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1
Detailed Design Review
Week 9: 11/06/2009
Agenda1. Design Review Objectives----------------------------3:00 pm
2. Project Background-----------------------------------3:05 pm
3. Mechanical System Architecture---------------------3:10 pm
4. Electrical System Architecture-----------------------3:40 pm
5. Failure Modes and Effects Analysis------------------4:10 pm
6. Risk Mitigation Plan-----------------------------------4:15 pm
7. Bill of Materials----------------------------------------4:20 pm
8. Test Plan------------------------------------------------4:25 pm
9. Budget--------------------------------------------------4:35 pm
10. Next Steps----------------------------------------------4:50 pm
2
Design Review Objectives� Optimize specs to reduce cost
� Optimize manufacturability and constructability
� Identify potential opportunities for improvement
� Ensure proper safety considerations
Project Background� Customer: Mini Baja club at RIT
� Endurance race and water event
� Project Scope:
� Recommendation for the best water propulsion option
� Documentation supporting this recommendation
� Usable test stand
3
Test Stand Design
System Architecture
4
Tank and Frame System
Tank and Frame BOM
Subassy Component Name
Number
Needed Specs Product Name Seller Price
Tank Tank Bladder 5 7' L x 4' W x 4' H Poly Tarp tarpsplus.com $ 90.00
Frame
Frame 1 95' x 1"sq x 11 gauge Square Tube Stock Steel and Surplus $ 135.00
Liner Structure 3 4'W x 8'L x 3/8"thick Plywood Home Depot $ 43.35
Window 2 2'W x 4'L x 1/4" thick Acrylic Plexiglass estreetplastics.com $ 77.98
Welding Supplies 1 Spool of filler wire ER70S-6 .030" dia x 2lb spool Mahany Welding $ 7.00
Bolts 20 1/2" - 13 x 2 1/4" Stainless Steel Bolts x10 www.fastenal.com $ 18.00
Corrosion Protection 6 Spray can paint Rust-o-leum paint Home Depot $ 24.99
Fixtures 8 1-1/4" x 1-1/4" x 1/8" x 1' Angle Iron Steel and Surplus $ 1.00
5
Tank and Frame Stress Analysis
Deflection with 100lb point load: Max deflection was 1.03621 mm
Stresses with 100lb point load: Max stress was 37.3MPa = 5 417psi (below the yield strength of the steel)
Sliding Structure System
6
Sliding Structure Options
Linear Motion saves ~$400
Sliding Structure Options
Different Bearing saves ~$30
7
Sliding Structure Options
Different Axle Housing Bracket saves~$140
Sliding Structure Options
Smaller Square Tubing saves~$50
8
Sliding Structure BOMSubassy Component Name
Number
Needed Specs Product Name Price
Sliding
Structure
Arm Structure_Drive Axle Housing 1Low carbon steel, 36" x 3/8" wall
thickness, 1.5" outside diameter
#7767T533 Round
Tubing$ 40.97
Arm Structure_Swing Arm 1Low carbon steel, 36" x .12" wall
thickness, 1.5" outside diameter#7767T43 Round Tubing $ 30.65
Arm Structure_Restraint 2 Share Material With Axle Carrier $ -
Arm Structure_Handle 1Low carbon steel, 36" x .12" wall
thickness, 1.5" outside diameter#7767T43 Round Tubing $ -
Custom Arm Structure Mounts_Body 2 3.25"x4.5"x1.125" Low Carbon Steel #8910K853 Material $ 42.22
Custom Arm Structure Mounts_Bushing 2 Bronze Bushing#6381K574 Bronze
Bushing$ 14.02
Custom Arm Structure_Nuts and Bolts 8Grade 8 Zinc Plated Bolts and Nuts
Self Locking Nuts
#91286A391
#97135A255$ 15.00
Bearings_Linear Motion 12 Corrosion Resistant Skateboard Bearing 608ZZ10-1 $ 7.08
Bolts_Linear Motion 12 Shoulder Bolt 92981A202 $ 14.04
