ME 358 Design and Manufacturing II Design Project:Material Transfer Test Day:Dec.21,2011 Report Due Date:Dec.23 by 10 am Project Description Your company is designing a new factory layout for their new products using existing buildings.One part of the manufacturing line transfers material from one building to the next.Unfortunately,there is a one foot difference in height between the adjoining manufacturing lines.Department A has designed a mechanism that will collect the material from the lowest conveyor belt and when the desired weight is reached will dispense the material to a container.Department B has designed a mechanism for the top conveyor that will take the material from the container at the conveyor belt height and transfer the material from the container to the conveyor.For purposes of this project you can assume that the transfer of material on and off a conveyor is instantaneous. Your task is to move the container (filled with material)up one foot perpendicular to the floor from conveyor A to conveyor B and then return to the starting position to repeat the process.You want to transport 24 kg of material between point A and point B as quickly as possible.Please note that with the motors supplied,this may not be accomplished in one step.You will need to determine, based on the motor specification and your transfer machine design what is the best strategy for a quick transport-several trips with small weights or a few trips with larger weights.One constraint imposed by Department A and B is that the chosen weight has to be constant so that they can program their machines accordingly.Your machine must fit within the confines of an imaginary box with dimensions of 300W x 500L x 500H.All machines must fit holding fixtures(clamps)to hold machines in place for testing.Power will be supplied by a 12V DC electric motor through a transmission(belts and power screws). To validate and test your machine,you will set the constant weights into the supplied container and lift and lower it the number of times required for 24 kgs.We will measure the overall time from turning on the switch to start the machine to the machine returning to the original state after the full number of trips.You can NOT do any operation after you start the machine.Try to use mechanical method to count the numbers of your trips.You should be able to set up and take down your prototype in the minimal time,no longer than 2 minutes.For testing purposes,your power transmission system must clamp fit on top of the table and clamp to the edge of a table and lift the specified mass in the container(unless you get permission from the instructors for another testing set- up).The weights will be in the container and your device must be able to attach to the connection ring. Note:This is all the information that we have at this time.To simulate a more real design scenario,we will continue to distribute information.Although this may be frustrating,this is normal in the design processes.First,please feel free to ask many questions to help clarify matters.Second,we encourage you to layout your calculations and your drawings on the computer(spreadsheets,CAD system,etc)so you can make changes quickly and easily
ME 358 Design and Manufacturing II Design Project: Material Transfer Test Day: Dec. 21, 2011 Report Due Date: Dec. 23 by 10 am Project Description Your company is designing a new factory layout for their new products using existing buildings. One part of the manufacturing line transfers material from one building to the next. Unfortunately, there is a one foot difference in height between the adjoining manufacturing lines. Department A has designed a mechanism that will collect the material from the lowest conveyor belt and when the desired weight is reached will dispense the material to a container. Department B has designed a mechanism for the top conveyor that will take the material from the container at the conveyor belt height and transfer the material from the container to the conveyor. For purposes of this project you can assume that the transfer of material on and off a conveyor is instantaneous. Your task is to move the container (filled with material) up one foot perpendicular to the floor from conveyor A to conveyor B and then return to the starting position to repeat the process. You want to transport 24 kg of material between point A and point B as quickly as possible. Please note that with the motors supplied, this may not be accomplished in one step. You will need to determine, based on the motor specification and your transfer machine design what is the best strategy for a quick transport – several trips with small weights or a few trips with larger weights. One constraint imposed by Department A and B is that the chosen weight has to be constant so that they can program their machines accordingly. Your machine must fit within the confines of an imaginary box with dimensions of 300W x 500L x 500H. All machines must fit holding fixtures (clamps) to hold machines in place for testing. Power