suggested
UPRM ME Capstone Design
Capstone Design
Engineering
Total
Note the iterations
Product
Presentation Format (Roy G Biv)
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David B. Dooner
INME 4057
„
Design Prologue
Project Statement
Gantt Chart
Product Design Specifications
Brainstorming (next week)
Idea Evaluation
Design Optimization
What is Capstone?
Engineers or Scientist?
Capstone
s
terial
s
ic
s
Tra
ns
er
rm
fo
AC
Man
s
ufac
Vibrations
Heat
Transfer
Controls
Machine
Design
Thermodynamics
Mechanism
Design
Computer
Programming
Mechanics
of
Materials
Physics
&
Chemistry
Dynamics
Calculus
&
Diff. Eqs.
Theodore von Kármán
g
turin
Circu its
Fluid
Mechanics
Scientist explore what is,
Engineers create what has not been.
Keystone
Sta
b
Ma
La
cti ve
HV
Capstone
Design
tistic
Ele
Ec
ono
m
Corner
stones
Graphics
Design Prologue
Design Prologue
Experts anyone?
„
Tools
Hour glass
Gear mesh
Transfusion Bag
Do not mention!
Earth’s radius?
h
R=L δ
If you want to do the impossible, don't
hire an expert because he knows it
can't be done. -- Henry Ford
δ
L
Sun
h
Terra
Firma
R
93,000,000 miles
150,000,000,000 meters
Design Prologue
1
Where’s north?
Boy or girl?
Pregnancy test:
urine germinates cereals more rapid then non-pregnant one
urine would germinate wheat if male child
urine would germinate barley if female child
Pharaoh Ramses II
Engineering
or
Science?
Columbus Egg
Four Statues:
Re-Horakhty, the God of the Rising Sun;
Ramses II;
Amun-Ra, the Sun God; and
Ptah, the God of Darkness.
February 21st at 5:58 a.m. each year the sun
illuminated the first three statues & never shone on 4th
statue (& October 21st).
All changed after Aswan Dam
Port of Sant Antoni
Filippo Brunelleschi (1377 – April 15, 1446)
Design Prologue
Cooking vs Engineering
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Objective (nutrition)
Many ingredients
Many recipes
Many foods
New entrees
Tastier
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Objective (product/process)
Many tools (science)
Many styles
Many designs
New products
Less expensive
Suggestions
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&
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Design Prologue
Get design book
Folder
Design Prologue
2
The Project Statement
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Each Project is unique
Complexity varies
All projects need concept definition
Project Statement (days or months)
Project needs manager or group leader
Open flow
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Team Involvement
Communication Plan
Time Schedule
Problem Statement
Problem (sample)
Problem Statement
Statement of Work (sample)
„
Worldwide consumption of fossil fuels exceeds 13Mbbl/day.
Known reserves are forecasted to last for the next 50 years.
Per diem consumption of fossil fuels must decrease in order
to extend the current standard of living.
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Mission
Timeframe
Resources
3 parts
Propose areas within the transportation industry that would
result in an accumulative five percent increase in drivetrain efficiency
that can be implemented within 5 years for less than $500 of production costs.
Problem Statement
Student budget (hours!)
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Problem Statement
STUDENT budget (hours)
(3cr. Hr)x(3hr/cr hr)x(3 stud.) = 27
hrs/week!!!
So, 25-ish hrs/week/group (WOW)
3
Time schedule
Current Practice
Abbott Labs
128 tons
30’ dia
100 RPM
Violate fluctuations in torque exits due to the combustion process.
Statement
Sha ft coupl ing
c1
k1
F t (t)= periodic
Mass m1
Flywheel
Load
I.C. Engine
The market for internal combustion engines exceeds $60 billion dollars annually.
