Bruce Mayer, PE Registered Electrical & Mechanical Engineer BMayer@ChabotCollege.edu

1. Engineering 10 - ENGR11 Preview -Tank AgitatorDesign Project Bruce Mayer, PE Registered Electrical & Mechanical EngineerBMayer@ChabotCollege.edu

2. Dilbert Design

3. Pls Consider Taking ENGR11 in Sp10 ENGR 11 Engineer Design and Analysis 2.00 Units An introduction to the engineering design process from a practical and professional perspective. Student teams work on a term-long engineering project that entails the creation of a design for a useful object with moving parts that require the application of some external power source. Conceptual and Critical/Final design reviews require teams to describe and justify the effectiveness, and likely customer-acceptance, of the design. The student designer: select materials, components, sources of supply; produce detailed estimate for the production-cost. When needed students use engineering software tools (such as MATLAB) to assess and predict the kinematic, structural, thermal, electrical, fluid-flow, wear/corrosion, and magnetic performance of the proposed design. Students are encouraged to build from the design plans a form-and-fit mock-up, or if possible a fully functioning prototype. Strongly recommended: Engineering 22.

4. ENGR[10+11] Xfers to SJSU & UCB • The COMBINATION of Chabot’s ENGR10 & ENGR11 Transfer DIRECTLY as SJSU’s & UCB’s “ENGR10” courses

5. ENGR11 Emphasis  Creativity • Recall from Study Skills Lecture: • Engineering Requires Two Somewhat Contradictory Skills • Creativity to BEGIN the Practical Product Creation/Design Process • Attention to Detail & Analysis to COMPLETE the Practical Product-Realization Process • ENGR[25, 36, 43, 45] Emphasis is Analytical Problem Solving • ENGR11 Emphasis is CreativeProblem Solving

6. General Design Cycle/Process • Students Implement this Design Process in ENGR11 by way of Design Teams

7. Term Design-Project Goal • Complete an Engineering Design for a 24/7 “Wave-Like” Agitation System for a TidePool Tank in a Marine Biology Lab

8. Must Run Unattended and Automatically 24 hrs/day, 7 days/wk Power Sources Available 115 Vac, 15 Amp Electricity 100 psig, 3 cfm Compressed Air Gentle, Back-and-Forth Surface Agitation to Approximate Waves Breaking over an Exposed Tide Pool Design Requirements - 1

9. Wave Period = 10-15 seconds Tank Size in feet =2W x 3L x 1D Must Resist Sea Water Corrosion Low Cost → $500 Budget Must be Easy to Install and Uninstall (Biologists will use it) Tools Available Basic Mechanical and Wiring Hand Tools Hand Power Drill Reciprocating Saw (a.k.a. “SawzAll”) Design Requirements - 2

10. FULL Set of CAD (AutoCAD or SolidWorks) Design and Fabrication Documents Fabrication Dwgs for Machined Parts Material Callout and Finish Full Dimensioning Assembly Drawing Views and Basic Instructions for Assembly Bill of Materials with Part Numbers Electrical/Pneumatic Schematics Project Management Sources of Supply and Catalog No.s for purchased Parts Design Requirements - 3

11. Project Management cont. Projected Cost excluding Assy Cost for Machine Parts from Chabot Machine Tool Technology Instructors A. Long & M. Absher Purchase Parts from Supplier Catalog or Price-Quote Design Analysis & Literature Research Pro’s & Cons of Alternative Designs Safe Operation – Mech. & Elect. Force Load Analysis (statics) Corrosion Resistance Possible Failure Modes (FMEA) Design Requirements - 4

12. Extra Credit Milestone Schedule or PERT Chart GDT Dimensioning Must be able to EXPLAIN it Written Assy & Test Procedures MockUp or Working-Prototype User Manual Design Requirements - 5

13. Design Presentations • Assumes 4 Member Teams: M1 → M4 • Presentations Last 20-30 min • Two Members Team Up for Presentation • Must Divide Presentation Approx. Equally • Formal Presentations (as would be given to Management or Customers) • Done Using POWERPOINT • FollowUp → Write Action Item List • WHO will do WHAT by WHEN

