Professional Documents
Culture Documents
Course Contents
Ng Heong Wah
(NHW)
Product Definition
Conceptual Design
Embodiment Design
Detailed Design, Engineering Analysis & Documentation
John Heng
(JH)
Zhou Kun
(ZK)
Date
10/8
Monday,LT1,11:30pm12:30pm
NationalDayHoliday
17/8
ConceptualDesignII
NHW
19/8
Wednesday,LT1,9:3011:30pm
ProductDefinition&Design
NHW
Requirements,ConceptualDesignI (AHE)
EmbodimentDesignI
NHW
24/8
EmbodimentDesignII
NHW
26/8
DetailedDesignI
31/8
NHW
2/9
7/9
EngineeringAnalysisand
Documentation
Hydraulicsystemssizing&selection
14/9
Hydrauliccircuitdesign
AHE
21/9
Hydrauliccircuitdesign
AHE
28/9
5/10
28/9 2/10,RecessWeek
CostEstimationI
AHE
12/10 CostEstimationII
AHE
10
19/10
ZK
21/10 BasicsofMaterialsSelection
ZK
11
ZK
28/10 SelectionofMaterialsandShape
ZK
12
26/10 MultipleconstraintsandConflicting
Objectives
2/11 SelectionofMaterialsandShape
ZK
4/11
13
9/11
ZK
IntroductiontoMaterials
SelectionofMaterialsandShape:Case
Studies
Date
12/8
AHE
Hydraulicsystemssizing&
selection
9/9
LadderLogicprogramming,
pneumaticcircuitsI
16/9 LadderLogicprogramming,
pneumaticcircuitsII
23/9 ApplicationofPLCsinautomated
systems
28/9 2/10,RecessWeek
7/10 ElectricMotordrivesystemdesign,
sizing&selection
14/10 Electromechanicalsensing&
actuationcomponents
NHW
AHE
JH
JH
JH
JH
JH
SelectionofMaterialsandShape: ZK
CaseStudies
3
11/11 Brakes&Clutches
AHE
DesignProjectSchedule:Tutorialssession~about40mins.Projectsession~Restof3hoursVersion:3
WeekNo
1
DatesMonday
10/8
Project
Tutorials
Tutorialquestions
Free
Concept
No
Presentation
Labs
Report
Submission
FinalPresentation
2
17/8
3
4
5
6
24/8 31/8 7/9 14/9
T1
T2
T3
T4
NHW NHW NHW AHE
7
21/9
T5
JH
8
5/10
T6
JH
MA4001DesignClasses
Mon:1:30pm4:30pm
MA1MA4,4groups AHE,NHW,OLS,ZK
Tues:1:30pm4:30pm
MA5MA7,3groups OLS,JH,WMS
Wed:1:30pm4:30pm
MA8,1group Sridhar
Thurs:1:30pm4:30pm
MA9MA11,3groups SLK,XZ,YWY
9
12/10
T7
AHE
10
19/10
T8
ZK
11
26/10
T9
ZK
12
2/11
T10
13
9/11
Sridhar
Ng Heong Wah
Zhou Kun
Lab sessions
~40 mins
Tutorials
Rest of 3 hrs
Project
Do a Design Project:
Apply knowledge of design processes, costing, materials and
machine elements , to design a product
Project for this semester is:
Course Grading
4 students form a team. All teams will work on same project.
Your subject grade
Examination 100%
Report 80%
Team level.
The marks consist of
mid-semester
presentation and
project report.
Team receives
same marks.
50:50
Logbook 10%
Project 100%
Interview 10%
Individual level,
Your name in front.
contains details of:
Individual level
Interview at any time in
semester.
as
Supervisors
look
for
knowledgeable response.
6
3. Project Marks
This project is worth 50% of the course marks for MA4001. The other 50% is from
the course examination paper. The project team will comprise of four members and
individual marks will be allocated according to:
Individually kept logbook will be inspected by the tutors on a regular basis and
queried. All students are required to fill the log book with details of work done
whether it be sketches, design calculations, internet search and any other work that
they personally conducted for the project relevant to the design development.
Phone calls, faxes of product or part data from suppliers can be stapled to pages in
the log book. Therefore, no two log books should contain the same information.
Each logbook will have the student's name written on the cover in ink. An exercise
book or notebook at least A5 size is suitable. They will be submitted with the group
project report at the end of the project.
Every team member will have to present to the lab group at the middle semester
and be interviewed at the end of semester.
For the presentation, each team will prepare a short oral discussion of the project
concepts.
The interview will be between the tutor and the team and will consist of questions
to individual team members concerning their individual involvement in the project.
Interview will be spread over the two to three lab sessions, with tutors deciding
on interview timings, generally at each week sessions, he will interview two to
three teams.
