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Product Readiness Review

Product Readiness Review. MAE 491/492 - 01: Fall 2010 Course Instructor: Dr Christina Carmen Team # 2 - Optical Guitar Pickup: 11/11/2010 Team Members: Jared Nelson, Ben Fowler, Chris Kirchner, Samuel Hobbs, and Stephanie Buckner. Team Lead: Jared Nelson

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Product Readiness Review

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  1. Product Readiness Review MAE 491/492 - 01: Fall 2010 Course Instructor: Dr Christina Carmen Team # 2 - Optical Guitar Pickup: 11/11/2010 Team Members: Jared Nelson, Ben Fowler, Chris Kirchner, Samuel Hobbs, and Stephanie Buckner. Team Lead: Jared Nelson Customer: Mr. Tim Blackwell, UAH Center for Applied Optics

  2. Overview Purpose of the PRR Slide 3 Mission Statement Slide 4 Product Design Specifications Slide 5-6 Detailed Drawings Slide 7-10 Technical Analysis Slide 11-23 Verification Testing Slide 24-28 Cost Analysis Slide 29-30 Manufacturing Slide 31 Assembly/Installation Slide 32-37 Problems and Solutions Slide 38 Lessons Learned Slide 39 Customer Response Slide 40 Summary Slide 41 Acknowledgements Slide 42 Product Demonstration Slide 43-45

  3. Purpose of the PRR • Review the results of verification process • Product testing • Technical analysis • Provide final cost analysis and information • Demonstrate product • Verify product meets Product Design Specifications • Verify customer satisfaction Team 2 - Product Readiness Review

  4. Mission Statement Team 2 is designing an Optical Guitar Pickup. The team’s goal is to design and fabricate a product that will be able to temporarily or permanently attach to both acoustic and electric guitars. Once attached, the EZ Tabber will be able to write out the musical notes in the form of tablature. The EZ Tabber will work by using small light diodes and motion sensors to determine the individual frequency of each string. The frequency values will be measured and recorded in real time as the musician is playing them. The string vibration will be seen by the motion sensors and be converted into a frequency input that will be sent to a computer. The computer will determine the frets that are being played for the given frequency input, based on the tuning of the guitar. The computer will write out the tabs for each note that is being played. The invention and production of the EZ Tabber could revolutionize and improve the way musicians play their guitars. Team 2 - Product Readiness Review

  5. Product Design Specifications Team 2 - Product Readiness Review

  6. Product Design Specifications Team 2 - Product Readiness Review

  7. Design Drawings EZ Tabber with mounting plate Team 2 - Interim Design Review

  8. Design Drawings EZ Tabber: Base Plate 3/13/2014 8 Team 2 - Interim Design Review Team 2 - Interim Design Review

  9. Design Drawings EZ Tabber: Acoustic Mounting Plate 3/13/2014 9 Team 2 - Interim Design Review Team 2 - Interim Design Review

  10. Design Drawings EZ Tabber: Diode/Sensor Housing 3/13/2014 10 Team 2 - Interim Design Review Team 2 - Interim Design Review

  11. Technical Analysis (OGP): • The selected design for the EZ Tabber was imported into Patran via a step file and meshed using TET 10 solid elements. • Rather than a loads model, which will produce stress and strain data, Team 2 ran a Eigen Vector solution to determine the normal modes of the system. • By knowing the modes of the system, the frequency bands that may cause problems with vibrations can be predetermined. • This normal modes analysis will allow Team 2 to predict the deformation shapes that the system is most likely to be subjected to at various frequency ranges. • Patran and Nastran were used to solve for the first 30 modes of the selected design because the first 30 modes encompass the frequency range that our product will be subjected to. • In this analysis, ABS-M30 plastic was used as the OGP material. • Material Properties were taken from ABS-M30 spec sheet. Properties are seen below: • Modulus of Elasticity: E = 350000 psi. • Poisson’s Ratio: V = 0.33. • Density: p = 0.036 lb / in^3. Team 2 - Product Readiness Review

  12. Technical Analysis (OGP):Meshed Geometry: TET 10 Plate Elements: GEL = 0.1 in RBE2 Elements: Top View: RBE 2 Elements: RBE2 Elements: CBAR Elements: Right Side View: Team 2 - Product Readiness Review

  13. Technical Analysis (OGP): Normal Mode 1: 11.603 Hz • The first normal mode of the system was at 11.603 Hz. • A deformation plot from Patran is given to the right. Team 2 - Product Readiness Review

  14. Technical Analysis (OGP):Normal Mode 1: 11.603 Hz Team 2 - Product Readiness Review

  15. Technical Analysis (OGP): Normal Mode 2: 25.006 Hz • The second normal mode of the system was at 25.006 Hz. • A deformation plot from Patran is given to the right. Team 2 - Product Readiness Review

  16. Technical Analysis (OGP):Normal Mode 2: 25.006 Hz Team 2 - Product Readiness Review

  17. Technical Analysis (OGP): Normal Mode 3: 27.867 Hz • The third normal mode of the system was at 27.867 Hz. • A deformation plot from Patran is given to the right. Team 2 - Product Readiness Review

  18. Technical Analysis (OGP):Normal Mode 3: 27.867 Hz Team 2 - Product Readiness Review

  19. Technical Analysis (OGP) Summary From this analysis, Team 2 determined that the effects of vibration at the normal modes of the system are negligible. It was determined that the loads and vibrations that the EZ Tabber will be subjected to during normal use will not cause any fatigue or plastic deformation concerns. It can be concluded with low risk that the structural integrity of the EZ Tabber will be acceptable over the lifecycle of the product. Team 2 - Product Readiness Review

