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Engineering Design Workshop

Join Santa Clara Valley Science and Engineering Fair Association workshop with Bruce Kawanami to learn about the scientific process behind quality design projects for engineering fairs. Explore the engineering design process, from defining needs to final documentation, and develop projects such as a solar-powered scooter, wireless ear pods, and self-lowering kitchen shelving. Discover the importance of criteria, constraints, and testing in creating successful engineering projects.

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Engineering Design Workshop

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  1. Engineering Design Workshop for students Quality Design Projects for Engineering Fairs Sponsored by Santa Clara Valley Science and Engineering Fair Association

  2. Knowledge Scientific Process Why? SCIENCE & ENGINEERING Bruce Kawanami

  3. Knowledge Scientific Process Why? Prototype Need Engineering Design Process Specification Science/Technology SCIENCE & ENGINEERING Bruce Kawanami

  4. Engineering Design Process • Define a need • Establish criteria and constraints • Research, evaluate alternatives, test plan • Construct a prototype • Test against established criteria • Failure analysis, tweak, and re-test • Final documentation Bruce Kawanami

  5. Step #1 (Beginning) & #7 (End) Generate a Project Book • Project data book A complete record All key decisions Good drawings Test plans Results Conclusions Things learned Bruce Kawanami

  6. Step #1: DEFINE A NEED • Have a need, a customer for the project • Often stated as bigger, cheaper, faster, lighter • Engineering Goal template: The design andconstruction of a (engineering project) for(user) to do(some function). • Project MUST have technical content Bruce Kawanami

  7. The design andconstruction of a (project) for(user) to (function).Project: solar powered scooter User: childrenFunction: zip around the block Technical Content: solar energy, energy storage, motor torque, mechanical gear ratios, electronics Bruce Kawanami

  8. The design andconstruction of a (project) for(user) to (function).Project: wireless ear podsUser: music or radio listeners Function: avoid tangled wires Technical Content: Analog electronics, wireless communications Bruce Kawanami

  9. The design andconstruction of a (project) for(user) to (function).Project: kitchen shelving that lowers itselfUser: short, weak, or disabled personsFunction: easily reach items stored high Technical Content: Motor torque, structural design Bruce Kawanami

  10. ENGINEERING GOAL STATEMENT EXERCISE

  11. Step #2: Criteria & Constraints “Design criteria are requirements you specify for your design that will be used to make decisions about how to build the product” Size Appearance Physical Features Performance Use Environment Bruce Kawanami

  12. Some Design Constraints • Cost • Time Bruce Kawanami

  13. Criteria & Constraints for Solar Powered Scooter • Transport up to 35 kg rider • Speed of at least 8 kph on level surfaces • Travels through 10 meters of shade • Material cost • Testing completed by Feb 28 Bruce Kawanami

  14. Criteria & Constraints for Wireless Earpods • Transmits 10 meter radius • Receiver weighs < 75 grams • No dropouts, ‘good fidelity’ • Material cost • Testing completed by Feb 28 Bruce Kawanami

  15. Criteria & Constraints for Lowering Shelf • All shelves lower 45 cm • Safely move 16 kg up and down • Shelves will tilt < 10 degrees • Material cost • Testing completed by Feb 28 Bruce Kawanami

  16. Step #3: List Alternatives • Research reveals what has been done • Likely to find good alternatives for cheapest, fastest, or lightest • Select best alternatives that meet the design criteria and constraints • Create a test plan based on the design criteria from Step #2 Bruce Kawanami

  17. Web Researched Alternatives Wireless earphones Electrically powered scooters Lowering shelves Bruce Kawanami

  18. Solar Powered Scooter Test Plan • Transport up to 35 kg rider • Test Plan: Transport a 35kg load • Speed of at least 8 kph on level surfaces • Test Plan: 100m distance should take less than 45 seconds • Travels through 10 meters of shade Test Plan: Charge up battery. With 35kg rider, ride through 10m of shade Bruce Kawanami

  19. Wireless Earpod Test Plan • Transmits 10 meter radius • Test Plan: Walk receiver in a 10m radius around transmitter • Receiver weighs < 75 grams • Test Plan: Weigh completed assembly • No dropouts, ‘good fidelity’ Test Plan: Survey student peers, likely customers Bruce Kawanami

  20. Lowering Shelf Test Plan • All shelves lower 45 cm • Test Plan: Design motor to travel 45 cm • Safely move 16 kg up and down • Test Plan: Select motor to lift 16 kg • Shelves will tilt < 10 degrees Test Plan: Design in leveling guides and careful construction techniques Bruce Kawanami

  21. Step #4: Construct Prototype • Prototype is implementation of chosen design alternative • It is a proof of design, production and suitability Bruce Kawanami

  22. Project Construction Bruce Kawanami

  23. Step #5: Test it Well • Execute the developed Test Plan • Learn beyond minimum requirements! Characterize the limits of your project. Bruce Kawanami

  24. Solar Powered Scooter Testing 1. Transport 35 kg rider. Exceeds Test Plan: Maximum mass transported 2. Speed. Exceeds Test Plan: Measure and plot speed vs. rider mass. 3. Travels through shade. Exceeds Test Plan: • Measure and plot distance in shade travel vs. rider mass. • Extra Knowledge:solar energy, storing energy, electric motor torque, gears Bruce Kawanami

  25. Wireless Earpod Testing 1. Transmits 10 meter. Exceeds Test Plan: Measure maximum transmission distance. 2. Receiver weight. Exceeds Test Plan: Know the weight of each component and alternatives. 3. No dropouts, ‘good fidelity.’ Exceeds Test Plan: • Higher number of surveys. • Extra Knowledge:capacitors, inductors, antenna, ordering free samples, soldering Bruce Kawanami

  26. Lowering Shelf Testing 1. Moves 45 cm. Exceeds Test Plan: Measure elapsed time 2. Move 16 kg. Exceeds Test Plan: Measure and plot mass vs. elapsed time 3. Tilt. Exceeds Test Plan: • Measure and plot degree tilt vs. location of mass. • Extra Knowledge:motor torque Bruce Kawanami

  27. Step #6: Failure Analysis and Tweak/Redesign Iterations • Evaluate the test results. Do they satisfy design criteria? • If not, can you tweak the process as opposed to a complete redesign? • This is the longest step…. Bruce Kawanami

  28. Failure Analysis and Tweak/Redesign Examples • Solar scooter: Cannot move 35kg …. • Add more solar cells, bigger motor, higher gear ratio, reduce scooter weight • Wireless earpods: Range only 4m …. • Increase transmitter voltage • Lowering shelf: Shelf tilt up to 15°…. • Add stabilizing guides Bruce Kawanami

  29. Step #7: Complete the Project Book (Started at project definition) • Project data book A complete record All key decisions Good drawings Test plans Results Conclusions Things learned Bruce Kawanami

  30. Draw a Good Picture • Drawings for project notebook, application, display • Photos, sketches, CAD 2-D or 3-D • Show assembly, components, materials Bruce Kawanami

  31. Summary

  32. Design Features • Meets a need, has a “customer” • Design criteria and constraints • Evaluate alternatives and generate test plan • Build prototype • Test/evaluate against test plans • Analyze, “tweak” (), redesign (), retest • Project book: record, analyses, decisions, specs Bruce Kawanami

  33. Best of Luck Engineering is exciting! Use creative problem solving! Ignite your passion! Bruce Kawanami

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