Engineering Design and Research

1. Engineering Designand Research Welcome to ENGINEERING DESIGN AND RESEARCH. Upon entering the class please have a seat towards front of the class (Do not move chairs from one table to another).

2. Course_OverviewEngineering Design offers students the opportunity to understand and apply knowledge / skills required to create & transform ideas + concepts into a product that satisfies specific requirements. Students will experience design engineering in the creation, synthesis, iteration, and presentation of design solutions. This course will maintain a focus on: the history (and future) of engineering, how engineers apply mathematical, scientific, creative, and technical knowledge / skills in creation (refinement) of technical products/systems. A key approach will be the employment of a sequential, and iterative design and development process to solve authentic engineering tasks/problems. .

3. . The following major ‘topics’ or ‘chapters’ will be included to organize instruction of appropriate standards and benchmarks and reflect contemporary engineering industry practices:• Principles of Design• Engineering Resources• Engineering Design Process• Project Management

4. Major projects = Rockets - Team America Rocket Challenge – Work in a team to develop a rocket that can launch an uncooked egg 700 feet in air, deploy recovering system to safely land egg as close to 45 seconds as possible.Green Energy Design – Research & design a ‘concept’ Green Home that is off ‘the grid’– Develop floor plans, Build ‘to scale’ modelTopic Investigations – Research specified area of engineering to create a presentation that includes written report, power point presentation and informative video .

5. *Portfolio/Journal: To document and support participation and progress in the class students will submit a project portfolio/Journal documenting the student’s work. Portfolio format – The portfolio should be presented in the following format.Title Page - Include name of challenge, team name and logo, name of student and mod number.Table of ContentsBody – Design Brief,Class notes (Class reading, video, or computer research lesson), data, design sheets, and modifications.Conclusion – Was solution successful? Recommended modifications

6. LAB SAFETY – It is imperative students practice proper lab safety and refrains from horseplay in the technology lab. Students not following lab safety will not be permitted to work in the lab setting and will be assigned alternative lessons.Absolutely no horseplay.Wear safety glasses during lab activities.Do not distract students using power tools, cutting tools, hot glue guns, or electronic devices.Use tools / equipment only after proper instruction from teacher.Use tools / equipment correctly, after receiving teacher permission, and only when teacher is in classroom.Report all accidents and safety concerns immediately to instructor.

7. ENGINEERING DESIGN RESEARCH Proposed Outline – The proposed outline indicates one lesson (lasting more then one class period) per week. INTRODUCTION – Engineering, Technology, Society and the Environment Engineering & Technology – Chapter 1 pp. 3 – 43 UNIT 1 Principles of Design – Part 1 Lesson 1 Design - A Formal ProcessBasic Drafting Review, CAD, Selected text from Mechanical Drawing Books, & Google Sketch up, Lesson 2 Design Requirements and Prioritizing Constraints – Rocket DesignChallenge & Rocket Modeler, Fundamental rocket design principles from Rocket Modeler Text: Engineering & Technology Chapter 2 pp 49 – 88

8. ENGINEERING DESIGN RESEARCH Proposed Outline – The proposed outline indicates one lesson (lasting more then one class period) per week. UNIT 2 Engineering Resources Lesson 1 Technology Systems – Unit2 Lesson1 T-drive: Advanced Tech – Eng Dsgn Rsch ( Lesson Plan) Discuss Technical Systems – Spin-offs from NASA Construct & Test first rocket Lesson 2 Mathematics – Text: Engineering Design: Math & Science Applications pp. 429 – 467 Construct & Test second rocket Text: Eng Dsgn Chpt 3 pp.. 62-85 Dsgn Team Lesson 3 Material Science –Text: Engineering and Technology Chapter 4= Materials & Materials Processing – pp 131 – 177 Intro: Team America Rocket ChallengeIntro: Rocket Sim Create Rocket design teams and designate responsibilities, Begin design process

