The layout of the topics has been developed and continuously improved over a decade of teaching capstone design. This book should also be of interest to industry professionals involved in product development, design problem solving and the sponsoring of keystone design projects.
Define, Conceive, Prove, Document
Introduction
Engineering design, sometimes known as the engineering method, is a formal, rigorous, and systematic process for optimizing a problem. Problems are often expressed as a desire to solve a situation that has not been solved before or improvements on something that already exists, be it a process, a device or a concept. Consequently, by the very nature of this statement of problems, they are incomplete and ill-defined. The engineering design process begins with the definition and understanding of the problem and what needs to be achieved. Once a problem has been presented, it is necessary to better understand the problem. Additional information about the problem area and related topics can be gathered through an online search of the literature, related patents, and competitor information. The problem-solving engineer is responsible for developing the design specifications and any constraints that may be appropriate. Solutions are then generated in the form of concepts that meet the design specifications and the constraints. The concept can be a device or a process. be possible to prototype it If the concept is a process, it might be modeled in a software model. The prototype or the model can be tested against the design specifications, constraints and any additional considerations such as ethical and environmental The test results are then used to assess the suitability of the solution concept to the problem Iterations on the concept, prototype and model are used to develop the solution improve, optimize or streamline Once a satisfactory solution is achieved, it is documented, communicated and delivered to the sponsor of the problem or project The engineering design method is unique to engineering, and it distinguishes the work of engineers from all other forms of professionals, including DOI.
Engineering Design Process
Some concepts will take longer, or may cost more, resulting in those ideas being shelved or eliminated. It is imperative in the engineering design process to estimate costs and timelines as accurately as possible. The process often involves a proposal, resulting in a legal contract between design engineers and clients or sponsors. Contractual requirements, prices and schedules can limit design engineers to take more conservative approaches to ensure they deliver on time. and within budget. The design problem and the approach to its solution are greatly affected. from cost and schedule factors. Cost and schedule considerations are part of the responsibility of each engineer on the team, their methodology for solving engineering problems based on their experience, knowledge and skills Engineers who are successful in preparing winning project proposals and successfully completing work that they proposed will thrive Those who fail in this process will work under the guidance of others Preparing the project proposal, accurately determining the cost and meeting the project timeline are prerequisites for having the opportunity to do great work technical in design. The same elements apply. for high stone engineering design, which we will cover later in this chapter.
Design and Engineering Accreditation
We can update our flowchart to incorporate this important element of real-world engineering design into our problem-solving process. 10 Engineering Capstone Design a process of continuous improvement The program must also have a sufficient number of qualified faculty and provide institutional resources to successfully carry out its mission.
Open-Ended Design Problems
Is the problem too complex, or do you not feel like you have the technical knowledge to try it out? Are you looking for the best design solution to the problem or a design solution.
Regulations, Codes, and Standards
- Regulations
- Codes and Standards
- Specifications
American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME) – the professional association for mining and metallurgy. Institute of Electrical and Electronics Engineers (IEEE) – the professional association for the advancement of technology.
Capstone Design Process
You assess your prototype against your design specifications and document the assessment. You will be required to prepare a comprehensive draft report for Part I. You will provide the report document to your professor and to your sponsors. Ask them for comments and feedback. We call that document the preliminary. Many standard test methods are published through national professional engineering associations. Be sure to follow these testing procedures if appropriate for your design.
Preparing for Capstone Design
Connect student team members to common project goals and how to achieve them. For each of the evaluation criteria (design specification), evaluate each of the design concepts against the reference model, using worst (−1), same (0) or better (+1) scores.
Design Project Team
- Selection of Team Members for Design Projects
- Background Research on the Project
- Educational Preparation
- Professional Preparation
- Qualifications
- Professionalism in Interactions
- Team Dynamics
- Roles and Responsibilities
- Effective Team Management
- Progress Reports
- Communications
- Online Communication
Project Management
- Planning
- Scheduling
- Entering Project Information into MS Project
- Independent and Dependent Tasks
- Assigning and Accepting Responsibility
- Working with the Project Plan
- Resources
- Gantt Chart
- Network Diagram and Optimizing the
- Resource Leveling
- Project Reports
Defining the Design Problem
- Methods for Understanding Open-Ended Problems
- Brainstorming
- Gathering Information
- Surveys
- Sources of Information
- Literature Search
- Patents and Patent Search
- Design for X
- Design Specifications
- Customer Needs and Requirements
- Design Specifications Leading Questions
- Design Specifications Assignment
Conceiving Design Solutions
- Creative Thinking
- Fostering Creative Thinking
- Barriers to Creative Thinking
- Techniques for Creative Thinking and
- Generating Solution Concepts
- Functional Decomposition
- Morphological Methods
- Axiomatic Design
- TRIZ Method
- Analyzing Concepts
- Engineering Analysis
- Modeling
- Simulation
- Decision-Making
- Pugh Chart
- Quality Function Deployment
- QFD Analysis Example
Critical Design Review
- Engineering Team Project Presentation
- Receiving Critique
- Incorporating Feedback
Proof of Concept
- How to Create a Proof of Concept
- Demonstrate the Design Solution Meets
- Generate an Improved Design Solution
- Build a Prototype and Test It
- Collect Test Data, Analyze, and Document
- POC Presentation
- Viability and Usability
Documentation
- Engineering Design Documentation
- Engineering Logbook
- Design Binder
- Electronic Files and Project Archive
- Verbal Presentation with Slides
- Guidelines for Capstone Design Presentations
- Photos
- Video Presentation
- Timing Studies
- Poster
- Guidelines for Posters
- Technical Information Sheet
- Guidelines for Capstone Technical
- Style Guide for Capstone Technical
- Preliminary Design Report
- Guidelines for Preliminary Design Report
- Final Design Report
- Guidelines for the Final Design Report
Build, Test, Redesign, Repeat, Document
Logistics of Building the Design
Access the review and document the current process to collect data and create a dynamic model of the process. Or should the model be a smaller representation of the design with some extreme conditions removed to enable the team to build a working model. Typical industry-sponsored design projects can fall into either the category of full-size build or scaled-down version. The design team must coordinate the scope of the working model with the sponsor and other project stakeholders.