will be supplied by a 12V DC electric motor through a transmission (belts and power screws). To validate and test your machine, you will set the constant weights into the supplied container and lift and lower it the number of times required for 24 kgs. We will measure the overall time from turning on the switch to start the machine to the machine returning to the original state after the full number of trips. You can NOT do any operation after you start the machine. Try to use mechanical method to count the numbers of your trips. You should be able to set up and take down your prototype in the minimal time, no longer than 2 minutes. For testing purposes, your power transmission system must clamp fit on top of the table and clamp to the edge of a table and lift the specified mass in the container (unless you get permission from the instructors for another testing setup). The weights will be in the container and your device must be able to attach to the connection ring. Note: This is all the information that we have at this time. To simulate a more real design scenario, we will continue to distribute information. Although this may be frustrating, this is normal in the design processes. First, please feel free to ask many questions to help clarify matters. Second, we encourage you to layout your calculations and your drawings on the computer (spreadsheets, CAD system, etc) so you can make changes quickly and easily
Assignment Your team is responsible for generating competing concepts and down selection,modeling,building and demonstrating a working prototype of the material transfer machine.The key to this project is the power drive system to repeatedly lift the weights one-foot in the minimal amount of time. Since the power screw system has already been ordered,your primary responsibility will be to engineer and construct the power transmission system.Some of the other parts that you need to design might include (but are not limited to)the frame,the bearings,bushings,the connection to the power screw,and the belts. Main Tasks Stage 1.Conceptualization (Week 3-5) In this stage you want to explore a wide selection of concepts for your transmission.Once you have several concepts then pick the best one.Don't skimp on this stage,make sure to give it some time to be truly inspired. 1.Decompose your problem into the main functions 2.For each function(and then as a system as a whole)generate concepts for how to accomplish that function.Try using different concept generation methods such as brainstorming,concept trees,etc. 3.Down select objectively to the best concept as a group.Try using a rigorous method such as concept selection matrices. Deliverable:At the end of this task you should have many different designs,an objective evaluation of the design leading to the chosen concept,a rough drawing(perhaps a simple physical mock-up)of the system and each individual component,a simple operation drawing/diagram showing how the machine will operate through a full cycle. Stage 2.Parameter Design (Week 6-7) Model your design performing whatever analysis and/or experimentation required to size/specify your device.It should be engineered using your course work.The following should be addressed in this stage. 1.Mathematical power transmission analysis,including accounting for losses and efficiencies 2.Mathematical analysis of the belt-drive portion of the power system 3.Mathematical analysis of the screw-drive portion of the power system 4.Manufacturing plans in the form of text (instruction list)and figures-be brief! 5.Documentation of estimated material costs-scrap and garbage is not"free" 6. Documentation of design person-hours and manufacture person-hours. Deliverable:At the end of this task you should have each component modeled with an excellent free body diagram with all the forces and torques noted,a well formatted and commented spreadsheet with all calculations for the unknown variables,failure analysis check of appropriate parts,table of material researched with associated costs,list of design parameters with standard units and materials specified
Assignment Your team is responsible for generating competing concepts and down selection, modeling, building and demonstrating a working prototype of the material transfer machine. The key to this project is the power drive system to repeatedly lift the weights one-foot in the minimal amount of time. Since the power screw system has already been ordered, your primary responsibility will be to engineer and construct the power transmission system. Some of the other parts that you need to design might include (but are not limited to) the frame, the bearings, bushings, the connection to the power screw, and the belts. Main Tasks Stage 1. Conceptualization (Week 3-5) In this stage you want to explore a wide selection of concepts for your transmission. Once you have several concepts then pick the best one. Don’t skimp on this stage, make sure to give it some time to be truly inspired. 