Angle_Linear Motion 2 Low Carbon Steel Angle 1/4" Thick $ 6.56
Spacers_Linear Motion 48 Steel Spacer1mm Thick
#98055A115$ 8.39
Square Tubing_Linear Motion 1 Low Carbon Square Tubing 1"x1" 14 Gauge $ 140.00
C-Channel_Linear Motion 2 Square U-Channel $ 25.00
Sliding Structure BOMSubassy Component Name
Number
Needed Specs Product Name Price
Sliding
Structure
Position Locking Pin 2 Low Carbon Steel Round Stock.75" Round Stock
Material
$
2.00
Drive Shaft Support Bearing 1 Mounted Ball Bearing 6244K530$
35.79
Cross Member for Drive Shaft Support
Bearing 1 Low Carbon Steel Rectangle Bar 10"x1 1/4 3/8" Thick
$
1.50
Spacer Material 1 Low Carbon Steel1.5" OD 3/8" Wall
Thickness Round Tubing
$
1.00
Drive Axle Housing Bearing 2Hardened Carbon Steel
Sleeves_Flanged_Double Sealed
#6384K365 Sealed Ball
Bearing
$
19.32
Seal 1 Shaft Seal #8910K815$
4.87
Gussets and Tabs 1 1/4" Low Carbon Steel 1/4" Low Carbon Steel$
3.00
Shaft Material 1 Al 6061 1.5" OD x 1ft length R3112$
11.25
Hub 1 Mini Baja Hub Mini Baja Hub$
-
Axle Carrier 13" OD .5" Wall thickness Low Carbon
SteelRound Tubing
$
5.00
Inboard Tapered Roller Bearing 1 Steel 55mm OD 30mm ID#6677K58 Tapered
Roller Bearing
$
-
Outboard Tapered Roller Bearing 1 Steel 72mm OD 35mm ID#6677K62 Tapered
Roller Bearing
$
-
9
Sliding Structure Stress Analysis
Equivalent (von Mises) Stress on bolt Deformation
Drive System
10
Drive System BOM
Subassembly Component Name
Number
Needed Specs Product Name Price
Drive Mechanism
Driven Pulley 1 Timing Belt Pulley H-Pattern - Steel Goodyear 48H150SK $ 110.42
Driven Pulley Hub 1 Timing Belt Pulley Hub Goodyear SK $ 14.00
Driver Pulley 1 Timing Belt Pulley H-Pattern - Steel Goodyear 18H150SH $ 39.66
Driver Pulley Hub 1 Timing Belt Pulley Hub Goodyear SH $ 9.00
Timing Belt 1 Heavy Series Timing Belt Goodyear 780H150 $ 39.80
Motor 1 3 HP DC, max 1750 rpm, 180 volt, 100 lbs 3 HP DC $ 400.00
Wire (For Motor Drive
and Motor)1 12 AWG 12 AWG $ -
Shaft and Coupling 1 72" long, 5/8" dia., full keywayKeyed Shaft and Set
Screw Coupling$ 77.00
Drive System Stress Analysis
DeformationMax: 0.07”
11
Drive System Stress Analysis
Equivalent (von-Mises) StressMax: 56,000 psi
Shear Stress, XY PlaneMax: 22,000 psi
Drive System Stress Analysis
Normal Stress, Z AxisAverage: 600 psi
Shear Stress, YZ PlaneMax: 15,000 psi
12
Electrical System
Electrical System BOM
24
Subassy Component Name
Number
Needed Specs Product Name Price
Data
Processing
Micro-controller (DAQ) 1
Two 10-bit analog outputs, One 32-bit counter,
External trigger input, 12-bit (DI), 11-bit (SE)
resolution, 8 SE or 4 DI analog inputs, 16 digital I/O
lines
MiniLab 1008 USB-1208LS $ -
USB Cable 1 1', B to A connection N/A $ -
Testing Software 1 N/A TracerDAQ $ -
Calibration Software 1 N/A InstaCal $ -
Data Processing Software 1 Labview Universal Libraries LabView $ -
Data
Gathering
Hall Sensor 1 handles 2000 rpmHoneywell 4AV16F Vane
Sensor$ 25.12
Vane 1 ferrous vane, max 1.02 mm thicknessLow-carbon, cold-rolled
steel$ -
Circuit Board 1 4" x 4", epoxy glassVector Electronics Circuit
Board$ 7.09
Wire 1 28 awg, basic insulation, 100' coil Alphawire #2856/1 WH005 $ -
Load Cell 1 50 lbs, 150% Overprotection. FUTEK LSB300 $ -
Load Cell Voltage
Conditioner1 2mV/V Input, 5/10V Output FUTEK CSG110 $ -
Safety
MeasuresKill Switch Button 1
Fits 7/8in. and 1in. frame or handle bars. 36in.
