R.I.T. 175 th Anniversary Chopper Senior Design Team (Project Number 05912)
Chopper next slide to start.... A DESIGN CASE STUDY or “Tales of an engineering design...
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Transcript of Chopper next slide to start.... A DESIGN CASE STUDY or “Tales of an engineering design...
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Choppernext slide to start...
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A DESIGN CASE STUDYor “Tales of an engineering design consultant”
Presented by:Prof. Will DurfeeDepartment of Mechanical EngineeringUniversity of [email protected]
• Please sit with your team• Take one index card, one sheet plain paper
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• Stimulated Muscles = Power • Brace = Trajectory guidance • Brake = Control, stability
HUMAN/MACHINE DESIGN LABDepartment of Mechanical EngineeringUniversity of Minnesota(www.me.umn.edu/divisions/design/hmd/)
Fu
x,vT
X
PE Force-Velocity
CE Force-Velocity
Fscale
IRC
CE Force-Length
Activation Dynamics (2nd order)
PE Force-Length
u
V
X
V
X
Force
Passive Element
Active Element
Muscle mechanicsSmart orthotics +
electrical stimulation for gait restoration
Haptic interfaces for virtual product prototyping
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The case begins
At 2 pm on an otherwise ordinary day, you get a phone call...
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So the first question is...
What the heck is “roof ventilation”???
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http://ogrowald.home.texas.net/ogalleryindex.htm
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What’s the rest of the obstacle course look like?
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How about a close-up of a firefighter chopping a hole in a roof?
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Test chopping
• 3004 Cedar Av, destroy the roof• Video taped 12 firefighters, 4x4 hole• Time: 1:47 -- 13:28• Blows: 47 -- 268• Conclusions
– the task: hit hard enough and often enough to break through roofing material
– few, heavy blows, or lots of lighter blows– light tapping does nothing– bigger people take less time– roof surface is at feet
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Design requirements
• Task = sum of blows• Accuracy of blow• Weight and feel of ax• Endurance• Reliability• Cost• Ease of operation• Operates outdoors• Reliability• Reliability
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OK, time to brainstorm
You be the consultant.
As a team, brainstorm on at least three different ways to solve this problem. Quick sketch the “best idea on the blank paper. Deliver to Durfee in 12 minutes.
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The competition
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My design...
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Da Vinci notebooks: 4,000 pages of notes and sketches
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Early ideas
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The saga of the strike surface...
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8 layers of 3/4” BCX plywood
top with 1/4” lexan + 1/8” vinyl
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2” nylon
1/4” lexan + neoprene
1/4” lexan + carpet
1/4” neoprene + 1” lexan ==> held up…more or less
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Over two years, machine worked well…sort of...
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Parts and materials
Estimated
$1,330
Actual
$3,198
Labor
Estimated
$1,370
Actual
who knows...
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Major shortcomings
• Cable breaks• Top plate cracks• Complicated recalibration
involving a laptop and reprogramming the microcontroller chip
• A pain to maintain
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You be the design critic
On your index card, list 3 ways to improve the design. Deliver to Durfee in 3 minutes.
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Ref What Vendor Vendor PN Cost NotesShock accelerometer, 5K G range Dytran 3200B5 330.00$ Shock accelerometer, 5K G range Dytran 3200B2 350.00$ Cable, mini coax, 10-32 stainless plug to BNC, 10 ft. Dytran 6469A10 28.00$ Constant current diode, 2 mA Dytran 6123 4.00$ Connector adaptor, 10-32 to solder Dytran 6115 15Cable, new type, mini coax, 3 ft Dytran 6011A03 26
Tech Tools PIC programmer Digi-Key MP-PROG-ND 199.00$ Tech Tools 40-pin ZIF adapter Digi-Key MP-ZIF40-ND 49.00$ IC, PIC16F876-20/SP, microcontroller Digi-Key PIC16F876-20/SP-ND 9.38$ Resonator, ceramic w/ caps, 4.0 MHz Digi-Key X902-ND 0.56$ Resonator, ceramic w/ caps, 20.0 MHz Digi-Key X909-ND 0.68$ PCM C compiler CCS PCM 99.00$ Palm IIIxe CompUSA 3C80304U 249.99$ Palm HotSync cable Best Buy 10104U 19.99$ Null modem cable (9 pin), Belkin CompUSA F3B207-10 14.99$ IC, MAX536A, RMS-to-DC Maxim MX536AJQ 15.30$
Temp IC, Dallas DS1620 Jameco 114382 5.49$ ZIF socket, 28 pin Jameco 104002 8.25$ IC, MAX233 CPP, TTL-to-RS-232 Jameco 106163 4.95$ Neoprene rubber sheeting, 12"x12", 1" thick, firm, 60A durometer McMaster-Carr 8568K719 36.96$ 5/8-11 x 1-1/2 HHCS, grade 8 Jerry's5/8 lock washer, grade 8 Jerry's1/4-20 x 3/4 SHCS, stainless Jerry's1/2-13 stop nuts, nylon insert Jerry's1/2-13 x 3 HHCS, grade 8 Jerry's1/2 washer, grade 8 Jerry'sCalibrator sledge, 20 lb, fiberglass handle Home Depot 42904202227 48.78$
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Lessons learned
• For one-of, overdesign• Design for strength, stiffness• Mechatronics is a great skill• It’s all in the details• Budget wisely• Continual communication with client• You learn by building it yourself
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