Flat, round, square, hexagon, shank and key shank are some of the shapes that can be purchased. Flat bar, square bar, round bar, sheet and plate are some of the shapes available.
Resources Needed
Actual Versus Model
Materials
- Materials Selection Charts
- Metals
- Plastics
When the design team is working with the materials for their design, they must collect and document the MSDS and the quantities of materials stored in the laboratory for emergencies and fire safety In the event of a fire, firefighters must have access to the list of stored materials . in the capstone lab to use appropriate fire retardants for the chemistry present The US Occupational Safety and Health Administration (OSHA) requires MSDS for all products MSDS can be used to assess the chemical hazards of materials used in design and appropriate methods of protecting designers during construction with those materials. Service requirements may lead to the selection of metals for the production of the working model of the design Metals are usually solid at room temperature (Mercury is an exception) Metals have a reflective surface and can be polished Metals are ductile and malleable so that they can be formed into various shapes such as sheets, bars, tubes and blocks Metals are much stronger materials than many alternatives and are usually good conductors of heat and electricity Metals have high density and are heavy. The melting and boiling points of metals are high. , and therefore, they are suitable for high temperature applications. Angle, channel, beam, flat bar, square bar, square tube, round bar, rectangular tube, funnel, sheet, plate, wire, rebar, rings, rings and shells are some of the shapes that can be purchased steel material.
Angle, channel, beam, flat bar, square bar, round bar, square tube, round tube, tube, plate and plate are some of the shapes available. Angle, channel, flat, square, round, shank, keyway, square tube, rectangular tube, round tube, pipe, sheet and plate are some of the shapes available.
Manufacturability
- Manufacturing Process Selection
- Design for Manufacturing and Assembly
- Mistake Proofing
Many different manufacturing methods can be used for a designed product. Design team members have different skill sets, so part of the manufacturability analysis is to assess how those skills apply to different methods of producing a working design model. Fabrication and fabrication costs (and time) can be optimized during the design phase. Finishing operations such as polishing and painting are time-consuming and expensive and can be reduced. Tolerance is a common problem. A tight tolerance significantly increases the cost of machining and manufacturing parts. A loose tolerance can reduce product quality and adversely affect its performance. Design teams must carefully consider the tolerance needs for their project and allow time for iterations to find the optimal value. During the design phase, the design and manufacturing aspects of each part must be considered to make manufacturing and assembly easy, so that errors can be mitigated. Assume that manufacturing and assembly are too complex and require special skills or training. In this case, costs can quickly rise and significantly increase the production of a working model before the testing phase can begin. As far as possible, the use of outsourced manufacturing and production services should be minimized to maintain cost and schedule.
Objects are created layer by layer on a 3D printer Standard printers at lower prices extrude a molten plastic filament sintering on top of the previous layer of plastic 3D printing is also called additive manufacturing instead of machining where the material is removed (subtractive manufacturing) The print head in a 3D printer typically moves in the x-y plane and the glass build plate moves in the z direction. Due to converting a precise geometry to an STL approximation, problems can occur in the STL file, such as small triangles, super long triangles, the surface is not waterproof, and misoriented surface normals. Most slicing software includes options to repair the model or repair the mesh If the mesh is problematic beyond the capabilities of the slicing software, another software program can be used to repair the mesh. Meshlab (wwwmeshlabnet) is an example of a software program that can manipulate, repair and optimize meshes in an STL file Simplify3D is another example of software that is effective for mesh repair and slicing of STL files for many different types of printers ( Figure 915).
Quality
It is essential that the engineering students try to make/implement their design solutions and not let someone else build/implement their designs. Engineering students must deeply understand the implications of their design choices regarding manufacturing or implementation. Suppose the students are admitted. to outsource their design solutions In that case they will not learn from all the changes that need to be made during the production or implementation of their design solution. Learning from the changes is an essential part of the design process.
Bill of Materials
Procurement
Review the design specifications for any changes that may be appropriate, based on what was learned during building the working model and testing. The team should capture and document the sponsor/customer requirements and specific design features that helped the sponsor achieve its objectives. What specific design features helped the sponsor or user achieve success. Consider improving these valuable aspects of the design. The improvements should be retested and user responses collected to check for improvements and greater satisfaction with the design solution. If only the user experience was better.
Did the user interact with the design solution in the way the design team planned or expected? In some cases it may not be possible to meet all design specifications because the system is too limited, or the design specifications may not be met.
Redesign
- Application of Test Results
- Adjustments to Design-Build
- Major Design Changes
- Optimization
- Quality Engineering
- Cost Evaluation
- Return on Investment
- Design Optimization
Closing Out the Project and Documentation
- Planning a Final Capstone Event
- Estimating the Audience Size and
- Select a Date
- Select a Format
- Create a Program
- Promote the Event and Invite People
- Invite Media
- Design Presentation to Sponsor