shielded lead wire with spade end.Kill Button Switch $ 10.99
Power
Electronics
Motor Drive Controller 1 3HP, 230VAC in, 180 VDC out, 1PH KBCC-225 $ 203.00
Motor Drive Controller
Accessory1 05V input, 0-10V output, Voltage Follower isolation Signal Isolation Unit $ -
Power Supply 1 96-264VAC to 24VDC PSAA15W-240 $ 21.00
Power Supply 1 110/120VAC to 220/230VAC @50/60Hz, 3000WattsVOD 3000 2 WAY - STEP
UP/DOWN TRANSFORMER$ 89.99
13
AC vs. DC Motor� AC
� Can’t be run below 50% without additional cooling
� Higher current requirement
� DC
Subassembly Component Name Specs Product Name Price
Drive Mechanism Motor 3HP, 1800RPM, 3PH MTC-003-3BD18* $ 191.00
Power ElectronicsMotor Drive Controller 3HP, 230VAC in, 1PH in, 3PH out. GS2-23P0 $ 296.00
Motor Drive Controller Accessory 230VAC, 1PH in. GS-23P0-LR-1PH $ 138.00
Subassembly Component Name Specs Product Name Price
Drive Mechanism Motor 3 HP DC, max 1750 rpm, 180 volt, 100 lbs 3 HP DC $ 400.00
Data GatheringHall Sensor handles 2000 rpm
Honeywell 4AV16F Vane
Sensor$ 25.12
Power Electronics
Motor Drive Controller 3HP, 230VAC in, 180 VDC out, 1PH KBCC-225 $ 203.00
Motor Drive Controller
Accessory
05V input, 0-10V output, Op Amp.
Conditioning, Voltage Follower bufferSignal Isolation Unit -
Motor Drive Controller
Accessory (Alternative)230VAC power, 0-10VDC in, 0-10VDC out. SI-6 $ 113.00
Power Converter
110/120VAC to 220/230VAC @50/60Hz,
3000Watts
VOD 3000 2 WAY - STEP
UP/DOWN TRANSFORMER $ 89.99
Integration Feasibility Analysis
26
� InstaCal
� Installation
� Calibration
� Testing
14
Integration Feasibility Analysis� InstaCal’s Analog Loop
Back Test
� Verifies operation of digital outputs and analog inputs
Integration Feasibility Analysis
15
Integration Feasibility Analysis� TracerDAQ
� Strip charts
� Oscilloscope
� Function Generator
Integration Feasibility Analysis
U1
LM741
+3
-2
V+
7V
-4
OUT6
OS11
OS25
R11k
R2
1k
U2
LM741
+3
-2
V+
7V
-4
OUT6
OS11
OS25
V815Vdc
V915Vdc
DC MOTOR CONTROL1k
R410KSET = 0.2
R510KSET = 0.5
V
V
0
DAQ
FREQ = 60VAMPL = 2.5VOFF = 2.5
Signal Isolation Unit Schematic
16
Integration Feasibility Analysis
Time
0s 5ms 10ms 15ms 20ms 25ms 30ms 35ms 40msV(V7:+) V(R3:2)
0V
2V
4V
6V
8V
10V
(12.386m,183.620m)
(4.1408m,9.999)
(12.602m,1.8600m)
(4.1408m,4.9999)
Signal Isolation Unit Waveforms: Signal-in (green) and Signal-out (red).