There are 769 engine manufacturers in over 90 countries with over 142 million
engines produced annually. Over 54,000,000 engines are manufactured annually
for the automotive and light truck market. Non-transportation markets include
electric generators, industrial and construction equipment, power tools, and
recreational vehicles.
fly wheel
En gin e cran ksh aft ( ω = con stan t)
Problem
c1
k1
x1 (t)= cyclic
Ft (t)=periodic
k2
Devise a method to reduce/eliminate the torque & speed fluctuation inherent
within existing I.C. Engines.
c2
Mass m2
(a)
x1 (t)= constant
Mass m1
x2 (t)= cyclic
(b)
Gantt Chart
NC balancing application
I.C . Engi ne
to rqu e fl uctu ati on
Gantt Chart
I/O Equations for balancing
n et torqu e
fl uctu atio n
au xi liary torq ue
fluctu ati on
+
Tuned
Vibration
Absorber
=
Engine crankshaft (ω = con stant)
fly wheel
Generator
I.C. Engine
g ear
Sh aft cou pl ing
b eari ngs
N-C g ear
(ou tpu t)
p ini on
N-C gear
(in put )
auxi liary sh aft
h ous ing
pinion-gear ratio =
# of cylinders
2
(b)
Gantt Chart
Modeling of Torque
Gantt Chart
Torque Fluctuation
clearance volume
displacement volume
3
p3
re
u
ss
e
r
p
r
e
d
in
ly
C p2
Idealized
)
n
io
stu
b
m
o
(c
Actual
n
o
iti
n
Ig
Exp
an
sion
2
ambient
pressure
Co
mpr
essio
n
4
Exhaust
p1
Intake
v2
(TDC)
1
v1
(BDC)
Cylinder volume
crank
Y
crank pin
α
ω
connecting rod
l
r
θ
piston @TDC
ϕ
piston
crankpin @BDC
X
x
piston @BDC
stroke
8.38"
r +l
13.31"
Gantt Chart
Gantt Chart
4
Expand Steering market
Expand Rear axle market
Expand Robotic market
Hire design staff
Hire office staff
Hire CAD/CAM machinist
See expanded 12 month schedule
Purchase 5 Hp I.C. Engine
Purchase water brake
Design testbed
Order 'testbed' materials
Q1 meeting
Reverse engineer I.C. engine for adaptar
Detailed design of balancer
Contract for NC gear pair
Purchase 'adapter' materials
Assemble balancer & testbed
Instrument I.C. engine and testbed
Run multiple tests
Q2 meeting
Analyze test data
Draft report on test data
Revise prototype design
Draft provisional patent
Visit patent attorney
Q3 meeting
File provisional patent application
Make International demonstration
Prepare Business Plan
Visit with accountant
Visit targeted companies (sales contracts)
Q4 meeting
Year 1
Year 2
Year 3
Year 4
Year 5
Name # 1
Name # 2
Gantt Chart
Gantt Chart (1st quarter)
week 17
week 16
week 15
week 14
week 13
week 12
week 9
week 8
week 7
week 6
week 5
week 4
week 3
week 2
week 1
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Research and Required Data
Adquisition
Preliminar Sketch
„
Stress Calculations on Test
Frame and Brackets
Material Selection and Cost
Analysis
Computer and Engineering
Drawings
Construction of Brackets and
Test Frame
Assembly and Testing
(Project Data Adquisition)
Gearbox Planning
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Computer Drawings on
Gearbox Frame
Gearbox Frame Construction
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Assembly with Gearbox
Testing and Data Adquisition
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Data Analysis
Month 12
Month 11
Month 9
Month 8
Month 7
Month 6
Month 5
Gantt Chart
PDS defines outcomes from project
Measurement of success (your grade)
Task assignment
Timeframe of outcome
PDS
PDS is NOT is essay format
Quantify parameters
Comprehensive & unambiguous
Include date & version of document
PDS
Gantt Chart
Product Design Specification
Engineering or Poetry?