9. ENGINEERING DESIGN RESEARCH Proposed Outline – The proposed outline indicates one lesson (lasting more then one class period) per week. UNIT 1 Principles of Design part II Lesson 3A Human Factors Affecting Design – Ergonomics Packet – Capsule design – team members design their rocket system/ component Lesson 3B Environmental and Industrial Factors Affecting Design - Text: Engineering and Technology Chapter 1 – Sections 4 Technology and Society and Section 5 Technology and the environment – Begin construction of rocket components Lesson 4 Research and Market Profit Influence on design – Engineering Your Future – Chapter 5 pp125 – 143 – Complete construction of first TARC rocket Lesson 5 Refining Design - - Text: Engineering Design - Chapter 8= Testing and Evaluating – pp 206 - 220 – Analyze initial TARC designs Begin secondary design & construction of modified rocket components

10. ENGINEERING DESIGN RESEARCH Proposed Outline – The proposed outline indicates one lesson (lasting more then one class period) per week. UNIT 1 Principles of Design Lesson 1 Design - A Formal Process Lesson 2 Design Requirements and Prioritizing Constraints Lesson 3A Human Factors Affecting Design Lesson 3B Environmental and Industrial Factors Affecting Design Lesson 4 Research and Market Profit Influence on design Lesson 5 Refining Design UNIT 2 Engineering Resources Lesson 1 Technology Systems - Building Blocks and Technology Transfer Lesson 2 Material Science Lesson 3 Mathematics Lesson 4 Patent Process

11. ENGINEERING DESIGN RESEARCH UNIT 3 Engineering Design Process Lesson 1 Trade Offs vs. Creativity in Design - Reverse Engineering Info Packet and Product to take apart Lesson 2 Design Principles and Problem Clarification Lesson 3 Modeling Techniques Lesson 4 Communicating Results

12. ENGINEERING DESIGN RESEARCH UNIT 3 Engineering Design Process Lesson 1 Trade Offs vs. Creativity in Design Lesson 2 Design Principles and Problem Clarification Lesson 3 Modeling Techniques Lesson 4 Communicating Results UNIT 4 Project Management Lesson 1 Managing Engineering Design Lesson 2 Quality Assurance and Product Development Engineering & Technology Chapter 5= Manufacturing – pp 184 - 220

13. LAB SAFETY – It is imperative students practice proper lab safety and refrains from horseplay in the tech lab. Students not following lab safety will lose lab privileges and be assigned alternative lessons. - Absolutely no horseplay. - Wear safety glasses during lab activities. - Do not distract students using power tools, cutting tools, hot glue guns, or electronic devices. - Use tools / equipment only after proper instruction from teacher and after receiving teacher permission. Report all accidents and safety concerns immediately to instructor. Wear safety glasses when using power equipment -No tools or equipment to be used when instructor is out of class

14. Info Packet – Engineering & Technology Chapter 1 – Engineering, Technology, Society, and the environment Sections 1 - 3 pp.4 – 25 In your notes title a sheet Technology history Write and answer questions 1 – 5 as you read sections 1 - 3

15. Engineering Design Research L2 Introduction of Topic Investigation Assignment DRILL: Identify two historic engineers who lived in the 1400’s and made contributions that changed society Please obtain ‘Engineering Your Future’ Text and turn to page 15. Read A CASE STUDY OF TWO ENGINEERS pp. 15 – 20 Identify two engineers discussed and contributions to society

16. Identify two engineers discussed and contributions to society Leonardo Da Vinci Envision mechanized innovations including weapon design , flying machines, Johannes Gutenberg First mass producing printing press

17. Go to Engineering Design and Research Topic Investigation power point at H:\EngineeringDsgn&Rserch\EDR TopicInvest- Inventor-Engineer.ppt

18. Engineering Design & Research L3 –Visualization and Graphics • OBJECTIVE : Improve visualization ability and become familiar with several common graphical communication techniques • DRILL: Explain the concept of visualization and how it might help an engineer • Text : Engineering your Future – pp 230 - 278

19. Engineering Design & Research • Please turn in your Topic Investigation Proposal • Only two topic Investigations will be permitted for any one engineer or invention • We will List the Topic Investigations • Once two of the same have been achieved no more for that topic will be accepted.