1. Decompose your problem into the main functions 2. For each function (and then as a system as a whole) generate concepts for how to accomplish that function. Try using different concept generation methods such as brainstorming, concept trees, etc. 3. Down select objectively to the best concept as a group. Try using a rigorous method such as concept selection matrices. Deliverable: At the end of this task you should have many different designs, an objective evaluation of the design leading to the chosen concept, a rough drawing (perhaps a simple physical mock-up) of the system and each individual component, a simple operation drawing/diagram showing how the machine will operate through a full cycle. Stage 2. Parameter Design (Week 6-7) Model your design performing whatever analysis and/or experimentation required to size/specify your device. It should be engineered using your course work. The following should be addressed in this stage. 1. Mathematical power transmission analysis, including accounting for losses and efficiencies 2. Mathematical analysis of the belt-drive portion of the power system 3. Mathematical analysis of the screw-drive portion of the power system 4. Manufacturing plans in the form of text (instruction list) and figures – be brief! 5. Documentation of estimated material costs-scrap and garbage is not “free” 6. Documentation of design person-hours and manufacture person-hours. Deliverable: At the end of this task you should have each component modeled with an excellent free body diagram with all the forces and torques noted, a well formatted and commented spreadsheet with all calculations for the unknown variables, failure analysis check of appropriate parts, table of material researched with associated costs, list of design parameters with standard units and materials specified
Stage 3.Manufacturing Plan (Week 8) Develop manufacturing plans for your design.This includes full dimensioned and toleranced engineering drawings on Unigraphics(or another CAD package with permission of instructor).You should have a build plan with an ordered list of machine steps with speeds.This will be reguired before permission is given to begin building.In addition,an assembly drawing of how all the pieces will be put together should be sketched out. Deliverable:At the end of this task you should have a CAD drawing and build plan for each component you will be making along with a simple assembling drawing.This will be required before permission is given to begin building Stage 4.Build and Test (Week 9-15) Build your prototype using the material ordered (see below)and the machine shops.Work in the machine shop cannot begin until each group member has completed the required training on the Lathe and Milling machine (assuming each member completed the cutting/drilling training in ME 250. The power supplies will be made available during this period for trial tests. All machines will be tested on Wednesday-each team given a designated testing time. Since we do not want to take all of Wednesday it is important to have the set-up and take down be as quick as possible.You will be given only 2 minutes to set up and two minutes to take down.If you go over this time you will lose 5 points per each minute over.When designing your prototype,do not forget that it will need to be portable for set-up and takedown. You will be given one formal trial during which the overall time from turning on the switch to the machine stopping in the original state.If you do not succeed,you will be given an additional trial(s)at the discretion of the instructor and you will be given a 5-point penalty per trial.A 3 point penalty will be assessed for any machine not returning to its original state and stopping.The parts available for this project are as follows:
Stage 3. Manufacturing Plan (Week 8) Develop manufacturing plans for your design. This includes full dimensioned and toleranced engineering drawings on Unigraphics (or another CAD package with permission of instructor). You should have a build plan with an ordered list of machine steps with speeds. This will be required before permission is given to begin building. In addition, an assembly drawing of how all the pieces will be put together should be sketched out. Deliverable: At the end of this task you should have a CAD drawing and build plan for each component you will be making along with a simple assembling drawing. This will be required before permission is given to begin building Stage 4. Build and Test (Week 9-15) Build your prototype using the material ordered (see below) and the machine shops. Work in the machine shop cannot begin until each group member has completed the required training on the Lathe and Milling machine (assuming each member completed the cutting/drilling training in ME 250). The power supplies will be made available during this period for trial tests. All machines will be tested on Wednesday – each team given a designated testing time. Since we do not want to take all of Wednesday it is important to have the set-up and take down be as quick as possible. You will be given only 2 minutes to set up and two minutes to take down. If you go over this time you will lose 5 points per each minute over. When designing your prototype, do not forget that it will need to be portable for set-up and takedown. You will be given one formal trial during which the overall time from turning on the switch to the machine stopping in the original state. If you do not succeed, you will be given an additional trial(s) at the discretion of the instructor and you will be given a 5-point penalty per trial. A 3 point penalty will be assessed for any machine not returning to its original state and stopping. The parts available for this project are as follows:
