MEC-E1003 Machine Design Project course. Sven Bossuyt Sept. 28, 2018

Transcription

1 MEC-E1003 Machine Design Project course Sven Bossuyt Sept. 28, 2018

2 Schedule: overview and milestones week 40 October 5 week 43 concept pitch week 46 status report Stirling engine manufacture and assembly exercise December 14 gala with poster and prototype demonstration week 51 December 21 final report!2

3 Schedule: Stirling engine starter project Week 37-39: Manufacture and assembly exercise fabricate two parts and inspect all parts of a Stirling engine kit machine parts following given design specifications measure and inspect the dimensions of all parts Week 39-40: Assembly and Test exercise assemble the Stirling engine kit and test performance assemble the inspected kit parts operate the engine and confirm performance completion of the Stirling engine starter project!3

4 Schedule: design concept Already during weeks come up with ideas for your machine design project i.e. about functions, mechanism, its manufacturability (individual task) select best ideas / create new ideas for your group project Weeks 40-43: Develop concept and initial design decide components, check/verify functionality (models/mbs, etc.), FEA (in critical places) and necessary steps of product design iterate and detail the design first draft of design documentation Week 43: Concept presentations in lieu of midterm exam pitching about concept, design process, material selection, manufacturing plan, assembly plan or other aspects you don't receive a grade, you receive feedback!4

5 Schedule: realisation Week 44: Project plan Manufacturability and Safety make manufacturing plan and iterate design accordingly booking time in lab for manufacturing might be neccessary Weeks 45-46: Status report Prototype development manufacture and test components iterate design Weeks 47-50: Prototype + Information poster Assembly and testing assemble and test prototype, finalize design documentation advertising your project (poster for Gala)!5

6 Design Brief

7 Learning goals for the course Students can relate theory and exercises to practice 2. can iterate a design from the initial concept to a working prototype 3. can document their contribution within a team-based effort 4. are familiar with typical issues in project management and teamwork, and ways to address those issues 3 October 2016!7

8 Design project 2 options make your Stirling engine better - you define what "better" means make something else - you choose what you make assessment criteria mechanical functioning - non-mechanical parts or functions are not assessed design documentation execution and planning of the manufacturing and testing presentation!8

9 Open brief: Design, develop, and build a machine. For the concept, as a team, reflect on mechanical engineering aspects you would like to learn about, and everyday- or industry-related activities and solutions you would like to improve, or to simply try and replicate. In other words, you re free to do whatever* you wish. In the end of the course, there will be a final gala where you will be required to show a working prototype of your solution. *If it requires special materials or machinery, you might want to talk to the course staff. We can provide small budgets, and will definitely try and get you access and training to any of the University s facilities you might need to use. 3 October 2016!9

10 There are general requirements, process requirements, and manufacturing constraints Requirements = Set by staff Constraints = Set because of realities Must = You have to do this Recommended = You don t necessarily have to do this 3 October 2016!10

11 General requirements Must include at least 5 machine design elements, like power screw, spring, bearing, gear, clutch, brake, belt, chain, coupling, linkage, and/or cam. Must have some functionality. Must be ready for exhibition and live demonstration on Dec 14 Recommended to focus on mechanical engineering, as the course can not support you with electronics, programming, and other such features. + The course can offer limited budget for the teams 3 October 2016!11

12 Process requirements Must be modeled in 3D CAD with a meaningful structure, dimensions, and tolerances, in regards to its operation. Must be structurally verified and analyzed with MBS. Must be manufactured according to CAD drawings. Must Include at least 1 part, whose shape is optimized with FEM, and material with CES. Must have the key tolerances of at least 1 key part verified after manufacturing, with appropriate measurement devices or machines. Recommended to use Siemens NX for concurrent development. 3 October 2016!12

13 Manufacturing & assembly constraints Must consist primarily of standard components. Some can be found in the K3 material center. Must have 1-2 of its parts custom manufactured at Aalto facilities. Recommended to be assembled in the machine design lab in K3. The lab techs can help you, but you ll need to reserve a timeslot. 3 October 2016!13

14 Examples

15 1. THE IDEA Sitting inside inner wheel Outer wheel rotates Structure: 1. Rollers 2. Outer wheel 3. Gearing 4. Seat and handles 5. Inner frame !15

16 4. PART MANUFACTURING Plates: angle grinder, guillotine, hydraulic press, bandsaw, milling !16

17 CONCEPT

18 DESIGN

19 FINISHED CAN DISPENSER

20 CONCEPT DESIGN The rotation movement is transmitted from the crank to the bottle holder by a gear-belt system The bottle holder is sheet-formed and welded to the shaft itself connect to the last gear of the transmission system!20

21 Sand Digger for Adults Multiple concepts were considered for this project Ultimately the group decided on a digger for adults The product is an adult-sized manually used digger The user can move the bucket by moving the arms and the seat turns with the user The product was created for entertainment value!21