Engineers quantify
„ 100 mph
„ 0-60 mph in 5 sec
„ 10 ft radius @ 75 mph
„ 500 lb payload
Robotic data
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#
May
Project Planification
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*
Product Design Specifications
April
week 11
March
week 10
February
January
Activity
Month 4
1
Month 3
Version:
Month 1
21-Jan-05
Month 2
Date:
Gantt Chart (12 month)
Month 10
Gantt Chart (5 yr)
Poets qualify
„ Fast
„ Light footed and nimble
„ Agile
„ dexterous
Product Design Specification
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$10B World Market
$100K/bot
75% control related
Japan dominates market
15,000/year (2004 US sales)
USA—1/7 world market
1991 (Solution to 7R!!!- -- Mt. Everest)
Product Design Specification
5
Robotic Manipulators
NC gear
attached to
link 3
z
2
4
1
3
des ire d path
and orien tation
NC gear
attached to
link 5
z'
y
Animation
end-ef fecto r
y'
5
x
x'
4
10
5
7
7
6
9
6
4
5
NC gear
attached to
link 3
11
8
bevel NC
gear pair
NC gear
attach ed to
groun d
2
12
1
3
Product Design Specification
Sample PDS
SOS (Don’t Give UP!)
Title: Geared Robotic Manipulator
Date: Today
„
Columbus Conceives "The Enterprise of the Indies"
„ 1992 cost of Columbus' voyage: $150K
„ 1992 cost of a Seville house in 1492: $9K
„ 25% error in estimate of the earth's circumference
„ Over 10 years experience
King John of Portugal fails to back the plan in 1484
Obtains support from Spain (8 years later)
Go East by heading WEST?
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12 Months on WRONG idea
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D/W
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Requirement
Responsible
Foot print same or less than current
programmable manipulator
Single degree of freedom (i.e., 1 motor)
Cost less than $15K
Develop torque relations
Construct Physical Model
Preform FEA on link lenghts
Generate User's manual
Generate software for re-programming
Generate maintenance manual
Adhere to Gantt Chart
Participate in weekly team meetings
Material provided by Supplier
Global position repeatibility 0.001 mm
Sepcify dimensions for 100% duty cycle
Weigh less than 100 lbs
D
D
W
D
D
D
D
D
D
W
W
D
D
W
D
D - - Demand or must
W - - Wish or preferred
Team
Team
Achieved
Yes/No
G.S.
Machinist
G.S.
Technician
G.S.
Project leader
design group
design group
ABC Company
design group
G.G.
design group
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eliminated
added
Product Design Specification
Rear axle data
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Brainstorming
Automotive Rear axle
135 million automobiles in USA
400 million automobiles worldwide
40 million automobiles/year
5 % growth rate
10-12 year life of automobile
fuel consumption (13 Mbbl/day)
miles traveled:
Mileage
cost:
efficiency improvement:
10,000 mile/year
20 mi/gal
$1/gal
0.01
e=92%
Idea Evaluation
Idea Evaluation
6
Windage
Film thickness
input rotation
axis
1.0
αo
pr ojec tion
plane
output rotation
axis
αi
Full fluid
lubrication
Λ> 4
E + R i + Ro
wo sinα ο cosαο
log
wi sinα i c os αi
{f(P, ξ, η, a, b, E’, R , U , U , C , T )}
θ
r
s
p
o
lubr ican t lev el
g
Proje cted back
f ace of
input gear
{
lubricant level
Ro cosα
E
7"
0.3
Scenario 2
Ro
6"
0. 7
o
Ri
Ri c osα
g
i
R i cosαi + Ro cosα o +
w i sinαi cosαi + w o sinαo cos αo
Idea Evaluation
Alternative Design
Idea Evaluation
Idea evaluation
Gleason Works
75
Market share (%)
Klingelnberg
25
Proposed
0
Output cutter
Efficiency
-
Manufacturing cost
1
2
3
4
5
6
Bearing inner race
ring gear mounting flange
side gear
spider gear
internal spline
¼ X 2 in roll pin
-
-
-
Flexibility
-
-
Post processing
-
-
Power denisty
-
-
Spiral angle
-
-
Pressure angle
-
-
Face width
-
-
Interchangeability
-
-
Established technology
+
+
strength
-
-
Noise
-
-
# of -
11
11
# of +
1
0
1
0
# of S
D a t u m
{
Mixed
lubrication
Λ< 1
0.001
Projecte d b ack
fac e of
o utput ge ar
wi
Scenario 1
Boundary
lubrication
t
n
iec 0.1
if
ef
o
c
n
o
tic 0.01
ir
F
Idea Evaluation
Steering information
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NC steering application
Direction of travel
75,000,000 vehicle steering units/year
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Idea Evaluation
40,000,000 cars/trucks
Lawn & garden
Off-road
Trend is EAS (Electrically Assisted Steering)
30 million hydraulic units/year
5% loss at idle (hydraulic systems)
0.01% loss at idle for EAS
EAS to be 20% market by 2007 & 50% by 2010
Idea Evaluation
Instantaneous
center of turn
wa
la
γl
γr
radius of turn ρ=1/κ
Idea Evaluation
7
I/O relation for steering
NC steering mechanism
γ5r
steering knuckles
-45
45
tie rods
-30
-15
0
γ2l
γ2l
15
left steer angle (rad.)