Software Flow
17
Risk Assessment
Risk Mitigation PlanPotential Failure Mode R P N Actions Recommended Resp. Due Date Plan B
Rip or tear 8 Order material samples to test Stephanie/Greg 10/23/2009 Use solid, water-proof tank
Casters break 15 Gather detailed information about caster specs Stephanie/Greg 11/4/2009 Find alturnitive casters to use
Frame breaking 180 Have multiple stress test to cover different situations Stephanie/Greg 11/5/2009 Redesign test stand
Frame bending/fracturing 24 Perform multiple stress tests to cover different situations Stephanie/Greg 11/5/2009 Redesign frame structure
Project cost exceeds $1500 budget 147 Each subsystem group updates current and expected expenditures weekly Everyone 11/20/2009 Ask Dr. Hensel for larger budget
Project cost exceeds $1500 budget 147 Discuss updated budget weekly Everyone 11/20/2009 Ask Dr. Hensel for larger budget
Motor can't generate required wheel speed, forward propulsion is less than
real life140 Determine importance of data accuracy Blaine/Eric 11/20/2009 Ask Baja if they want accuracy
Motor can't generate required wheel speed, forward propulsion is less than
real life140 Research motor capabilities prior to purchase Blaine/Eric 11/20/2009 Ask Dr. Hensel for larger budget and buy overly-large motor
Motor can't generate required wheel speed, forward propulsion is less than
real life140 Discuss assumptions and needs with professors before purchase Blaine/Eric 11/20/2009 Ask Dr. Hensel for larger budget and buy overly-large motor
Motor can't generate required wheel speed, forward propulsion is less than
real life140 Allocate more money to motor if necessary Blaine/Eric 11/20/2009 Ask Dr. Hensel for larger budget and buy overly-large motor
Deformation or fracture of welds or members 16 Design frame to withstand forces several times greater (~6x) than expected Blaine/Eric 11/20/2009 Redesign structure with regard to failed element (loading or resonance)
Deformation or fracture of welds or members 16 Perform stress analysis Blaine/Eric 11/20/2009 Redesign structure with regard to failed element (loading or resonance)
Seizure, deformation, fracture of runners 16 Design secure lid Blaine/Eric 11/20/2009 Design alternate linear motion mechanism
Seizure, deformation, fracture of runners 16 Attach lid to shield drive parts Blaine/Eric 11/20/2009 Design alternate linear motion mechanism
Seizure, deformation, fracture of runners 16 Design even spacing to balance loads Blaine/Eric 11/20/2009 Design alternate linear motion mechanism
Rip or tear 8 Perform tensile test on samples before committing to final material Stephanie/Greg 12/4/2009 Use solid, water-proof tank
Rip or tear 8 Test material properties before committing to material Stephanie/Greg 12/4/2009 Use solid, water-proof tank
EE Team does not know LabView well 45 Test LabView to learn software Henny/Ticiano 12/11/2009 Use different software to program stand (DaisyLab)
EE Team does not know LabView well 45 Ask professors for guidance Henny/Ticiano 12/11/2009 Use different software to program stand (DaisyLab)
EE Team does not know LabView well 45 Have initial programs checked by professors. Henny/Ticiano 12/11/2009 Use different software to program stand (DaisyLab)
Seizure, deformation, fracture of bearings 32 Perform stress analyssi Blaine/Eric 12/11/2009 Redesign drive system
Seizure, deformation, fracture of bearings 32 Allow for safety factor when designing Blaine/Eric 12/11/2009 Redesign drive system
