Students will be required to perform detailed analysis and design of one of four products. This design work will be performed individually, although collaboration between designers is encouraged. Note that while collaboration is permitted, students are required to submit original work for this project. Duplicate or plaigarized reports and submissions will be disregarded, and graded as not turned in.
Multiple Phases:
1) Requirements and Constraints: students must identify the requirements of the product which they are to design, as well as the constraints which limit their design choices. Some constraint levels will be arbitrary (budget, manufacturing schedule, etc). Requirements should reflect a consideration of the product in use, as to what will allow it to be sold widely, perform well, etc.
2) Conceptual Design: students will provide rough drawings/sketches of their design concept, along with an explanation of the proposed functions/features.
3) Detailed Design and Supporting Analyses: the final phase will include the finalized product design, including any supporting analyses used to accomplish said design. These will be incorporated into a design report which thoroughly explains the form and function of the product, along with the rationale behind the major decisions/trades made in the design of the product.
Product Options:
1) Integrated Upright Hub Assembly: You are responsible for designing a front upright assembly for a modern commercial automobile. You must include everything between the A-arms and the wheel (meaning, at a minimum, the upright, wheel bearings, stub axle, brakes, and the necessary plumbing/wiring).
2) Single-speed reduction gearbox: Everything between the input and output shafts is your responsibility. Gear type and construction, shaft layout, bearings, case design, lubrication, and more are up to you to determine. Gear ratio may be fixed or variable, and should be defined in your requirements/constraints phase. Configuration is at your discretion.
3) Hydraulic Manifold and Accumulator: Accumulators are often used in hydraulic systems as a storage unit for fluid at high pressure (most often at the outlet of a pump), in order to serve high flow actuators (such as those found on most modern aircraft) without delay due to pump spin-up. Your task is to define a proper application (aircraft, heavy construction/farm machinery, etc), including actuator usage, and size an accumulator and manifold accordingly. You are responsible for the accumulator, manifold, any safety devices necessary, and the control devices for your selected actuator scheme.
4) Cam-driven valvetrain: You are responsible for everything from power input to valve motion output. The camshaft itself, its journals and bearings, valve linkages, valves, etc. You define the application, including rise/fall of the cam, valve open time, max driven speed, as well as drive method. A smart designer here would use as many off-the-shelf components as (s)he could.