14. Design Presentation - CDR • CONCEPTUAL Design Review (CDR) • By Team Members M1 & M2 • Describe Alternatives Considered • Why the Selected Alternative? • Identify Risks • Concept Drawings and Sketches • Likely Materials • ROUGH $-Cost Estimate • Team Member Assignments → Division of Project Effort

15. Design Presentation - CrDR • CRITICAL Design Review (CrDR) • By Team Members M3 & M4 • Detailed Layout and Schematics • Engineering Physical Analyses • Force/Loading • Corrosion/Wear • Energy/Power • Materials & Component Selection • 90+% Accurate $-Cost Estimate

16. Design Presentation - CrDR • First-Cut Drawing Package • Parts, Assy, Schematic • Bill of Material With Part Numbers • Sources of Supply for Purchase Parts • Phone Numbers of Suppliers • Catalog Number for Purchase Parts • FINAL Cost Estimate to ±5% • Demonstrate MockUp (extra credit)

17. AutoCAD Tank Template Template Posted to WebPage SeaWater_Tank_Template_E11-0001_BMayer_090714.DWG

18. For Parts Designed by the STUDENT, the Part-Cost will NOT be published. Instead the Designer must solicit from Fabricators ESTIMATES or QUOTATIONS for the Cost to Fabricate the Parts Material-$ Estimates Find Materials Costs on the InterNet Production Labor-$ Estimates Call Fab Shops See During Office Hours MTT instructors Mr. Ashley Long Mr. Mike Absher See B. Mayer Last Resort Labor & Materials Estimates

19. Design Resources • Good Component Catalogs • McMaster-Carr (the best) • Graingers (Motion Generators – motors) • Omega Engineering (Sensors) • Newark Electronics (Electrical Elements) • PIC Design (Mechanical Elements) • Cajon/SwageLok (plumbing & valves)

20. Example Schedule

21. Weekly Reports • Each TEAM will submit a Weekly Report (WkRpt) on the Dates Listed in the Course Schedule • Suggest Team Members Alternate Writing the Reports • Report Form → Chabot_Engineering_Weekly_Report_Template_0906.doc • Posted to WebPage

22. Weekly Reports • Report Length → 1-2 pages • Appendices NOT included • Report Content • Two Required §’s → • Previous Week Accomplishments • Plans for Next Week • Optional § → Appendix (or Appendices) • Example Posted on WebPage • Weekly_Report_Example_BMayer...doc

23. Engineering 11 AppendixMileStone Schedules Bruce Mayer, PE Licensed Electrical & Mechanical EngineerBMayer@ChabotCollege.edu

24. Design Reviews • Functional Requirements Review (FRR). The purpose of the FRR is to review the functional requirements specification document, to ensure the documented requirements reflect the current knowledge of the customer and market requirements, to identify requirements that may not be consistent with product development constraints, and to put the requirements document under version control to serve as a stable baseline for continued new product development. • Conceptual Design Review (CDR). The purpose of the CDR is to review the conceptual design to ensure that the planned technical approach will meet the requirements. • Critical Design Review (CrDR). The purpose of the CrDR is to review the detailed design to ensure that the design implementation has met the requirements • Final Design Review (FDR). The purpose of the FDR is to ensure that the design is completely and accurately documented and ready for formal release to manufacturing.

25. PC030053a The S2 investigators pose in front of their subject at the conclusion of the inspection. Mr. W. A. on Left. Bruce Mayer on right. Circa Dec00. GS3 Visit – Dec00 Mr. W. A. B. Mayer

26. S2 Team Inspect Primary Power Box (PPB) Mr. Y. N. Mr. Y. K. Mr. H. T. Mr. I. A. Mr. A. N.

27. Full S2/S8/CE Compliance – Detailed Schedule Ref. BMayer file 3100_S2S8CE_0109.mpp

28. Full S2/S8/CE Compliance – Detailed Schedule

29. 2100 ß-System: Pre Shipment Testing

30. 2100 ß-Site Schedule

31. 2100 ß-Site Schedule

32. 2100 ß-Site Schedule ON-Semi_2100_0109_DWG.mpp