07 Project - Design Documentation

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EM103 Design Project “Adrenaline Outpost”

Design Documentation PacketBryan, Layton, Mosely, White

Spring 2010

Contents

Sample cover page for the design documentation

Sample table of contents

Requirements for design documentation

Project deliverables

Math model evidenceBill of materials, project inventory, and cost estimate

Sample assembly drawing and parts inventory

Sample drawings of components

Sample bill of materials and cost estimate


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Return to CM __________

DESIGN DOCUMENTATION

Put the Name of the Project here

by

Team 25

William Harvey

Aaron Lindsey

Jerome Williams

May 6, 2006

In partial fulfillment of the requirements of the course

EM 103Introduction to Design

Put your professor’s name here

Department Of Mechanical Engineering

Rose-Hulman Institute Of Technology


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Table of Contents

Detail drawings

Platform and subassemblies ....................................................................................................................... 1Bill of materials ............................................................................................................................................. 5

Cost estimate ................................................................................................................................................. 6

Engineering analysis

Static analysis of platform ........................................................................................................................... 7

Dynamic analysis of jumper ..................................................................................................................... 10

Design concepts and decisions

Platform decision matrix and rationale ................................................................................................... 14

Recovery system decision matrix and rationale ..................................................................................... 18Harness morphological chart .................................................................................................................... 22

Project management

Gantt chart ................................................................................................................................................... 25


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Requirements for Design Documentation

Overview

Assemble your design documentation using the sample cover page and sample table of contentsprovided. (An e-copy of these templates is available.) The sample table of contents lists the documents to

include and their order. This set of documents constitutes your final team report on the design project.

Due date

Friday, 5 pm of 10th Week.

Detail drawings

Include part and assembly drawings for your design. Your drawings should definitely include

dimensions and tolerances, a bill of materials, and a cost estimate with rationale. Use a professional

package (AutoCad, Mechanical Desktop, Solid Edge, etc.) to produce your drawings. Someone elseshould be able to build your design using your drawings.

Engineering analysis

Include the math model assignment for your design. Include additional analysis associated with

experiments (e.g., prototype testing and comparisons) you might have conducted in making design

decisions. Provide evidence of modeling results in accordance with instructions from your instructor. For

the static analysis conclusion, provide a summary that convinces us that your design will not fail in any

of the modes you’ve analyzed. Support your conclusions with key engineering parameters. For the

dynamic analysis conclusion, provide a summary using the evidence described in the earlier math-

modeling-evidence handout.

Design concepts and decisions

Include the decision matrix and justification discussion comparing your major competing design concepts

(use the format from PPS-5 Making Decisions) and the assigned morphological chart. Include neatly

hand-drawn sketches of competing concepts in all cases. Conclude: clearly identify which of the concepts

is your final design and explain which of the criteria were most important in the decision and how the

criterion affected the decision.

Gantt chart

Include a final Gantt Chart that details the activities and the actual hours that each team member spent on

the project. Be as specific as possible about the activities. For example an activity of “construct project” is

too general. You should now be able to divide the activity into components such as “construct platform,”

etc. (Use format from PPS-6 Project Planning, Gantt Chart.)


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Project Deliverables

(This page is a copy of material provided previously.)

Platform

1. 3 feasible design concepts

2. 5 or 6 important design requirements (unambiguous and measurable) and decision matrix

3. CAD drawing(s) of the full-scale platform with dimensions. Include a fully assembled drawing

and separate drawings of subassemblies.

4. Complete parts list and cost estimate

5. Math model showing that the platform will support the expected loads with safety factor

6. Written description : describe/support with evidence to what extent the design meets the goals

and design requirements.

Harness

1. Full-scale mock-up

2. Show fitment on various sizes of persons

3. Material not required to be the same as design material, just size/shape/function

4. Morphological Chart

5. Written description: describe/support with evidence to what extent the design meets the goals

and design requirements

Scale model recovery system

1. 3 feasible design concepts

2. 5 or 6 important design requirements (unambiguous and measurable) and decision matrix

3. Scale-model of recovery function system

4. To be demonstrated on Test Day: test subject is a typical toy “fashion” doll

5. Student interaction limited to designed operator interactions

6. Written description : describe/support with evidence to what extent the design meets the goals

and design requirements

Scale model bungee jump test with fragile test subject

1. Math model analysis that forms the basis for the computer code

2. Program code to determine length of cord given a test mass

Project management deliverables

1. Gantt chart

2. Weekly minutes and copies of agendas


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Math Model Evidence

(This page is a copy of material provided previously.)

Dynamic analysis

1. List parameters: weight of jumper, bungee “k”, other constants used in the simulation

2. Plot of jumper’s trajectory, x(t)

3. Plot of jumper’s acceleration, a(t)

4. Max force on structure

Static analysis

1. Sketch(es) of platform indicating distances, loads, shape of relevant cross-sections

2. List relevant parameters e.g. Young’s modulus, moment of inertia, material strength, FOS, etc.

3. FBD

4. Assign numbers to all forces (including the max from the jumper)

5. Stress analysis on key members of structure (including FOS) showing that max stress is below

the material strength


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Bill of Materials, Project Inventory, and Cost Estimate

While you may have been able to scrounge up the material for free for the construction of this project, if

you were to manufacture this device in quantity, each component that comprises your machine would

need to be specified, ordered, and paid for.

Part of your design requirements will be to put together a set of working drawings for your project. As

part of this drawing set, you should include an assembled view of the device which includes a complete

Bill of Material and Project Inventory and Cost List. (see the attached example assembly drawing and

list). All parts used in your design will be accounted for at fair market value.

If you were working at a company, you would also be expected to take this bill of materials and create an

inventory sheet in the appropriate Company Management application software which documents all

parts, material, suppliers, costs, and other information associated the manufacture of this device. A

management system allows the company to link accounting, inventory, suppliers, and engineeringdrawings in an organized fashion. As an engineer, one of your responsibilities might be to locate, update,

and/or check the accuracy of parts within this management database.

For this project you will be expected to supply a cost of each part that is on your bill of materials. You are

expected to locate the cost of the item from one of several approved sources (see list). If you are unable to

locate a similar part from these sources, you will need to find an alternative supplier and then have this

supplier approved by your instructor.

You are to complete a Product Inventory and Cost List which includes among other things a description

and quantity of the part, the part available from the supplier, supplier ID number, cost of supply, andcost for the portion of the part that you use. You will not be required to include costs of labor, shipping,

handling, or overhead for your project. Be aware that on a real project these would need to be

considered.

An example of this Project Inventory and Cost List is attached. Note that each part requires you to

identify the Vendor (or supplier) number for each part. You may search through the approved supplier’s

on-line database to locate part numbers and cost of each item.

The list of approved suppliers and web sites include:

Lowes www.lowes.com

Home Depot www.homedepot.com

McMaster-Carr www.mcmaster.com

Ace Hardware www.acehardware.com

Thomas Net www.thomasnet.com

Grainger www.grainger.com


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Sample assembly drawing and parts inventory


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Sample drawings of components


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Sample bill of materials and cost estimate


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Documents

07 Project - Design Documentation