Course Learning Outcome:
A) Understand current development of reliability and condition monitoring methods.
B) Perform qualitative and quantitative analysis on mechanical systems.
C) Design a complete conditioning monitoring system for a machine using ISO standards.
D) Design of complete structural health monitoring system using SAE/ ISO standards.
E) Analyze a design for its reliability and maintainability using ISO standard techniques.
Assessment Task:
Ford Motors is planning to introduce a new model to address urban transportation challenge by investing in the emerging mobility service with the generation of cleaner vehicles and sustainable urban logistics. You have been asked to design the bearing for the rear wheels and the suspension system of the New Ford Tourneo Connect.
There is a trade-off with the size of the bearing, the size should be big enough to last 20 years and small enough to reduce the frictional power losses.
This is an open assignment, the result and viability of the bearings is not known.
Objectives:
A. To design and select materials for a reliable shaft/bearing assembly that can be used for the above mechanical structure and minimizes friction, wear and maintenance.
B. To propose a monitoring system (sensory- actuation system) that can be used to monitor system operational condition and prevent system/ sub-systems failure.
Assessment Detail:
You have been asked as an engineer in the 'Ford Motors' company to design the bearing for the rear wheel, suspension system and to propose a monitoring system for the above prototype.
The design process should take into consideration the main dimensions of the mechanical structure and materials of the shaft and bearings. You will need to estimate the size and weight of the rear wheel and to make realistic assumptions about the driving speed and suspension system. You will need to make realistic assumptions about the operating conditions of the bearings. Use bearing theory to select the materials for the journal bearings so they will wear no more than 2 mm during normal daily operation for 20 years when maintenance would be scheduled.
Provide a detailed, professional report that contains the following items mentioned below:
Part 1: Review the motor vehicle industry development, summarize the reliability methodologies development and condition monitoring techniques in the motor vehicle industry.
Part 2: Look thought different online resources to find failure data for various components of the Ford motor engine, and construct a reliability block diagram (RBD) analysis for the motor engine. List all the assumptions you have made.
Part 3: Perform failure mode effects analysis (FMEA) on the same Ford motor engine. What is the advantages and disadvantages of quantitative method like RBD over qualitative method like FMEA?
Part 4: Propose a monitoring system (sensory- actuation system) that can be used to:
- Monitor system operational condition
- Prevent system/ sub-systems failure.
Describe in detail the main elements of the system. Use block diagrams to support your discussion.
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