Course Number:MECH 4250Semester: Summer, 2010
Course Title:Comprehensive Design II
Credit Hours:2 (LEC 1, LAB 3)
Prerequisites:MECH4240, and any two of MECH3040, 3050, 3140
Co-Requisites: INSY3600, and the remaining two of MECH3040, 3050, 3140
Class Schedule
Lec/Lab MWF, 1:15-2:30, AE257
Instructor
Dr. David Beale, Mechanical Engineering Dept., 354 Ross, 844-3336,
Office Hours MWF 9:00 – 10:00 a.m. and by appointment.
Course Objectives
This course is a continuation of MECH4240. Upon completion of this course, the student will be able to:
- Design an industrially-relevant complex and integrated mechanical system and individual components (Program Outcome 4,6,8,9)
- Apply the engineering design process in a rigorous manner, step-by-step from need to final design, working in a design team with individual functional responsibilities. (P.O. 6)
- Effectively communicate the design and production process in a professional setting and using modern engineering design tools. (P.O.7,8)
- Consider many important design issues – including safety, cost, manufacturability, environmental and ethical concerns (P.O. 9)
Course Outcomes
In order to learn the course material, students will:
- Identify need, develop design constraints and specifications for a real world, industry sponsored engineering project. (Course Objective 1)
- Innovate, develop and communicate design concepts, and select the most promising for a design. (C.O. 2,3)
- Use techniques, skills and modern engineering tools to communicate a detailed design for manufacture. (C.O. 2, 3)
- Prepare and present a complete design – including analysis, dimensioned drawings, consideration of safety and manufacturability, parts list and cost analysis. (C.O. 2,3,4)
- Work in groups, and producing and presenting a final and midterm project reports. (C.O. 2)
- Construct, assemble and test a working prototype in accordance with engineering design drawings. (C.O. 1,4)
- Update drawing and iterate on design as necessary to improve functionality. (C.O. 2)
Website
General information and course material can be found at:
Textbooks
None
Homework
See attached.
Final Presentation
Demonstration (validation) of working prototype to industrial sponsor
Grading and Evaluation Procedures
See attached for detailed evaluation procedure.
90-100 A, 80-90 B, 70-80 C, 60-70 D, <60 F
Accessibility
The policy of Auburn University is to provide accessibility to its programs and activities, and reasonable accommodation for persons defined as having a disability under Section 504 of the Rehabilitation Act of 1973, as amended, and the Americans with Disabilities Act of 1990. Students needing special accommodations should see the instructor as soon as possible, or contact the Students with Disabilities Program office at (334) 844-5943 (Voice/TT).
Academic Honesty:
All portions of the Auburn University Student Academic Honesty Code, as found in the Tiger Cub and defined in the SGA Code of Laws, Title XII, will apply in this class.
Attendance Policy Points will be taken away for unexcused absences. Students will be allowed to make-up work due to excused absences (illness, death in family, court appearance, etc.) with appropriate documentation (written doctor’s excuse, court papers, etc.).
MECH4250: Course Overview and Process – Summer 2010
May 20 / Classes Begin / (Thu)May 31 / Memorial Day (Holiday) / (Mon)
June 24 / Mid-Semester (25th Class Day) / (Thu)
June 24 / Classes Meet on Monday Schedule / (Thu)
June 25 / No Classes - MS-I Exam Period / (Fri)
July 5 / Independence Day (Holiday) / (Mon)
Aug. 2 / Classes End / (Mon)
Aug. 3-5 / Final Exam Period / (Tue-Thu)
Aug. 9 / Commencement / (Mon)
Schedule (dates shown are only for demonstration purposes)
5/21Team Meeting Day - Draft MPCOD (Manager’s Project Contract of Deliverables)
5/25Team Meeting Date - Discussion and Submit for Approval of MPCOD, Cycle 1 CODsassigned
5/27Submit CODs - Cycle 1
6/17Deliverables Due for Cycle 1 CODs
6/21Team Meeting Day - Cycle 2 CODs assigned
6/21 Submit CODs – Cycle 2
7/13 Deliverables Due for Cycle 2 CODs
7/15Team Meeting Day - Cycle 3 CODs assigned
7/15 Submit CODs – Cycle 3
7/25 Deliverables Due for Cycle 3 CODs
7/27Grading of System Integration/System Validation
8/2Prototype Presentation and Delivery of Final Report
Manager's Duties And Grading of Manager
The manager is the project leader and systems engineer. He/she will either be selected by the group or selected by Dr. Beale. The manager's objective is to complete deliverables defined in the MPCOD (Manager's Project Contract of Deliverables).
Manager's Duties Include:
1) Creating and carefully crafting of the MPCOD with the student team. These are project deliverables listed on a single page. The SE effort defines the creation process of a final system, however some projects are too big for a single student team to complete in one semester and the engineering effort often extends beyond the time allotted in this course (hence the purpose of the MPCOD). This could require approval of the corporate sponsor, the student team and must be approved by Dr. Beale. It is the manager's responsibility to schedule tasks and make sure they are completed in order to deliver a working prototype. The manager's course grade will be given by Dr. Beale in consultation with the corporate sponsors, and based on how well the MPCOD deliverables are met, with the final report. Caution: Promise in the MPCOD only what you can deliver, assemble and test.
