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Mechatronics 5CCE2MCT Individual Coursework Project

©2022 Department of Engineering, King’s College London 1

5CCE2MCT Mechatronics

You will be required to undertake this alternative assessment in place of your deferred coursework

component or as reassessment for your failed coursework attempt. Please note, this also includes

in class tests which are scheduled within term outside of the examination window.

This alternative assessment for 5CCE2MCT Mechatronics (2024/25 academic year) is designed to

replace the outstanding components below:

Coursework 1 (30%) – Camera gantry control system design

Alternative Assessment:

Title Design & Analysis of a High-Precision Flow Dispensing System

The brief is provided at the end of this document.

Submission requirements:

• a 3-minute video recording in which you present the motor and mechanism design to

an engineering design team. The video should contain an animation of the mechanism

and an overview of the Simulink model and results.

• a 1-page written report presenting the results of your design analysis with a maximum

of 2 page of supporting figures in appendix. You should use 12pt Calibri (or alternative)

sans-serif font with 1 line spacing.

• a zipped folder where the project model and data can be shared with assessors.

The alternative assessment is due to be released on Thursday 26th June

As clarified in the email sent to students in June, no extensions will be permitted.

Coursework is due 4pm, Thursday 24th July 2025.

Those with approved KIPS/PAA in place please refer to communications received from the

Department (PAA Information for Engineering Assessments Period 3 – August 2025) for further

information. If you have not received this, then please contact the UG / PGT office as soon as

possible.

Submissions will not be accepted after the deadline has passed, please ensure that you leave

plenty of time to check over and upload your work. If you are unable to submit by this deadline,  Information on mitigation can be found via KA-01744 · Student Services Online

(kcl.ac.uk)

Submissions will not be accepted via email; submissions must be made via the correct KEATS

area.

Mechatronics 5CCE2MCT Individual Coursework Project

©2022 Department of Engineering, King’s College London 2

Support for carrying out this assessment is available:

You can reach out to Dr Francesco Ciriello at francesco.ciriello@kcl.ac.uk if you have questions

about this resit assessment.

Mechatronics 5CCE2MCT Individual Coursework Project

©2022 Department of Engineering, King’s College London 3

Mechatronics 5CCE2MCT Individual Coursework Project

Design & Analysis of a High-Precision Flow Dispensing System

Module Instructors

You are a design engineer working for a firm that specialises in developing high-precision

dispensation systems for delivering fluid solutions for medical devices. Your manager has sent

you a parametric model of a single-axis syringe pump that was developed on a previous project.

The mechanism can move the syringe plunger relative to its body by rotating a lead screw

mechanism attached a runner.

Brief

Your manager has asked you to design a new electromechanical actuation system composed of

a geared DC motor that drives the leadscrew runner of the syringe pump shown in Figure 1.

She provided CAD components and Simulink starter models for the assembly, n.b. these files

can be downloaded from the KEATS module page in the MATLAB project archive,

syringe_pump.mlproj. She has also sent you a list of requirements that she has discussed

with the customer appended to the end of this document. The client is particularly interested in

obtaining an accurate and continuous flow from the syringe. Your manager encourages you to

use the model as a starting point and welcomes further input on how to improve the mechanical

design.

You are responsible for:

• specifying DC motor, power supply, and gearbox characteristics

• design a digital motor controller

• demonstrate the effectiveness of your design.

You are highly encouraged to brainstorm additional information about the context in which

this mechanical system is to be used.

Deliverables

• a 3-minute video recording in which you present the motor and mechanism design to

an engineering design team. The video should contain an animation of the mechanism

and an overview of the Simulink model and results.

• a 1-page written report presenting the results of your design analysis with a maximum

of 2 page of supporting figures in appendix

• a zipped folder where the project model and data can be shared with assessors.

Mechatronics 5CCE2MCT Individual Coursework Project

©2022 Department of Engineering, King’s College London 4

Figure 1: Syringe pump

syringe_pump_start.slx

Learning objectives

• Model the electromechanical system that actuates the gantry using a combination of

mathematical, physical and data-driven methods and critique the choice of your

modelling approach

• Specify component parameters based on a design analysis of system requirements

• Implement and tune a feedback controller to control position and speed of the

mechanism

• Test the controller design against multiple loading scenarios

• Conduct a design space study to optimise system-level performance

• Report and justify recommended design implementation

Additional resources

You are encouraged to complete laboratory exercises of weeks 22-26 to develop skills in

modelling and control of mechatronics systems.

lead screw

rails

DC motor casing

runner

plunge

r

syringe body

syringe outlet

Mechatronics 5CCE2MCT Individual Coursework Project

©2022 Department of Engineering, King’s College London 5

Marking Criteria

Individual coursework submission accounts for 30% of module grade.