Parts Ordered and Available Material 1.Motor:DC:12V,current (w/o load)=2A,rotating speed (w/o load)=13000rpm,torque:500g- cm.Diameter of the output shaft:3mm Length of the output shaft:10mm,Diameter of motor body: 37.5mm、length:57mm(cost:￥35each) 2.Reversing switch:15A,250VAC (cost:4 each) 3.Limited switch (micro switch):15A-1/2HP-125 OR 250VAC (cost:Y4 each) 4.Wooden board:thickness:12mm,300mmX500mm (cost:Y20 each) 5.Power screw:d=8mm,length=1m (each group use 0.5m)(cost:Y8 each) 6.Leader:Diameter=12mm (cost:Y22 per kg) 7.Wire (red,green,black):5A (cost:Y40 per reel) 8.Small pulley:diameter=12mm (cost:Y10 each) 9.Large pulley:diameter=72mm (cost:Y10 each) 10.Drive belt:section diameter =4mm (cost:Y6 per meter)5mm (cost:Y7.5 per meter) 11.Steel string (section diameter=2mm,cost:Y1.5 per meter) 12.Others: Collet of the steel string(cost:￥1each)、 Collet of the wire (cost:Y0.8 for the big one,Y0.5 for the small one) Ball bearing:8mm (cost:Y2 each) hoop (cost:Y1 each),hoop for the motor (cost:Y0.4 each) fasteners(cost:￥o.3 per set).、 Aluminum bar(d=l0mm、cost￥22 per kg)、 Angle aluminum (40mmX40mm,thickness=4mm)aluminum strip (width=30mm, thickness=4mm)(cost:Y22 per kg) Please remember that others in the class are scrambling to design their substation and parts/materials are limited.Part catalogs will be provided which contain information about the parts as well as some analysis methods.You may alter the provided parts,such as the threaded rod and wood stock. Part Order When you have decided upon a design,you need to create a part order list and present it to be filled. Unfortunately,you will not be allowed to fill your order if there is an obvious error in the design that may lead to a failure.So,along with your order,you must show via your parametric design,your reasoning for choosing whatever sizes of parts that you require and the engineering and manufacturing plans developed in stages 2 and 3. Disclaimer:Note that just because your design is reviewed does not guarantee success.For testing you must use our power supply.You are not allowed to use any other power supplies or batteries in your design.If in question,please consult the instructor first
Parts Ordered and Available Material 1. Motor：DC:12V、current (w/o load) =2A、rotating speed (w/o load) =13000rpm、torque: 500gcm、Diameter of the output shaft: 3mm、Length of the output shaft: 10mm、Diameter of motor body: 37.5mm、length:57mm（cost: ¥35 each） 2. Reversing switch：15A、250VAC（cost: ¥4 each） 3. Limited switch（micro switch）：15A-1/2HP-125 OR 250VAC（cost: ¥4 each） 4. Wooden board：thickness:12mm、300mmX500mm（cost: ¥20 each） 5. Power screw：d=8mm、length=1m（each group use 0.5m）（cost: ¥8 each） 6. Leader：Diameter=12mm（cost: ¥22 per kg） 7. Wire（red、green、black）: 5A（cost:¥40 per reel） 8. Small pulley：diameter=12mm（cost:¥10 each） 9. Large pulley：diameter=72mm（cost:¥10 each） 10. Drive belt：section diameter =4mm（cost:¥6 per meter）、5mm（cost:¥7.5 per meter） 11. Steel string（section diameter=2mm、cost:¥1.5 per meter） 12. Others： Collet of the steel string（cost:¥1 each）、 Collet of the wire（cost:¥0.8 for the big one, ¥0.5 for the small one）、 Ball bearing: 8mm（cost:¥2 each）、 hoop（cost:¥1 each）、hoop for the motor（cost:¥0.4 each）、 fasteners（cost:¥0.3 per set）、 Aluminum bar（d=10mm、cost:¥22 per kg）、 Angle aluminum（40mmX40mm、thickness=4mm）、aluminum strip（width=30mm、 thickness=4mm）（cost:¥22 per kg） Please remember that others in the class are scrambling to design their substation and parts/materials are limited. Part catalogs will be provided which contain information about the parts as well as some analysis methods. You may alter the provided parts, such as the threaded rod and wood stock. Part Order When you have decided upon a design, you need to create a part order list and present it to be filled. Unfortunately, you will not be allowed to fill your order if there is an obvious error in the design that may lead to a failure. So, along with your order, you must show via your parametric design, your reasoning for choosing whatever sizes of parts that you require and the engineering and manufacturing plans developed in stages 2 and 3. Disclaimer: Note that just because your design is reviewed does not guarantee success. For testing you must use our power supply. You are not allowed to use any other power supplies or batteries in your design. If in question, please consult the instructor first
