Reference no: EM132385350

300600 Mechatronic System Design - eBike System Design Project

Western Sydney University

eBike System Design Project

Aim:

To narrow down the gap between theory and practice of Engineering by synergistically applying elements of theory learnt so far in your entire course to design mechatronic systems with the applications of systems engineering, sustainable engineering and design for X (DFX), i.e., design for assembly (DFA), design for manufacturing (DFM), and design for disassembly (DFD), etc.

Method:

You will firstly identify the existing design and then based on your analysis you will redesign the product with the following design principles:
• Systems Engineering
• Sustainable Engineering
• Computer Aided Engineering (Computer Aided Design and Numerical Simulations)
• Design for Assembly (DFA)
• Design for Manufacturing (DFM)
• Design for Disassembly (DFD)
• Failure Mode and Effect Analysis (FMEA)

You will be allocated in a group of 3 or 4 students at Week 4 of the semester working on a design project to achieve the design goal together.

As a group, you need to submit the slides and report along with Turnitin report as well as the CAD/FEA parts/assemblies/workshops. Peer-review report is also employed to show each member's contribution.

Format for all CAD assignments:

All assignments of the design project must be submitted electronically by uploading the relevant files into the appropriate assignment area in the vUWS site and hardcopy submission is not acceptable.

The following important notes are highlighted:
1. All group design reports will be assessed by "Turnitin" in the vUWS site. "Turnitin" ensures the originality of your reports by comparing against a repository of previously submitted reports, current and archived internet contents, periodicals, journals and publications.

2. Submit all files for marking. All SolidWorks part and assembly files used in the creation of an assembly must be submitted or else, the assembly cannot be opened. It is a good practice to keep all files for an assignment in a separate directory so that you do not miss any important files during the submission process.

3. Drawings can be submitted in e-Drawings format with all drawings in ONE file. Use the following checklist before you submit any drawings:
• All drawings must use the 3rd angle projection. The 1st angle will not be accepted.
• All line types, arrow styles, dimensioning, sectioning, auxiliary views etc. must conform to the Australian Standards.
• Create and use the WSU title block and sheet format for all drawings.

4. Make sure you retain a copy of all of your assignment files and create a back-up somewhere. If an assignment gets lost in the system this will help you demonstrate that the assignment was completed by the due date and allow you to easily re-submit the files for marking.

Essential Elements of the Project

• Each Project has to have a clear, broad objective (task) to achieve: e.g. lift a man in a wheel chair on to a theatre stage; place caps on bottles on a conveyer belt; lift a heavy object and transfer it from one end of a warehouse to another; etc. Common to all these is a general intent or purpose the needs of which have to be met (engineered).

• Given the task needing to be accomplished, it is necessary to provide specifications involving performance characteristics, i.e., 90-kg man, 2-m lift, 30 seconds, a 10-tonne object, 60-m long warehouse, 15 minutes, 3-cm diameter, etc.

• There is usually a number of ways to accomplish a given task. These should be identified and described.

• One design should be chosen as the optimum - and this selection justified. This is an important part of the Design Process and great care should be paid as to the reasons for choosing a particular design - against all others that had been identified as possible solutions to the set problem.

• A sketch of the chosen device/machine should then be made.

• Main components should then be designed involving choice of material and application of analytical procedures, justification of sizes, types of member cross sections, types of loading, drives, gears, controls etc. This is the most important part of the project as it shows application of design principles to sizing of machine components, selection of drives and machine components which when all put together perform the desired task - a trademark of an engineer. You do have to be good at it - it is not a chore; it is what Engineering Professionals are made of.

• Having sized all the machine components and selected any commercial items, the next task is to draw up an Assembly Drawing. It shows - usually in cross section - the whole machine with each part labelled (numbered). A parts list is given in the drawing (according to the Standard) - stating the part ID, material and the number needed ("number off" - or "no. off"). This is necessary for costing purposes, material purchase, manufacturing (machining) - and assembly. The drawing should be done in any CAD you are familiar with. CAD proficiency is also expected of you in Industry - especially in your early years of employment. You should be practicing with the School's Solid Works in any "free" time you may have - using given on-line tutorial guides. Individual machine parts should have an indicator of the surface finish required and each dimension should have a tolerance associated with it.

• A complete set of machine drawings "workshop ready" should be produced at the end of the project.

Design report

A design report would most likely contain the following items (separated by headings and subheadings):
• Title page
• Executive Summary
• Table of Contents page
• Introduction & Background
• Aim and Objectives
• Main body - The contents of this section (divided into suitably headed subsections) is subject to change, and it depends upon what is being examined. Typical contents would be analysis of initial object, redesign of object, assumptions made and analysis of redesign (discussion of why concept may or may not fail). No design is foolproof. In most cases, design is the art of compromise/trade- off. Typically, by making a change to an object, you will improve one characteristic of that object, but decrease another. These trade-offs should be recognised and discussed. The sub-sections in this main body can be suggested as follows:

1. Performance Criteria and Design Constraints
2. Concept Design and Decision Making
3. Design Analysis (Force, Stress, and Motion Analyses and Optimisation)
4. Final Design
5. Results and Discussion
• Recommendations/further work.
• Conclusions
• Acknowledgments
• References
• Appendices - Peripheral information, including catalogues, technical drawings and detailed calculations may be placed here or in the main body of the report depending upon its relevance (e.g. repetitive calculations should be left in the appendices, but you may wish to include a sample calculation within the body) ‘standard' calculations would also be better in this section, rough sketches of rejected designs (including descriptions as to why they were rejected). Also there should be an appendix to indicate the technical contributions from each member.

Attachment:- Mechatronic System Design Project.rar