Seizure, deformation, fracture of bearings 32 Provide adequate support/number of bearings Blaine/Eric 12/11/2009 Redesign drive system
Seizure, deformation, fracture of bearings 32 Test to ensure precise alignment Blaine/Eric 12/11/2009 Redesign drive system
Seizure, deformation, fracture of bearings 32 Use sealed bearings Blaine/Eric 12/11/2009 Redesign drive system
Does not seal correctly, rips or tears 32 Practice using heat sealer before creating tank Stephanie/Greg 12/14/2009 Use solid, water-proof tank
Does not transmit data, can't sense vane 24 Check that vane material is compatible before assembly Henny/Ticiano 12/18/2009 Seek alternative methods like back EMF
Does not transmit data, can't sense vane 24 Check and test sensor in safe operating conditions Henny/Ticiano 12/18/2009 Seek alternative methods like back EMF
Belt snaps, streches, falls off pulley, slips 18 Test to ensure precise construction Blaine/Eric 12/18/2009 Use alternate drive mechanism (geared shafts)
Belt snaps, streches, falls off pulley, slips 18 Use grooved timing belt Blaine/Eric 12/18/2009 Use alternate drive mechanism (geared shafts)
Belt snaps, streches, falls off pulley, slips 18 Design distance between shafts to achieve correct tension Blaine/Eric 12/18/2009 Use alternate drive mechanism (geared shafts)
Belt snaps, streches, falls off pulley, slips 18 Test to ensure precise alignment between shafts Blaine/Eric 12/18/2009 Use alternate drive mechanism (geared shafts)
Seizure, deformation, fracture of shaft or bearings 16 CNC machine customer part to ensure precision Blaine/Eric 12/18/2009 Redesign machined part and/or use stock parts
Seizure, deformation, fracture of shaft or bearings 16 Use sealed bearings Blaine/Eric 12/18/2009 Redesign machined part and/or use stock parts
Welds do not hold 14 Test weld strength before using stand Stephanie/Greg 12/18/2009 Send stand out to be wielded by licensed company
Shaft misalignment (axial, parallel, or both) 9 Make shaft alignment top drive system construction priority Blaine/Eric 12/18/2009 Redesign drive mechanism to allow for misalignment
Misalignment in bearings, bending at pulley 9 Provide support for pulley in design Blaine/Eric 12/18/2009 Redesign drive mechanism to allow for misalignment
Misalignment in bearings, bending at pulley 9 Make shaft alignment top drive system construction priority Blaine/Eric 12/18/2009 Redesign drive mechanism to allow for misalignment
Operation exceeds design limits 8 Keep operation within torque and rpm limits of coupling Blaine/Eric 12/18/2009 Order/fabricate more robust part
Frame breaking 180 Load frame slowly the first time Stephanie/Greg 1/8/2010 Rebuild frame
Frame breaking 180 Visually inspect when fully loaded before first test Stephanie/Greg 1/8/2010 Fix any issues that do not pass visual test
Tarp does not maintain shape, slips off frame 144 Test fill tank before using with wheel Stephanie/Greg 1/8/2010 Use solid, water-proof tank
Controller becomes damaged due to improper use. Electronics fail. 144 Include fuses and surge protection in design Henny/Ticiano 1/8/2010Needs to be resolved. Failure in implementing preventative measures can
be harzardous to health.
Controller becomes damaged due to improper use. Electronics fail. 144 Include proper use of controller in SOP Henny/Ticiano 1/8/2010Needs to be resolved. Failure in implementing preventative measures can
be harzardous to health.
