EC • LEVEL 2

Harbor Cargo Transfer Challenge

Design, build, test, and refine a manually controlled hydraulic machine that transfers a standard cargo block from a start zone to a raised target.

2–4students per team
2+controlled motions
3 of 5successful trials
200project points

Move it with control.

Your team will engineer a manual hydraulic machine that picks up the teacher-provided cargo, controls it through the full transfer, releases it on the raised target tray, and repeats the task reliably.

Official test setup

  • Teacher-provided 2 × 2 × 2-inch block weighing approximately 2 ounces
  • 4 × 4-inch start zone; cargo begins centered in the marked start position
  • 6 × 6-inch usable landing surface on a raised tray
  • Target landing surface is 4 inches above the start surface
  • 12 inches between the closest start-zone and target edges

Successful official trial

  • One operator touches only the input plungers or attached control handles.
  • Timing begins with the first input movement after “go.”
  • The cargo is released completely on or inside the target tray.
  • The cargo remains stationary for 3 seconds.
  • The complete sequence finishes within 60 seconds.

Qualification standard: at least 3 successful trials out of 5 official attempts.

Build inside the approved design space.

Required system

  • Teams contain 2–4 students.
  • Use 2–4 water-filled hydraulic syringe systems (one input/output syringe pair per system).
  • Create at least 2 independently controlled hydraulic motions.
  • Keep the stationary machine base within 12 × 12 inches.
  • The base may not overlap the start or target; moving mechanisms may extend beyond the base during operation.
  • Use a separate, stable, clearly labeled manual control pad outside the test area; no size limit applies.
  • The final system may not be air-powered or electrically powered.

CAD and fabrication

  • Create at least two original functional CAD parts that are 3D printed.
  • Include functional laser-cut machine components.
  • Create a laser-cut or engraved control pad with control names and directional arrows.
  • Downloaded supporting parts require approval, creator/site/license attribution, and do not count as original CAD parts.
  • Complete the detailed labeled sketch, Onshape assembly, fabrication files, and teacher approval before production.

Materials and design decisions

  • Use approved classroom materials or receive approval before using outside materials.
  • No student is required to purchase materials.
  • Cardboard is not an approved structural material.
  • Use water with no more than one drop of food coloring per hydraulic system.
  • Do not copy a complete tutorial, ready-made machine, or finished solution.
  • Document outside sources and explain every major design decision.

Official operating rules

  • The base and target remain fixed throughout a trial.
  • Only one operator may control the machine during a trial; teams may rotate operators between trials.
  • After “go,” the operator may touch only the control pad input plungers or handles.
  • No one may touch the cargo, machine structure, tubing, target, or moving mechanism during the trial.
  • Between trials, reset the cargo to the marked center position and return the machine and controls to their recorded start positions.
  • No design changes are allowed during the five official trials.

Materials and safety

Hydraulic materials

  • 3, 10, 20, and 60 mL syringes
  • 1/8-inch flexible tubing and approved fittings
  • Luer-lock fittings preferred; secure slip connections
  • Water with no more than one drop of food coloring
  • Approved structural stock, hardware, ties, and adhesives

Safety rules

  • Never use needles.
  • Pull-test every tubing connection before operating under load.
  • Keep hands clear of pinch points and moving mechanisms.
  • Release system pressure before changing a connection.
  • Stop for leaks, cracks, swelling tubing, or slipping tips.
  • Clean water spills immediately and keep electronics away from the test area.
  • Follow posted laser cutter, 3D printer, adhesive, and fabrication procedures.

Eight stages. Evidence at every step.

01

DEFINE

Clarify the cargo-transfer problem, scoring criteria, constraints, and successful end condition.

02

RESEARCH

Connect pressure, force, piston area, travel, and trapped air to useful machine motions.

03

IDEATE

Create and label three genuinely different concepts before choosing a direction.

04

SELECT

Use a weighted decision matrix and evidence to select the strongest concept.

05

MODEL

Prepare a detailed sketch, Onshape assembly, laser files, and two original 3D-printed CAD parts.

06

TEST

Run baseline trials and record accuracy, success, cycle time, control, and failure modes.

07

REFINE

Make one controlled change, retest, and compare the evidence.

08

COMMUNICATE

Demonstrate the machine and defend the engineering with team and individual evidence.

One possible way a hydraulic machine could complete the challenge.

Labeled concept illustration showing a manual syringe-powered hydraulic arm moving a two-inch cargo block from a marked start area to a raised four-by-four-inch target.
Concept example only—not a required design or fabrication plan. Teams must develop and document their own solution.

One portfolio that grows each week.

Each student completes at least three dated engineering-record entries every week. Teams update the listed portfolio slides and clear each approval checkpoint before moving into the next high-cost phase.

Checkpoint 1 • Slides 3–8

Define the problem, record syringe research, create three concepts, complete the weighted matrix, and select a direction.

Checkpoint 2 • Slides 9–12

Complete the detailed system sketch, task schedule, Onshape assembly, fabricated-part plan, and two original 3D-printed parts.

Checkpoint 3 • Slide 13

Document laser-cut parts, the engraved control pad, hydraulic installation, fit changes, working mechanisms, and team responsibilities.

Checkpoint 4 • Slides 14–16

Run three baseline trials, identify the highest-impact failure, make one controlled change, and complete three revised trials.

Checkpoint 5 • Slides 17–20

Complete five official trials, evaluate the design, present the evidence, and finish each student’s individual reflection.

Show the engineering, not just the machine.