20. Text : Engineering your Future – pp 230 – 278 • Complete Research packet

21. Engineering Design & Research L4 –Drafting Review • OBJECTIVE : Identify common measuring tools to measure linear distance as we review text to prepare to set up first drafting drawing • DRILL: How has technological advancement of the last twenty years aided in research efficiency? • Review Mechanical Drawing Text

22. Introduction to Drafting • Basic Drafting tools include: • T-Square • 30/60 Triangle • 45 triangle • Drafting Scale

23. Borders and Title BlocksDraw top of title block 1/2

24. Borders and Title BlocksDraw borders to following measurements ½ inch ¼ inch ¼ inch 1/4 inch

25. Borders and Title Blocks 3” 1” 1” 1” 1”

26. Title Block – Lettering Guides: Draw two light horizontal lines, one line 1/8” from top of title block and one line 1/8” from bottom.

27. Drafting Scoring ToolExample__/ 2 Line work .__/ 2 Lettering . __/ 2 Dimensioning__/ 3 Accuracy .*values may change according to drawing • Be sure to use light construction lines as you are laying out (constructing) the drawing.

28. Refer to pages 62 -68 of Mechanical Drawing textbook for information pertaining to Orthographic ProjectionRefer to pages 130 - 135 of Mechanical Drawing textbook for information on dimensioning.P. 130 Dimensioning 11.2P. 130 Lines and symbols 11.3 P. 130 Dimension lines 11.4P. 130 Arrowheads 11.5p.130 Extension LinesP. 133 Placing dimensions… 11.2 UnidirectionalP. 134 Theory of dimensioning 11.13

29. For the drafting review you are to measure an ‘visualization block’ and draw it as an orthographic, oblique and isometric drawing.Only the Orthographic drawing needs to be dimensioned.

30. Engineering Design and Research L5 – Safety ReviewSafety VideoSafety test • OBJECTIVE : Safety • DRILL: Identify three important safety rules to follow while working in the Technology Lab

31. How many of the following rules did we get? • When working around machines with moving and/or spinning parts be sure to secure dangling jewelry, long hair, loose clothing, and remove accessories that might get caught. • When working with equipment focus on what you are doing. Do not speak to people operating machines. • Stay out of machines ‘Safety Zone’ (3 foot perimeter) if you are not directly involved in operation. • Immediately report all accidents/ injuries to instructor. • Report any ‘unsafe’ conditions to instructor • Use tools / equipment only as directed and after instruction • Do not carry hand tools etc. in your pockets

32. A few more important safety items • Tools for cutting should be sharp…Dull tools cause injuries • Wear safety glasses • Return tools and equipment to proper location as soon as you are finished using it! • Do not carry long stock by balancing it in center. • Wear an apron to protect / secure clothing • Do not put sharp tools or hot items near neighbors, face, or handle carelessly. • Do not use electrical tools or items in such a way that is likely to cause shock. • Always leave class with same number of body parts that you entered with.