Lots of vibration transferred from motor to stand 128 Research motor running specs to determine likely vibration force Blaine/Eric 1/8/2010 Separate motor and frame into separate structures
Lots of vibration transferred from motor to stand 128 Design sufficient buffering and spacers into frame Blaine/Eric 1/8/2010 Separate motor and frame into separate structures
Lots of vibration transferred from motor to stand 128Write procedure for identifying unsafe running conditions and stopping process
into SOPBlaine/Eric 1/8/2010 Separate motor and frame into separate structures
Does not seal, difficult to put on and remove 108 Measure track distances and ensure level welding Stephanie/Greg 1/8/2010 Rework design so it is easier to assemble and seal
Does not seal, difficult to put on and remove 108 Double check all measurements and test before delivering to customer Stephanie/Greg 1/8/2010 Rework design so it is easier to assemble and seal
No transfer of data. Not compatible with certain operating systems. 48 Include test run in SOP. Henny/Ticiano 1/8/2010Begin testing other provided DAQ board. Arduino Duemilenove is another
cheap alternative.
Does not seal correctly, rips or tears 32 Demonstrate assembly proceedure Stephanie/Greg 1/8/2010 Use solid, water-proof tank
Does not transmit data, can't sense vane 24 Implement using appropriate schematics Henny/Ticiano 1/8/2010 Seek alternative methods like back EMF
Does not transmit data, can't sense vane 24 Include test run in SOP. Henny/Ticiano 1/8/2010 Seek alternative methods like back EMF
Frame bending/fracturing 24 Once built, visually inspect frame when it is fully loaded before beginning test Stephanie/Greg 1/8/2010 Test stand weight capacity befor running experiment
Frame bending/fracturing 24 Start test at low RPM and visually inspect before running full test. Stephanie/Greg 1/8/2010 Start test several times at increasingly higher RPMs before running full test
18
Risk Mitigation PlanPotential Failure Mode RPN Actions Recommended Resp. Due Date Plan B
Rip or tear 8 Order material samples to test Stephanie/Greg 10/23/2009 Use solid, water-proof tank
Casters break 15Gather detailed information about
caster specsStephanie/Greg 11/4/2009 Find alturnitive casters to use
Frame breaking 180Have multiple stress test to cover
different situationsStephanie/Greg 11/5/2009 Redesign test stand
Frame bending/fracturing 24Perform multiple stress tests to cover
different situationsStephanie/Greg 11/5/2009 Redesign frame structure
Project cost exceeds $1500
budget147
Each subsystem group updates current
and expected expenditures weeklyEveryone 11/20/2009 Ask Dr. Hensel for larger budget
Bill of Materials� Sliding Structure
� Drive Mechanism
� Tank
� Frame
� Data Processing
� Data Gathering
� Safety Measures
� Power Electronics
19
Materials Cost Breakdown
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
$-
$50.00
$100.00
$150.00
$200.00
$250.00
$300.00
$350.00
$400.00
$450.00
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53%
BudgetItem Target Actual
Raw Materials
- Tank 300 398
- Drive Train System 280 718
- Fenders 300 0
Electronics
- DC Motor 300 693
- Microcontroller 100 0
- RPM Sensor 60 25
- Load Cell 200 21
- Accessories 15 18
Propulsion Testing- Wheels for testing 0 0
- Wheel mounting - 0
Total $1505 $1872
20
Test Plan for Hardware Confirmation� Components (wks 2-12)
� Hall Sensor� Motor Controller� Tank Liner Validation� Signal Isolator
� Subsystems (wks 6-13)� Tank Water Holding� Rail/Runner Movement� Shaft Alignment
� Integration (wks 11-15)� LabView Data Acquisition System� Wheel in Water� Structure Natural Frequency� Complete System Movement
Next Steps� Confirm action items from review-----------NOW
� Make improvements based on review-------Nov. 13
� Create MSD II WBS and Project Plan------- Nov. 13
� Order parts------------------------------------- Nov. 20
� Address safety risks of running test stand-- Jan. 8
� Build test stand-------------------------------- Jan. 8
� Program sensors to acquire data------------- Jan. 15
21
Action Items
Questions
?