30
ϕ2r
θ2l
Tire
ϕ2
Tire
right steer angle (rad.)
}
β=1 (reverse Ackermann)
β=0.5 Coordinated steering
β=0.125 with slip angles
β=0 Ackermann steering
15
γ2r
0
noncircular gears
-15
30
-30
45
-45
Chasis
wa
Idea Evaluation
Weighted Rating Method
Convential Steering
Worst
140
0.25
Maintenance
50
200
0.25
50
10
2.5
50
2.5
65
9
Cost
150
300
0.15
200
6.666667
1
225
5
0.75
250
3.333333
0.5
Performance
80
40
0.35
50
2.5
0.875
60
5
1.75
75
8.75
3.0625
Total
1
Total
6.153846 1.538462
Magnitude
115
5.913462
Rating
In DATA we trust!
NC Steering
75
100
Rating
Prototype & Testing
Best
Simplicity
Weight Magnitude
Rack & Pinion Steering
Total
Magnitude
3.846154 0.961538
10
125
Idea Evaluation
Rating
Total
2.307692 0.576923
5.961538
2.25
6.389423
Sum column
= %(Val.-worst)/(Worst -Best)
Idea Evaluation
Cambridge 2000
Idea Evaluation
Virtual prototytpe
hyperboloidal pitch surface
transverse surface
e
sv
tran
rface
su
e
sv
tran
rfce
ilsu
ax
rfaceu
rf
ilsu
ax
axial surface (cylindroid)
If a picture is worth a thousand
words, a working prototype
is worth a million pictures.
Idea Evaluation
8
Actual prototype
Optimization
High tech
Instrumentation
We can't solve
problems by using the
same kind of thinking
we used when we
created them.
Albert Einstein
Idea Evaluation
Back of envelop calculations
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Drive train failure?
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Power: 55 Hp
Speed: 8,000 RPM
Shaft torque: 30 ft-lb
Q=mCpΔT
46.7
CVT (80% vs 90%?)
100.67
„
Design Optimization
F=ma
Place significance with #’s
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Weight: 700 lb
F=ma: F=320 lb
Shaft torque: 300 ft-lb
Design Optimization
Component vs System
Design Optimization
Design Optimization
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Objective Function
„
30 %
90 %
„
27% efficient
„
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Constraints
„
40 %
80 %
32% efficient
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Design Optimization
Minimum weight
Minimum cost
Maximum profits
Maximum power/weight ratio
Pressure
Stress
Time
Temperature
Design Optimization
9
Results
Best vs Winner
Mac vs Windows
(VHS vs Beta) vs DVD
Automobile vs Rail
Boeing vs AirBus
UPRM vs Winner (rice transporter)
Newton vs Lagrange
Newton vs Leibniz
Design Optimization
Summary
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Design Optimization
Comments/questions?
Design Prologue
Work Statement
Gantt Chart
Product Design Specifications or PDS
Idea Evaluation
Design Optimization
10