high).
Add mounting points for electronics (e.g., 4x M2 holes for STM32, 2 mm deep).
Export as STEP and DXF, ensuring all measurements are exact.
Assignment: Submit final .FCStd file, STEP/DXF exports, and a report justifying measurements (e.g., why 150 mm arm length).
Key Features
Robotic Components: Focuses on practical designs—robotic arms (joints, grippers) and AGVs (chassis, wheels)—relevant to real-world applications.
Electronics and Microcontrollers: Incorporates precise enclosures for ESP32, STM32, or Raspberry Pi, ensuring compatibility with embedded systems.
FreeCAD Emphasis: Uses FreeCAD’s Sketcher, Part, and Assembly tools, aligning with your preference, while teaching CAD fundamentals.
Strict Measurements: Enforces ±0.1 mm precision throughout, reflecting your strict standards (e.g., hole spacing, part lengths).
Progressive Learning: Starts with sketches, moves to 2D drafting, 3D modeling, assemblies, and final detailing, building skills incrementally.
Real-World Tie-In: Prepares designs for fabrication (3D printing, laser cutting), linking CAD to physical robotics.