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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,
apply for mitigation as soon as
possible. 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.
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.
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.
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
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
©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)