33. SAFETY VIDEOThe following video deals with safety in the Tech Ed lab, as well as general safety rules to follow outside of class. As there is so much information presented in video you will not be asked to take notes. You are expected to pay attention

34. SAFETY QUIZPlease be sure to immediately fill in name, period and date.Do not write on question sheet.

35. Safety Test Answers • 1 = F 11 = F 21 = c • 2 = T 12 = T 22 = A • 3 = T 13 = T 23 = D • 4 = F 14 = F 24 = B • 5 = T 15 = T 25 = B • 6 = T 16 = T 26 = A • 7 =T 17 = F 27 = C • 8 = F 18 = F 28 = A • 9 = T 19 = F 29 = D • 10 =F 20 = T 30 = C

36. Consider these two images. One is a serene setting found throughout the globe. The other is an example of technological beauty. However, in order to have the convenience and beauty of a bridge, there will be considerable tradeoffs with respect to ethical, political, and economic constraints. • Create a note sheet titled Engineering Tradeoffs and Constraints and • 1) Identify Ethical, Political, Economic, and Ecological tradeoffs / constraints that must be considered in bridge design and location

37. Engineering Design Research L6 Design Requirements and Prioritizing Constraints Text: Engineering & Technology Chapter 2 pp 49 – 88 Objective: Prioritize Design Constraints to Avoid Conflict Between Economic, Ethical, Safety and Political Issues. DRILL: Explain how Economic, Political, and Ethical issues can arise in trying to create a car to meet the challenges of high gas prices and pollution concerns. What other issues might arise in the car design?

38. Engineering Design Research L6 Design Requirements and Prioritizing Constraints Text: Engineering & Technology Chapter 2 pp 49 – 88 Read pages 48 – 52 As you read please answer feedback questions 1 & 3 on page 53. Look at figure 2.3 and read the supporting text. How did the variations between designed and constructed walkways cause the failure

39. Kansas City Hyatt Regency Hotel Walkway Collapse Background The Hyatt Regency Hotel was built in Kansas City, Missouri in 1978. This hotel consisted of a 40-story hotel tower and conference facilities, which were connected by an open concept atrium. Inside the atrium, there were three walkways that connected the hotel to the conference facilities on the second, third, and fourth floors. The atrium was 145 feet long, 117 feet wide and 50 feet high.

40. The Hyatt Regency Walkway Collapse Presented By: Jonathan Foster 4/9/02

41. An Engineering Disaster Kansas City, Missouri - 1981

42. July 17, 1981 • Approximately 2000 People Came for a Dance Competition • At 7:05 pm a large crack was heard and two walkways collapsed • Leaving 114 Dead and Left over 200 injured

43. Gillum-Colaco International Inc. (G.C.E. Inc.) Proposed Design for the Walkways • wide flange beams were to be used on either side of the walkway which was hung from a box beam • a clip angle was welded to the top of the box beam which connected to the flange beams with bolts • one end of the walkway was welded to a fixed plate while the other end was supported by a sliding bearing • each box beam of the walkway was supported by a washer and nut which was threaded onto the supporting rod

44. Proposed Design

45. The Revised Design • one end of each support rod was attached to the atrium’s roof cross beams • the bottom end went through the box beam where a washer and nut were threaded on • the second rod was attached to the box beam 4" from the first rod • additional rods suspended down to support the other levels in a similar manner

46. Actual Design

47. The Fourth Floor Connection

48. Reasons For Disaster • Lack of Communication • Interpreting Preliminary Drawings as Finalized Drawing • Insufficient Review of the Final Design

50. Kansas City Hyatt Regency Hotel Walkway Collapse Timeline The project began in 1976 with Gillum-Colaco International Inc. (G.C.E. Inc.) as the consulting structural engineering firm. They were contracted in 1978. The construction on the hotel began in the spring of 1978. In December of 1978, Havens Steel Company entered the contract to fabricate and erect the atrium. The following February, Havens changed the design of the connection for the second and fourth floor walkways from a single to a double rod. During construction in October 1979, part of the atrium roof collapsed and an inspection team was brought in to investigate the collapse. G.C.E. vowed to review all the steel connections in the atrium. In July 1980, the hotel was open for business. On July 17, 1981 at 7:05 p.m., a loud crack was heard as the second and fourth floor walkways came crashing down to the ground level. There were about 2000 people gathered in the atrium for a dance contest. After the collapse, 114 people were dead and left more than 200 were injured.