Grading Design Report(12 point,1"margins,double spaced,15 pages or less not counting pictures or appendices with detailed analyses.) (10%)Report Quality-Clearly written,free of spelling/grammar mistakes,ease in reading and ease in understanding concepts and analysis (5%)Design Description-Description of the design concepts generated(breadth is important), explanation of why final concept selected with selection matrix,description of final concept including decomposition into subsystems and operation of concept.Figures are important! (30%)Parametric Design-Modeling of design and analysis to back up choice of dimensions and the explanation of all assumptions and rational behind major design decisions.Make sure to describe the flow of energy and the flow of the force/torque among the components.It is expected that this section and appendices will have a detail mathematical analysis of the power transmission,such as the belt-drive and screw-drive subsystems,accounting for losses and efficiencies.For analysis purposes,when numerical values are not known,suggest how you might determine them.When the mechanics are very complex,provide an approximate or "model"equations.Make sure that all spreadsheets,matlab code,equations are well labeled with nomenclature tables,labeled variables,columns,etc to insure understandability and readability. (10%)Manufacturing Plan-Instructions on how to mfg.design including dimensioned engineering drawings,build plan,assembly instructions and part list. (5%)Cost Analysis-Determine the cost of your design based on cost of parts(nothing is free!),cost of design hours (keep track of how many hours you spent on this project),and assembly cost (labor,tools,etc.). (15%)Prototype Quality-Overall design,quality of workmanship,smoothness of operation and noise level (15%)Test Results-What were your test results?How did they compare to the rest of the class? What and test results,and how close you are to the class results? (10%)Design Critique/Analysis-Evaluate your design and outcome.Discuss your test results and critique it against the class results(to be given on the web after the testing).What worked, what did not,why,and what can be done to overcome problems and make design better (performance,reliability,cost,etc.).Some thought provoking questions will be supplied after the testing for you to address in this section. Note:The project score of each student depends on the score of the team and group participation evaluation
Grading Design Report (12 point, 1” margins, double spaced, 15 pages or less not counting pictures or appendices with detailed analyses.) (10%) Report Quality - Clearly written, free of spelling/grammar mistakes, ease in reading and ease in understanding concepts and analysis. (5%) Design Description-Description of the design concepts generated (breadth is important), explanation of why final concept selected with selection matrix, description of final concept including decomposition into subsystems and operation of concept. Figures are important! (30%) Parametric Design - Modeling of design and analysis to back up choice of dimensions and the explanation of all assumptions and rational behind major design decisions. Make sure to describe the flow of energy and the flow of the force/torque among the components. It is expected that this section and appendices will have a detail mathematical analysis of the power transmission, such as the belt-drive and screw-drive subsystems, accounting for losses and efficiencies. For analysis purposes, when numerical values are not known, suggest how you might determine them. When the mechanics are very complex, provide an approximate or “model” equations. Make sure that all spreadsheets, matlab code, equations are well labeled with nomenclature tables, labeled variables, columns, etc to insure understandability and readability. (10%) Manufacturing Plan - Instructions on how to mfg. design including dimensioned engineering drawings, build plan, assembly instructions and part list. (5%) Cost Analysis - Determine the cost of your design based on cost of parts (nothing is free!), cost of design hours (keep track of how many hours you spent on this project), and assembly cost (labor, tools, etc.). (15%) Prototype Quality - Overall design, quality of workmanship, smoothness of operation and noise level (15%) Test Results – What were your test results? How did they compare to the rest of the class? What and test results, and how close you are to the class results? (10%) Design Critique/Analysis - Evaluate your design and outcome. Discuss your test results and critique it against the class results (to be given on the web after the testing). What worked, what did not, why, and what can be done to overcome problems and make design better (performance, reliability, cost, etc.). Some thought provoking questions will be supplied after the testing for you to address in this section. Note: The project score of each student depends on the score of the team and group participation evaluation