22 TEAM MACHINE Hydraulic press frame info A hydraulic press frame has multiple real world applications and requires engineering design work to operate safely and reliably. Forces affecting the frame has been calculated and simulated before building the prototype. A hydraulic press is a versatile tool and a user can use it in operations such as pressing bearings in and out of sockets, bending sheet metal or testing material properties by crushing them. Before the pressing can begin, a user must chose a proper tool head and attach it to tool adapter with a screw. The pressing pipes rest on top of the pressing table and can be adjusted or removed entirely if necessary. After the necessary setup, the hydraulic press is operated by using the bottle jack lever to push the tool head down. After the pressing pressure of the jack is removed by turning a valve at the side of the jack, and the springs push the slider up Frame of the pressing frame is standard 80 mm x 80 mm square steel pipe and the wall thickness is 4 mm. 2. Bottle jack is a hydraulic and capable of pressing force equal of 5 tons. It is bought separately costing e. 3. Gas springs 2x are pushing the slider upward after the pressure is released from the bottle jack. 4. Pressing table can be adjusted into different positions 5. Pressing pipes 2x are used when pressed objects are narrower than the gap between the pressing table. 6. Slider is keeping the tool adapter in line when pressing. The slider and the bottle jack are bolted together. 7. Tool adapter is used to mount the tool heads from pressing tool kit (bought separately !22

23 Anchor Escapement Mechanism Kaisa Kulmavuori, Alex Bjurs, Tuukka Uosukainen, Teemu Tero, Tuomas Tiainen What it is: A mechanism originally developed for timekeeping. A feedback system, where escapement provides constant motion, and synchronization of mechanism movements. Numerous versions, but usually three common components: a source of potential energy, controlling components an energy restoring component. How it works: Based on the movement of an anchor against an escape wheel. Powered by hanging weight. Pendulum swing keeps the anchor movement stabile. The escape wheel catches the anchor with every swing. Releasing the anchor pushes the escape wheel, which in turn rotates. Why to use it? Cool technical product to use as a decoration. To study the clock mechanisms. To have in order to being able to answer the question of how do the clocks work. Component Pendulum 1 Anchor 1 String or belt 1 Escapement gear 1 M10 threaded rods 2 M10 bolts 4 Back plate 1 Radial bearings for M10 Hanging weight 1 Count 4!23

24 "Cold drinks, in seconds, without electricity" The drink cooler brings together elements of engineering and design to produce a compact solution for an everyday problem without the need for electricity or tethers. The container houses a tubular mesh which holds the can in place while the outer slot holds ice and water. When closed, a silicon disk connected to a planet-gear system presses on the can and rapidly spins it. This cools the drink by means of conduction with the cold water. Its 3D printed design is freely available for non-commercial use.!24

25 Mechanical Guitar Player Our goal was to produce an upscaled musical box to play some recognizable tune. We decided to use whole instrument for creating the sound. Guitar was chosen to be the starting point and so was the mechanical guitar player born. The basic principle of the guitar player is explained beneath: RED: The sound is generated by guitar picks attached to a band (not in picture) that moves horizontally above the strings. The horizontal movement is achieved by tightening the band around two rotating cylinders, of which one (back) is free and the other (front) powered by a crank handle. BLUE: The rotation speeds of the cylinders moving the band and the disks pressing the buttons are synchronized by a transmission belt (not pictured) connecting the two driving axles. YELLOW: The pitch changing mechanism is based on buttons pressed against the fingerboard by tappets on continuously rotating disks. When the tappet moves away, the button is raised back to its starting position by a spring Group Gr8!25

26 DART THROWING MACHINE 1: Arm 2: Release mechanism 3: Damping system 4: Frame 5: Adjustment scale 6: Step shaft mechanism!26

27 Assessment

28 Contribution to team effort Mutual assessment within each team including self-assessment repeated several times throughout the course may be overruled in teams where it doesn't work well Multiplicative combination of three factors timeliness participation and effort quality Correction factor to team grade normalised to the average for the team!28

29 Criteria for assessment of the contribution to the team effort criterion characteristics lowering the grade grade 3 (good) characteristics improving the grade timeliness work is often not ready on time work is usually completed on time, according to the common plan agreed work is always completed before the agreed deadline participation avoiding duties participation in the group work, attending meetings, and contributing to discussions, taking their part of duties taking responsibility for their own duties and readily available to help others quality deliverables and tasks are incomplete, not working, or poorly documented the deliverables and tasks are completed in a way that meets expectation the deliverables are working reliably and are well documented!29

30 Final reports and grading 30% Stirling engine starter project as determined by Prof. Kevin Otto 70% Final report of design project report should include - final design documentation, - manufacturing and testing reports, - conclusions about course and demo one grade for the whole report and gala presentation - individual grades modified according to contribution to team effort!30