Shared team portfolio

  • One shared team presentation
  • Original sketches, CAD, photos, measurements, and trial data
  • Named outside sources with links or citations
  • Design decisions, failure analysis, and before/after evidence

Individual evidence

  • Three dated engineering-record entries per week
  • One individual reflection slide per team member
  • Your own explanation of the hydraulics, decisions, tests, and contribution
  • Be ready to answer an individual question during the final presentation

Check here before stopping your work.

Does every team solve the same problem?

Yes. The cargo, test area, performance rules, and required evidence are shared. Your mechanism, motions, structure, CAD parts, and control-pad design must reflect your team’s own decisions.

What are the base and control-pad limits?

The fixed machine base must fit within a 12 × 12-inch footprint and remain outside the start and target areas. Moving parts may extend beyond the base. The separate control pad has no size limit but must be stable, labeled, and outside the test area.

How is the test area measured?

The closest edge of the 4 × 4-inch start zone is 12 inches from the closest edge of the 6 × 6-inch target. The cargo begins centered in the marked start position. The target’s usable landing surface is 4 inches above the start surface.

How many hydraulic motions are required?

At least two independently controlled hydraulic motions are required. A third independently controlled motion may earn bonus points after the required system qualifies.

What CAD and fabrication work is required?

Each team creates at least two original functional CAD parts that are 3D printed, functional laser-cut machine components, and a laser-cut or engraved control pad with labels and arrows.

May we use a model from Thingiverse or Printables?

Yes, with teacher approval and attribution. Record the creator, website, and license. A downloaded or remixed part may support the machine but does not count as one of the two required original CAD parts.

May we bring materials from outside the classroom?

Yes, after approval. No student is required to purchase materials, and cardboard is not an approved construction material.

Who may touch the machine during a trial?

One operator may touch only the input plungers or attached control handles. No one may touch the cargo, machine structure, tubing, moving mechanism, or target after “go.” Teams may rotate operators between trials.

What makes an official trial successful?

Within 60 seconds, the machine must move and release the cargo completely on or inside the 6 × 6-inch target tray without prohibited contact. The cargo must remain still for 3 seconds.

What makes an attempt unsuccessful?

An attempt is unsuccessful if time reaches 60 seconds; the cargo is dropped and not recovered by the machine; the base or target moves; a hose disconnects or a major leak stops operation; prohibited contact occurs; the cargo is not fully on the landing surface; or the 3-second hold is not completed.

What may happen between official trials?

Reset the cargo and controls to their recorded start positions. Teacher-approved refilling or reseating of a connection may be recorded for safety, but teams may not change geometry, syringe sizes, linkages, control limits, or the design during the five official attempts.

What goes into the portfolio each week?

Use the checkpoint map above. The team updates one shared portfolio, while each student completes at least three dated engineering-record entries separately every week.

Can we use AI during the project?

AI may help explain concepts, generate research terms, or troubleshoot a failure your team has documented. It may not create your sketches, measurements, test data, observations, selection decision, or complete design.

200-point rubric

CategoryFull-credit evidencePoints
Design process and selectionProblem definition, syringe research, three different labeled concepts, decision matrix, approvals, and responsibilities40
CAD and technical planHydraulic-system sketch, detailed labeled design, Onshape assembly, laser/control-pad plan, two original printed parts, and production approval30
Build quality and hydraulic systemStable 12 × 12 base, labeled control pad, two independent motions, organized fluid system, durable workmanship, and documented changes30
Testing and evidence-based refinementQualification, three baseline trials, failure analysis, one controlled change, three revised trials, comparison, and clear evidence40
Final performance challengeFive official trials scored using the published performance rules below40
Communication and individual understandingData-based evaluation, two-minute explanation, contribution record, individual question, and individual reflection20
Total200

Final performance scoring — 40 points

CriterionScoring rulePoints
Placement accuracy14 = 5 successful placements; 11 = 4; 8 = 3; 5 = 2; 2 = 1; 0 = none14
Repeatability12 = five consistent results with a repeatable sequence; 9 = four mostly consistent results; 6 = three comparable results; 3 = one or two comparable results or frequent unplanned corrections; 0 = no repeatable result12
Controlled motion8 = smooth and deliberate with no drops or unintended contact; 6 = controlled with minor corrections; 4 = noticeable jerking, drift, or repeated corrections; 2 = limited control; 0 = sequence cannot be completed8
Cycle timeAverage successful time: 6 = 30.0 seconds or less; 5 = 30.1–37.5; 4 = 37.6–45.0; 3 = 45.1–60.0; 0 = no successful timed trial6

Official limit: 60 seconds per attempt. Cycle-time benchmark: 30 seconds. Only successful trials are included in the average.

Optional bonus — maximum +10

BonusVerified requirementPoints
Perfect reliabilityAll five official trials are successful+3
Precision placementAt least three official placements finish completely inside the marked 3 × 3-inch center zone+2
Third controlled motionA third independently controlled hydraulic motion contributes meaningfully to the sequence+2
Adaptability trialAfter qualification, complete one additional trial with the target moved 2 inches+3

Bonus never replaces qualification or required evidence. The Challenge Champion is the qualifying team with the highest final-performance score. Tie-breakers are successful trials, average successful time, and controlled-motion quality.

Use support tools without outsourcing the engineering.

Appropriate support

  • Generate research search terms or ask for concept explanations.
  • Get help understanding pressure, force, piston area, travel, or mechanisms.
  • Troubleshoot after your team records the actual failure.
  • Ask for CAD feature guidance while you control and verify the model.

Not acceptable

  • Submit generated sketches, measurements, test data, or observations.
  • Let AI choose the concept or write the selection justification.
  • Replace engineering records, reflections, or live explanations with generated text.
  • Share student information or copy a complete generated solution.