Mechanical Engineering Senior Design Projects at Bradley University

1. Mechanical EngineeringSenior Design Projectsat Bradley University Course Coordinator: Dr. Scott L. Post Assistant Professor Mechanical Engineering

2. ME 410/411 Senior Design This is a capstone senior design project. It is an opportunity for you to participate in a realistic design process on a design team and on real design challenges. The structure and conditions under which you will work are modeled after those to which you will likely be exposed after graduation as a practicing engineer in industry.

3. About Me • Undergrad: University of Missouri-Columbia • Grad School: Purdue • Previous Teaching Experience: Michigan Tech • Expertise in Diesel Engines and Aerodynamics • Engine Research supported by: CAT, John Deere, Detroit Diesel, Cummins, Dept. of Energy, Army Research Office • Aerodynamics Research supported by: NASA • Additional support by National Science Foundation • Experience in running engine test cell, alternative fuels, high-speed photography, laser velocimetry, computational fluid dynamics (CFD)

4. This is Not a Class: • There is no Homework • There are no Quizzes • There are no Exams • There is no Final • There are no “points” • There are only… Deliverables

5. Deliverables • Deliverables are tangible items that can be physically transferred to the client. • Hardware - prototypes, testing apparatus, models • Software • Reports • Each engineering team and client must negotiate a list of deliverables that satisfy the client’s needs. • The client, the advisor, and the students must sign an agreement specifying the list of deliverables. (the Proposal) • Default on the deliverables results in a grade of “Incomplete” and postpones graduation.

6. Additional Student Responsibilities • Progress Reports • Purchase requests • Recovery Plans • Travel Requests • Weekly Meetings • Weekly Task Sheets • Budget Tracking • Intellectual Property • Maintain Log Books • Meeting Agendas • Milestone Tracking • Performance Evaluations (MDC Form)

7. Results Oriented • The vast majority of teams since 1999 have transferred all deliverables to their clients on time. • A few teams have defaulted. They did not graduate until they completed the transfer. • Students will be “fired” for non-performance. This has happened more than once. • A warning is given first and the student is place on “probation”

8. Why do the Clients Sponsor Projects? • All Deliverables • Intellectual Property • 1200 Student•hours of engineering work • 40 Faculty•hours of technical advice • Visibility to all of the senior class • Early access to graduates • Visibility on the department’s web page

9. Course Objectives 1) To provide a realistic experience in the practice of engineering design as applied to mechanical engineering. 2) To develop the ability to work on teams under the guidance of supervision to meet the needs of a client in industry (or other external agencies). 3) To develop an engineering solution under realistic schedule and budget constraints for a relevant and unique open ended project. 4) Continue the development of practices, personal traits, and ethical behavior that are required by a successful, professional engineer.

10. Course Description • The faculty develops 14-17 new projects each year • Spans the fall and spring semesters of each students senior year • Student teams are required to provide an engineering solution to a client’s need • The solution includes some design activity • The students are grouped in teams of 3-4 • Requires a commitment of about 400 hours per student, 1200-1600 hours per project (12 hours per week per student)

11. Course Information • Classroom: Jobst 114 • Tuesday & Thursday 12:00-1:00 PM • Office: Jobst 315 • email: slpost@bradley.edu • If you can not find me in my office, email is the preferred mode of contact. I am more likely to respond quickly to an email than a voicemail • phone: 677-2738

12. Course Prerequisites • Senior Standing • Graduation within two to three semesters • December 2008 graduation is latest for this year • Academic plan required for December graduates • Consent of Instructor • Signed IP form

13. Course Information • Text Book: • Engineering Design, by G.E. Dieter Suggested: • The Mechanical Design Process, [Second Edition] by D. G. Ullman • Writing Style and Standards in Undergraduate Reports, by Jeter & Donnell • Prerequisites: • Senior in ME, Graduation by December, 2008, completed IP agreement • Course Web Site: • http:hilltop.bradley.edu/~spost/me410

14. Expectations • You will be expected to exhibit responsible and ethical behavior. It is your responsibility to complete the assigned work prior to deadlines and to the best of your ability. It is your responsibility to initiate questions and find answers. Each team will be expected to maintain a portfolio that documents the experience, demonstrates the quality of your work, and validates your solution.

15. Academic Integrity Plagiarism is the only issue we might encounter in this course. Plagiarism is taking credit for somebody else’s work, even inadvertedly (see Stephen P. Ambrose). The solution: When in doubt, use footnotes/endnotes/ other documentation to cite the sources you use. If you have questions, ask when we discuss report writing.

16. Work Environment • We try to simulate an industry work environment with an eye towards profitability. • The approach is to plan the work, then work the plan. • Each team is under-staffed, under-funded, and overworked (i.e. profitable) • There is little margin for error. We expect first time quality under time pressure. • The students understand up-front that failure to deliver will postpone graduation.

