Autodesk Fusion Test Bench CAD

STATEMENT OF WORK (SOW)
3D CAD DESIGN – MECHATRONICS TEST BENCH
1. Project Objective
The objective of this document is to specify the technical requirements for the complete 3D mechanical and electrical enclosure design of a test bench for mechatronic gearboxes (DQ200 model), to be executed in Autodesk Fusion 360.
The equipment shall feature a self-supporting bent steel sheet structure, assembled exclusively using demountable mechanical fasteners (bolts, nuts, washers), without any welding processes.
2. Design and Technological Requirements
2.1 Manufacturing Technology
• Cutting: All sheet metal parts must be designed for CNC laser cutting.
• Forming: Bending via press brake.
• Self-Alignment (Tab & Slot System): Interlocking tabs and slots (Tab & Slot) must be designed at panel joints to guarantee accurate 90° alignment prior to tightening bolts.
2.2 Recommended Materials & Thicknesses
• Top Worktop & Sub-frame: Structural steel sheet (e.g., S235JR / S355) — 3.0 mm thickness.
• Lower Enclosure & Screen Console: Structural steel sheet — 2.0 mm thickness.
• Access Doors & Decorative Panels: Structural steel sheet — 1.5 mm thickness.
2.3 Assembly & Fasteners
• Fasteners: Exclusively metric M6 and M8 hardware (button head socket screws ISO 7380 or hex head bolts DIN 933).
• Locking Mechanism: Nylon insert lock nuts (DIN 985) and flat washers (DIN 125).
• Hole Tolerances: Clearance holes in sheet metal shall be 6.5 mm for M6 and 8.5 mm for M8.
3. Autodesk Fusion Project Architecture
The freelancer must strictly adhere to modular design principles (Distributed Design):
1. "New Component" Rule: Every new part must be created as a separate Component entity prior to generating 2D sketches.
2. Sheet Metal Workspace: All sheet metal components must be modeled in the Sheet Metal Workspace, using a standard bending rule with a properly set K-factor for structural steel.
3. Cloud Data Structure (Data Panel):
o 01_Master_Assembly (Main assembly)
o 02_Sheet_Metal_Components (Individual sheet metal parts)
o 03_Electronics_and_Electrical (Backplates, DIN rails, PCBs, power supplies)
o 04_Standard_Hardware (Casters, hinges, handles)
o 05_Fasteners (Bolts, nuts, washers)
o 06_Imported_Mounts_and_Motor (Pre-designed gearbox mount, motor mount, and DQ200 gearbox reference models)
4. Kinematic Motion (Joints):
o Lower doors must use Revolute Joints (restricted to a 0°–110° opening angle).
o Swivel casters must use Revolute Joints.
o Fixed enclosure elements and imported mounting plates must be constrained using Rigid Joints.
4. Hardware & Electrical Systems Integration
4.1 Mechanical & Structural Components
• Pre-Designed Gearbox & Motor Mounts (Client Provided): The mounting interfaces, mounting plates, and bracket designs for both the DQ200 gearbox and the electric drive motor are already completed (3D CAD models/drawings provided by the client). The freelancer is solely responsible for importing, accurately positioning, and bolting these existing mount assemblies onto the main test bench structure and worktop.
• Control Display: Upper console angled at 30°–45° prepared for an industrial touchscreen / monitor (VESA mounting pattern).
• Interface Elements: Mushroom-head Emergency Stop button (E-Stop), 2x control buttons, and ventilation louvers/grilles cut directly into the sheet metal.
• Mobility: 4x Heavy-duty industrial swivel casters (2 with brakes) mounted to the base plate via 4-bolt flange plates.
• Door Hardware: Surface-mounted hinges for sheet metal and industrial handles/latches.
4.2 Electronic Boards & Electrical Layout (According to Schematic)
• Internal Electrical Backplate (Sub-Panel): A dedicated, removable galvanized steel or zinc-plated mounting plate (2.0 mm) inside the cabinet for mounting electrical control hardware.
• DIN Rails & Wiring Channels: Standard 35 mm DIN rails and slotted PVC cable ducts (wireways) designed into the layout for organizing relays, terminal blocks, circuit breakers, PLCs, and 24V power supplies.
• Electronic Circuit Boards (PCBs): Dedicated mounting hole patterns and threaded standoffs (M3/M4 Brass Standoffs) for custom control/communication boards.
• Cable Routing & Cable Glands: Pre-cut holes/knockouts with rubber grommets or cable glands (PG/M threads) on rear and internal dividing panels for passing power, sensor, and CAN/USB data cables without wire pinch risks.
• Heat Dissipation & Airflow: Mounting cutouts for 120 mm cabinet cooling fans and filter louvers positioned according to the thermal load of the electrical components.
5. Required Deliverables
The freelancer shall deliver the following files upon project completion:
Deliverable Format Technical Requirements
Source 3D Model .f3z / Fusion Archive Fully parametric, clean timeline history (no yellow/red warnings), incorporating the integrated gearbox/motor mounts & electrical enclosure layout.
Laser Cutting Files .dxf Individual 1:1 scale .dxf file for each sheet metal part in unfolded state (Flat Pattern), including mounting plate and PCB standoff hole patterns.
Assembly Drawing .pdf General assembly view with overall dimensions, exploded view, electrical enclosure layout, and bill of materials callouts.
Bill of Materials (BOM) .xlsx / .csv Centralized table including: part name, sheet thickness, quantity, complete list of bolts/nuts, DIN rails, cable glands, and purchased hardware.
Photorealistic Renders .png (Min. 4K) 4 rendered images from the Render Workspace (isometric, front, internal electrical bay, and rear perspectives).
6. Acceptance Criteria & Quality Control
1. Interference Check: The assembly must show zero material overlap (0 interference in Fusion's automated clearance check), specifically ensuring alignment between the imported gearbox/motor mounts and the bench worktop mounting holes.
2. Assembly & Wiring Feasibility: Physical tool clearance (wrenches/Allen keys) must exist for inserting fasteners, and sufficient bend radius space must be allocated for all electrical wiring.
3. Sheet Metal Integrity: All flat patterns must unfold without sheet metal errors or warnings.