  20. Technical Analysis (Guitar): • The pressure load from the clamping mechanism of the EZ Tabber is applied to the face of a standard Acoustic Guitar. • The stress in the Face of the guitar faces will be measured and discussed. • The guitar face will be modeled with a paver mesh of CQUAD 4 Plate elements. • The pressure load will be modeled with a uniform pressure of 5 psi over the contact area of the clamping mechanism. • A 15in. by 15in. guitar face size is chosen to ensure that the Fixed SPC’s on the edge of the guitar face will not interfere with the analysis of the clamping mechanism. • In this analysis, Sugar Maple was used as the guitar material. • (material properties from Matweb:(http://www.matweb.com) seen below. • Modulus of Elasticity: E = 18e5 psi. • Poisson’s Ratio: V = 0.349. • Density: p = 0.0315 lb / in^3. • Shear Strength = 1.38 ksi • Compressive Yield Strength = 3.12 ksi Team 2 - Product Readiness Review

  21. Technical Analysis (Guitar):Guitar FEM Thickness Plot: Team 2 - Product Readiness Review

  22. Technical Analysis (Guitar):Guitar FEM Stress Contour Plot: Team 2 - Product Readiness Review

  23. Technical Analysis Summary (Guitar): The stress values from both surfaces of the plate elements were averaged in this analysis. The pressure load from the clamping mechanism of the EZ Tabber produced a max principal stress of 377 psi. The compressive yield strength of the material is 3.12 ksi. M.S. =[(3120 psi / 377 psi) - 1 ] = +7.28. Selected design approved by means of analysis. Team 2 - Product Readiness Review

  24. Verification Testing • Testing was conducted on October 28 and November 9 • Product assembly and testing lasted a total of approximately 6 hours plus 2 additional hours donated by the customer. • Verification tests are considered successful, as the team was able to demonstrate that the EZ Tabber is mechanically able to record frequency readings from each string. Team 2 - Product Readiness Review

  25. Verification Testing Team 2 - Product Readiness Review

  26. Verification Testing Team 2 - Product Readiness Review

  27. Verification Testing Frequency Reading Harmonics Team 2 - Product Readiness Review

  28. Verification Testing Frequency Reading Team 2 - Product Readiness Review

  29. Final Cost Analysis Team 2 - Product Readiness Review

  30. Cost Analysis Support • LED lights: • http://www.plasmaled.com/5mm8mmled.htm • Motion Detectors: • http://www. silonex.com • Rapid Prototype Machining: • www.redeyeondemand.com • Engineering Consultant: • $100/hr, approximately 10 hours. • Engineering Labor: • $25/hr, approximately 40 hours Team 2 - Product Readiness Review

  31. Manufacturing Methods Product is made using rapid prototype machine Diodes are bonded in place Electronics are bonded in place UAH machine shop is fabricating the product with the assistance of Steve Collins Assembly completed in CAO laboratory Team 2 - Product Readiness Review

  32. Assembly/Installation • Product assembly was a group effort • Team spent approximately 3 hours to assemble the product • During assembly, Sam Hobbs and Chris Kirchner aided Ben Fowler in part assembly. • Diode-Detector assembly • Diode-Detector housing placement • Foam core placement • Jared Nelson, with help from Sam Hobbs and Chris Kirchner, completed all wire soldering. • Soldering positive and negative wires to the light diodes and motion detectors • Sam Hobbs was in charge of pictorially documenting this work Team 2 - Product Readiness Review

  33. Assembly/Installation Team 2 - Product Readiness Review

  34. Assembly/Installation Team 2 - Product Readiness Review

  35. Assembly/Installation Team 2 - Product Readiness Review

  36. Assembly/Installation Team 2 - Product Readiness Review

  37. Assembly/Installation GO VOLS!!!! Team 2 - Product Readiness Review

  38. Problems and Solutions • Too many wires exiting the EZ Tabber • Consolidate to 1 wire exiting the wire housing • Soldered wires not withstanding the stress • Apply liquid soldering flux which makes soldering quicker and stronger • Incorrect piece manufactured • Steve Collins agreed to rebuild the piece at no cost to Team 2 Team 2 - Product Readiness Review

  39. Lessons Learned • Build, build, build • It is very helpful to build as many prototypes as possible, getting as many potential ideas as possible • Measurement Precision • If more care had been taken with the original measurements, Team 2 may have avoided the necessity of building a 2nd prototype • Motion detectors are very sensitive to ambient light • Future plans involve infrared lighting • LED lighting was necessary for prototype, giving the designers the ability to see the direction of the lights Team 2 - Product Readiness Review

  40. Customer Response During verification testing, Mr. Blackwell informed Team 2 that he was pleased with and excited about the product designed and manufactured by the team Mr. Blackwell believes we have designed a very good product which fulfills the agreed upon technical and mechanical requirements Team 2 - Product Readiness Review

  41. Summary • Customer is satisfied and informed the team that it fulfilled the agreed upon requirements • The team stayed within Mr. Blackwell’s budget, due to part and manufacturing donations • EZ Tabber has experimentally been successful in measuring the frequency of each string Team 2 - Product Readiness Review

  42. Acknowledgements Team 2 would like to thank Mr. Tim Blackwell for his knowledge and assistance in product assembly and verification testing Team 2 would like to thank Mr. Steve Collins and the MAE machine shop for their help in producing both EZ Tabber prototypes The team would like to thank Dr. Carmen for her assistance in this presentation and past documents that have played a vital role in the success of this project Team 2 - Product Readiness Review

  43. Product Demonstration Team 2 - Product Readiness Review

  44. Low E String Team 2 - Product Readiness Review

  45. D String Team 2 - Product Readiness Review

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