17. Course Requirements • Written Proposal to the client (October) • Executive Summary • Problem Discussion • Technical Work Plan • Budget Requirements • List of Deliverables (Mandatory Delivery) • Client Sign-Off • Oral Proposal Presentation (October) • Delivered to Faculty and Peers • Clients Invited

18. Course Requirements (cont) • Written Progress Report (December) • Reviewed by English Advisor • Reviewed by Faculty • Delivered to Client • Oral Progress Report (February) • Delivered to Faculty and Peers • Clients Invited • Oral Final Report (April) • Delivered to Faculty and Peers • Delivered to Clients on Location • Written Final Report (May)

19. Course Regulations • At some time during the course you will probably need to: • Travel • Buy things • Print Pages • Copy things • Call people • If you want to be reimbursed you must follow the prescribed procedures

20. Course Regulations • To get reimbursed for any course-related expenses, there are two things you have to do: • Get pre-approval (request form) • Submit a reimbursement form after expenses have been incurred

21. Travel Request • Prior to travel you must complete and process a Travel Request Worksheet. • The Travel Request Worksheet informs the university where, when, and why you will be traveling and serves as permission • It also authorizes travel expenses

22. Purchase Requests • Prior to any purchase you must complete and process a Purchase Request Worksheet. • The Purchase Request Worksheet authorizes your purchase and is required for reimbursement • You will not be reimbursed if you have not completed a worksheet • All purchases must be authorized by Dr. Mehta.

23. Purchases • Student purchases and reimbursement are the most common source for difficulties, anxiety, and hard feelings in this course • I suggest you use normal university purchasing mechanisms • If you choose to make a purchase with your own resources keep careful records and document the process

24. University Purchasing Mechanisms • Purchase Orders: • Plan well in advance and complete a PRW • Submit the PRW to Gayle after signatures • Gayle will get Dr. Mehta’s signature and process the purchase order • University Checks: • Plan well in advance and complete a PRW • Submit the PRW to Gayle after signatures • Gayle will get Dr. Mehta’s signature and request a university check

25. University Purchasing Mechanisms • University Credit Cards: • This should be your last option! • Complete the PRW. In addition to the normal signatures, you must get Dr. Mehta’s signature prior to the purchase. • You cannot use the credit card. You must submit the PWR to the card holder and the card holder must make the purchase. • Do not expect immediate turn-around. Failure to plan on your part is not our problem.

26. Teams and Teamwork

27. Proposal for a Team Leader • The team leader will be appointed by the team advisor and the course coordinator • The team leader is NOT “in charge” • He/she does NOT tell the other members what to do • Primary responsibility is scheduling • Other positions: Controller, webmaster

28. Team Web Page • Each Team should develop a web page and have Deb post it within the next week. (It will be updated later) • The web page must be authorized by the client (no proprietary info). • The web page should include: • Team number & project title • Team members & contact information • Advisor • Background • We can build a firewall for the client’s protection

29. Team Meetings • Minimum of one meeting/week - 1 hr • advisor • agenda • minutes • old business • new business • task sheet • Pick a regular meeting location and time. Avoid changing these. (I want to know when & where)

30. Team Meetings • Be on time. Start on time. • Start the meeting by distributing the agenda. • Rotate the responsibility of recording the minutes • Facilitate participation from everyone. • Document attendance • Do not cancel meetings

31. Meeting Agendas • Agenda should include: • Team Number & Project Title • Date & Time • Attendance • Announcements • Old Business • Review of work • Review of budget • Review of schedule • New Business • Planning (Task Sheets) • See Example

32. Project Log • Each team must purchase a bound logbook to record all team activities. • The logbook is a legal document. • All creative design activity must be documented in a bound log as legal evidence of origin of work. • Every team member must write a personal account of individual work done during the past week and sign the entry.

33. Project Log • Team members must make a minimum of one entry every week (more often is desired.) • If you do not have anything to put in the logbook - that is a sign • The team leader should log in the results of any administrative activity, as well as all group meetings and site visits. • The logs must be kept in the design room and be accessible to team members and advisors.

34. Project Log • Sketches, designs and graphs may be pasted in the log, along with the date and signature of the team member responsible. • Maintaining the logbook is one of the most important practices of this design activity.

35. Faculty Advisor Faculty Advisor Faculty Advisor Faculty Advisor Student Team #1 Caterpillar Tractor Student Team #2 Caterpillar Tractor Student Team #3 John Deere Student Team #7 Boeing - StL Course Structure Course Coordinator: Solicits Projects & Assigns Teams Monitors Progress … …

36. Summary • The mechanical engineering department has a unique senior design opportunity for both students and clients. • The first goal is to simulate an industrial work environment in an academic setting to culminate an undergraduate career. • The second goal is to deliver value to our clients on time and on budget.

37. Questions? Thank-you for your time. Dr. Scott Post Bradley University 1501 W. Bradley Ave. Peoria, IL 61625