Do not write things down on bits of paper and copy onto the log book neatly.
Ideas, calculations, sketches, relevant pages of catalogues, design
parameters, dimensions, schematics, graphs, reminders etc. are entered.
11
In many cities, high population density, scarcity and high cost of land resulted in
innovative automated car parking systems. These can range from small 2 to 3 cars
stacking systems to warehouse sized systems storing hundreds of cars in a space
efficient manner.
The largest systems are completely automated
using warehouse storage and retrieval
technologies and reliant on software controlling
the system.
This design project also expects you to solve the problem of car parking.
The objective of is to design a simple system capable of parking 2 to 3 cars on a
footprint of single parking lot based on a mechanical system.
The mechanical system is unlike the completely automated system described
above. The mechanical system car park is a method of parking that involves a
person such as a car park attendant or driver to initiate the mechanical movements
via electrical push buttons/switches etc.
The mechanical movements are generated by
electric motors driving machine elements such
as power screws, rack and pinions, chains, wire
ropes, pulleys and hydraulic actuators.
information available in internet search :
www.totalparkingsolutions.co.uk
www.wohr.parking.uk
www.carstackers.com.au
www.hardingsteel.com
www.ronblank.com/courses/kmp14a/kmp14a.pdf
a residential condominium pr
an industrial estate
Depending on each, the constraints are different and have to be included in the
design of the car park. So choose one of the above.
Use the knowledge of machine elements from your MA3001 courses and
engineering graphics from your MA2005 courses to innovate ways of moving
the car.
The structural frame supporting the cars, hydraulic or mechanical systems need
to be strong and stiff in order to function reliably. Moving parts need well
lubricated guides or rollers. The supporting frame must also ensure all the
moving part of the machine elements remain in alignment and large deformation
(even elastic) does not affect the functioning of the device. Strength of materials
calculations are required to confirm the strength of the frame members. You
need to carry out design calculations to ensure that your structural supports are
within the design stresses as well as the deflections are within tolerances.
Project Objectives:
To design a car stacker for parking and storing multiple cars (2 to 3) on the
footprint of a typical car park slot utilizing either the aboveground and/or
underground space.
To conduct a literature survey of the available mechanical car stacker system in
the market and patents disclosed of related inventions in the field.
Discuss the available design and write a critique ( for example discussing the
pros and cons of the concept as shown in fig 2.)
To develop the design requirements.
To generate a number of concepts (3) to perform the functions required.
Innovative and creative design is expected.
To select the best of the 3 design concepts using concept selection methods.
For the best design, to design in detail the mechanisms to transport the car from
parking position into the stacker, and in reverse return the car to the same
parking position.
Design may use either mechanical or hydraulic power transmission. For
hydraulic process, the hydraulic pump, control valves and relevant accessories
must be specified and included in the design. The source of power will either be
an electric motor/s. The car stacker use the machine elements/components
where-ever it is appropriate to the design; namely:
Hydraulic cylinders
Bearings
Belts and pulleys
Brakes and
clutches
Cables and wire
ropes
Chains and
sprockets
In carrying out this project, students working as a team will use the tools
learnt from the lectures to undertake the following;
Understand that the needs assessment will be used to create a set of criteria
and weighting factors to evaluate design concepts.
Use the structured matrix method for evaluating the design concepts with
respect to the selection criteria to finally select the most suitable concept.
Become familiar and can apply machine elements to create suitable actions of
the mechanical car stacker and select the most suitable noting its advantages
over other elements
Become familiar with the loading analysis and strength of materials calculations and
the selection of approximate dimensions of machine elements to adequately sustain
the applied loads within the factor of safety.
Become familiar with the selection procedures for some off-the-shelf machine
elements and use of parts catalogues in the product.
Be able to draw conceptual sketches and part drawings to drafting standards using
CAD programs or by manual drawings.
Demonstrate a high level of confidence and enthusiasm in the stacker and sal ability
in the market place.
How to start
This is quite a challenging project, but do not worry. There are
systematic steps to proceed with the design which is the course content
taught by the lecturers.
The steps:
1. Define and understand the problem
2. Conceptualise solutions, how many ways can it be done?
3. Embodiment design improve and make more effective the solution
concepts, Also make the design more manufacturable.
4. Detail design Produce drawings and instructions on manufacturing
a prototype.
31
Select one solution using decision matrix method. Create a simple layout
of main functions using embodiment principles.
Product Picture
Report to be submitted by
Week 13 (9th Nov to 13th Nov)
34
Chapter 1:
Introduction
Give reasons for the designing this product, research and survey
on existing design and systems, design requirements list,
quantifiable parameters.
Chapter 2:
Conceptual Design
- Contains the function analysis chart, morphological chart and
many hand drawn sketches of alternative conceptual designs.
Selection of best design using matrix selection method.