Your submission will be scored with regards to its merits in six core areas:

Area Actions

Science &

Mathematics

(20 marks)

Justify modelling and control design approach

Interpret design performance using mathematical and statistical techniques

Critique choice for actuator and sensor characteristics and technology

Engineering

Analysis

(20 marks)

Apply engineering tools to solve the design task

Conduct critical analysis to identify, classify and describe system performance compared

to benchmark

Adopt systems approach to improve on design

Extract and evaluate pertinent data to solve unfamiliar problems

Engineering

Design

(20 marks)

Evaluate user needs and requirements

Identify and work with design constraints and unknowns

Communicate to a technical audience

Deliver efficient, effective and robust design

Engineering

Context

(10 marks)

Identify and mitigate areas of risk

Engineering

Practice

(20 marks)

Demonstrate design effectiveness in the context in which the system is applied

Additional

General skills

(10 marks)

Demonstrate effectiveness, clarity and originality of communication

Mechatronics 5CCE2MCT Individual Coursework Project

©2022 Department of Engineering, King’s College London 6

Requirements

Your manager discussed these requirements with the customer. You are welcome to add you

own requirements to this initial draft and clarify requirements with the module convenor.

Battery / Power Supply Requirements

Use 18650 Li-Ion batteries (example)

Battery Voltage: 3.7V per battery*

Battery Capacity: 2.6 Ah

Battery Resistance: 250 mΩ per battery

Battery Lifespan: 60-120 minutes

*n.b. 1 battery is 3.7V (1S), 2 batteries is 7.4V (2S), 3 batteries is 11.1V (3S) and so on.

DC Motor Requirements

Stall current: 0.2A-1A

Stall torque: 500 g.cm

No-load speed: 20-70 rpm

Dead zone torque: 20 g.cm**

**n.b. motor torque must be higher than the dead zone torque for the motor to spin.

Motor Sensor Requirements

Hall Sensor Encoder with 94 counts per revolution

Syringe Pump Requirements

Lead screw 7 - 10 mm / rev

Delivered flowrate 1-8 mL / min***

Linear travel force 100 g

Syringe linear travel rate 100 mm / min

Syringe radius 10-25 mm

Syringe length 250 mm

Specific gravity of fluid: 1-2

***n.b. the client is interested in delivering as low as possible continuous flowrate. You can adjust the diameter

of the syringe.

Safety Requirements

Fail safe mechanisms for operation and calibration

System Response Requirements

Rise time < 3-5 s per 10 mm travel

Settling time < 5-7 s per 10 mm travel

Overshoot < 1%

Undershoot < 2%

Steady-state error < 2%

Tracking Response Requirements

Relative error < 1%

Absolute error < 1%

Assessment Brief for P3 Resit and Deferrals 2022/23

7 | P a g e

Detailed Mark scheme

Area Actions Marks

Science &

Mathematics

(20 marks)

Justify modelling and control design approach

Interpret design performance using mathematical

and statistical techniques

Critique choice for actuator and sensor

characteristics and technology

• Model a DC motor using a method of choice (3 marks)

• Justify method choice (3 marks)

• Deduce DC motor model parameters from requirements (3 marks)

• Implement an appropriate controller for each axis (3 marks)

• Attempt to improve controller architecture (1 mark)

• Model an incremental rotational encoder (3 marks)

• Comment on DC motor technology choice (1 marks)

• Develop state estimation to convert rotational encoder readings to linear motion (3 marks)

Engineering

Analysis

(20 marks)

Apply engineering tools to solve the design task

Conduct critical analysis to identify, classify and

describe system performance compared to

benchmark

Adopt systems approach to improve on design

Extract and evaluate pertinent data to solve

unfamiliar problems

• Reference data to justify model parameters (2 marks)

• Consider input saturation (1 mark)

• Define a benchmark or target performance (1 mark)

• Demonstrate improvement through a tuning method compared to the benchmark or target

(2 marks)

• Comment on model uncertainty and/or runs a sensitivity analysis (2 mark)

• Demonstrate attempts at optimising system performance using formal methods, e.g.

parameter sweep, response optimization or equivalent (2 mark)

Engineering

Design

(20 marks)

Evaluate user needs and requirements

Identify and work with design constraints and

unknowns

Communicate to a technical audience

Deliver efficient, effective and robust design

• Identify and evaluate trade-offs of using a reducing gearbox (9 marks)

• Use appropriate technical language and engineering schematics to communicate design (5

marks)

• Demonstrate attempts at optimising system performance using physical intuition (4 mark)

• Attempts to improve mechanical parameters for design (2 marks)

Engineering

Context

(10 marks)

Identify and mitigate areas of risk • Implement a strategy for calibration (2 marks)

• Recognise increased cost of high-performance components and attempt to minimise cost (2

marks)

• Identify sources of noise or disturbance in system (3 marks)

• Model noise or disturbance in system (3 marks)

Engineering

Practice

(20 marks)

Demonstrate design effectiveness in the context

in which the system is applied

• Address requirements provided (10 marks)

• Identify additional requirements (2 marks)

• Report on system response test(s) (7 marks)

Assessment Brief for P3 Resit and Deferrals 2022/23

8 | P a g e

• List key design parameters using a table or engineering drawing (1 mark)

Additional

General skills

(10 marks)

Demonstrate effectiveness, clarity and originality

of communication

• Report within single page and with less than 10 grammatical errors (5 marks)

• Provide high quality schematics (diagrams, plots, or equivalent) to support your argument (5

marks)


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