Chapter 3:
Chapter 4:
Chapter 6:
Cost Estimation
-Estimate the total cost of 1 prototype using product explosion
diagram. Discuss and include the direct and indirect cost.
Chapter 7:
Conclusions
- Give a short account of major achievements of the design and
problems encountered.
References
Appendices:
36
Work as a Team
37
38
Next Week
Prepare yourself:
Explore the design problem
Setting up your design requirements
Research the internet Dont copy, improve and innovate
Think of solutions
39
40
The real key to world competitive product lies in high-quality product design.
Decisions made in the design process cost very little in terms of the overall product cost
but have a major effect on the cost of the product.
You cannot compensate in manufacturing for defects introduced in the design phase.
4Cs of Design
Creativity
Complexity
Choice
Compromise
41
Performance characteristics
(properties)
Processing (manufacturing)
characteristics
Environmental profile
43
Efficiency
Safety
Interchangeability
Compatibility
44
Detail design is the phase where all of the details are brought together, all
decisions are finalized, and a decision is made by management to release
the design for production.
Poor detail design can ruin a brilliant design concept and lead to
manufacturing defects, high costs, and poor reliability in service.
THE REVERSE IS NOT TRUE!
45
Engineering Drawings: The information on a detail drawing includes: Standard view of orthogonal
46
projection; Auxiliary views; Dimensions; Tolerances; Material specification; Manufacturing details. Design
layouts show the spatial relationships of all components in the assembled product (the system).
47
Assembly drawings are created in detail design as tools for passing design intent to the production department.
The detail drawings allow the determination of final cost estimates, since
knowledge of the material, the dimensions, tolerances, and finish of each part
are needed to determine manufacturing cost.
Cost analysis also needs specific information about the particular machines
and process steps that will be used to make each part.
Note: Cost estimates will have been made at each step of the product design
process with successively smaller margins for error.
A design project report usually is written at the conclusion of a project to describe the
tasks undertaken and to discuss the design in detail.
A design project report may be an important document if the product becomes involved
in either product liability or patent litigation.
48
Cost evaluation
An engineering design is not complete until we have a good idea of the cost required
to build the design or manufacture the product.
Among functionally equivalent alternatives, the lowest cost design will be successful
in a free market place.
Understanding the elements that make up cost is vital because competition between
companies and between nations is fiercer than ever.
It is in the conceptual and embodiment design stages that a majority of the costs
49 are
locked into the product.
Primary
energy (fuel)
Prime
Movers
(engines)
Coal
Secondary Movers
Power Transmissions
Motors
Actuators
Fixed Ratio
Variable Ratio
Steam turbine
Electric
motors
Fluid cylinders
Mechanical
coupling
Mechanical Coupling
(some)
Oil
I/C engine
Fluid motors
Fluid actuators
Clutch
Clutch (some)
Gas
Gas turbine
Fluid coupling
Hydroelectric
Electromagnetic
coupling
Electromagnetic
coupling (some)
Nuclear
Belt
Gearboxes
Oceanographic
Chain
Terrestrial
Gears
Power Converter
M-1
Prime
mover
Power Source
Power Transmitter
I-2
Component
No. 1
2-L
Component
No. 2
Load
Power Sink
ii
ii
I
Q
Hydrostatic Drive
( bar )( lpm )
kw
600
N x m/s
Potential
Parameter
Flow Parameter
Force ,N
Velocity, m/s
IxV
Head, bar
Discharge, litres/min
Voltage, V
Current, I
motor
Pump
Input power
(kW)
Control valves
Pressure
Control
Valves
Directional
Control
Valves
Power actuators
Flow
Control
Valves
Linear actuator
Output power
(kW)
motor
Pump
AC/DC
Motors
SPECIAL
Motors
DC
Motors
Single-phase
induction
Synchronous
Threephase
415 ~ 440v
Servomotors
Self
excited
DC Brushless
220 ~ 240v
Repulsion
start
SquirrelCage
Separately
excited
Universal
Synchronous
Induction
Squirrel-cage
Wound-rotor
Split-phase
Capacitor start
Capacitor motor
Permanent split-capacitor (PSC)
Shaded-pole
Stepper Motor
Permanent
Magnet
Shunt
Series
Compound
Permanent Magnet
Variable Reluctance
Hybrid
(heat)
Motor Efficiency 90.5%
Power
T . = 100%
TRated
Constant Torque, P =
1.
Constant HP
100% = N .
NSync
Speed in %
Torque-speed characteristics
1. Constant Torque (Traction Load) ---- conveyors, crane hoist systems
2. Torque to speed (laminar flow load) viscous friction, magnetic brakes
3. Toque inversely to speed (traction load) constant horse power loads
4. Torque to square of speed (turbulent flow) centrifugal pumps, fans & blowers