2) Prepare a Work Breakdown Structure at first team meeting, to be included with the MPCOD showing tasks and completion dates and responsible parties. This can be continuously updated throughout the semester.
3) Approve and guide student COD preparation. CODs here could be for manufacturing of a part by the student or outside machine shop, planning for and testing of a subsystem or component, updating drawings, etc.
4) Assist Dr. Beale if requested in grading student deliverables.
5) Make sure that the final report is completed and delivered by the end of the semester to Dr. Beale and corporate sponsor. The final report will be a continuation of the systems engineering process and incorporates much of the final report from last semester. If the last semester final report covered through Phase C (detailed design), you will add the “right side of the Vee-chart” details to the report, in particular completed and updated orthographic projections, verification and documentation of testing of each subsystem, verification and documentation of the integrated subsystems, and validation testing (i.e. operating the system in a fashion like the ConOps require). Include safe operating instructions, update drawings and requirements as necessary, and update the website to include this information.
7) Prepare for and present (with other students) a prototype demonstration (i.e. System Validation) to the corporate sponsor at the end of the semester, or sooner. There are no PowerPoint presentations this semester. There is no midterm report/presentation.
8) The manager's grade will be determined by Dr. Beale based on
1) Consultation with the industrial sponsor,
2) prototype presentation (System Validation) results,
3) assessment of final report and how well it meets the deliverables stated in the MPCOD.
9) Email to Dr. Beale one day before each class where students will be working. This will allow Dr. Beale and the TA to track down and assist students during classtime. Here is an example email:
Tuesday Class: Group meets in AE156 for 10 minutes. After that, CAD team will be in SB2 computer lab, Machine Design team should be in DML, and lastly John Smith will be going to the fastener store.
10) Each student must make copies of the signed COD for themselves and the manager.
11) Keep a chart of COD assignments, that lists for each student their name, COD title, date assigned and date due.
12) To act as Systems Engineer. A significant aspect of SE is to assign students to perform and document verification testing and assembly, update drawings and interfaces, and to always be aware of potential sources of risk and managing that risk.
System Integration/System ValidationGrade
10% of each student's final course grade will be determined based on the assembly of the prototype, and how well his/her components mate and interface within the prototype, and performance during System Validation testing in accordance with the ConOps. To be assured a good System Integration/System Validation Grade, each student must responsibly and proactively work with other team members. If parts don't fit together, bolts holes don't match, unwanted interferences occur, your part is undersized, etc., these faults will be evident during assembly. CODs and deliverable will pinpoint the particular student(s) responsible for a substandard or failed assembly. It will be the manager's responsibility to schedule the date for the grading of the assembly. Similar can be said for electrical and electromechanical and software systems - faults in these systems will also be evident. Dr. Beale will assign an Integration/Assembly Grade to each student. This grading will occur just before or at the final.
Grading Milestones (for all except Manager, who is graded by Dr. Beale)
MilestonePercentage
COD Deliverables #1,#2, or more20%*
Peer Reviews 30%
System Integration/System Validation Grade 10%
Final MPCOD Evaluation with Final Report, Webpage, Design Notebook35%
Attendance 5%**
* Total of all 2 deliverables equals 20%. Deliverables to be graded may be selected randomly. Turn in your CODs + Deliverables to your manager, who will keep them in a binder that can be inspected and then graded by Dr. Beale upon request. At least 1 of your deliverables will be graded, although all 2 must be turned in. More than 2 deliverables is acceptable, particularly if some deliverables are not very challenging or significant. Some students may have 2 or all 3 graded.
** Attendance will be taken, but it is not necessary to report to the classroom.
TheDML will be open 12:45-5 this semester. Deliver a complete set of drawing to Dr. Payton for parts you plan to make in the DML. Carefully plan 1) parts you will make in the DML, 2) parts you request to be made by Dr. Payton and his TAs, e.g. complicated parts, CNC parts, 3) parts to be made by outside contract shops. Dr. Payton’s office hours are 1-2.
Important Points
1. It is allowed to complete your COD deliverableson or ahead of schedule- the same is true for the project.
2. Manager has prerogative to assign tasks as necessary to complete MPCOD.
3. At the end of the semester Dr. Beale will grade the manager based on the performance on the MPCOD’s stated deliverables.
4. Make sure you work well and professionally with your manager. When grading deliverables, Dr. Beale may solicit input from the manager .
5. Before signing your COD make sure you can deliver by your completion date. For example, do not agree to make a part by a certain date unless you have investigated machine tool availability.
6. This class emphasizes skills you will need when you become practicing engineers, such as working under contracts, timeliness, teamwork, responsibility, quality of output, accountability and planning.
7. Don't underestimate how important it is for your grade to clearly and precisely state your deliverables and "Measures of Performance" in the COD.
8. If you hit an obstacle trying to accomplish your deliverables on time, see me as soon as you can and I will remedy the situation.
9. Use your resources we have provided to you, such as Dr. Payton, other professors, corporate sponsor, Dr. Beale, etc.
10. There are many kinds of deliverables. For example: Making a Gantt Chart, making a CAD drawing, investigating and choosing the best bolts and fastening hardware, assembling several parts; contracting and monitoring manufacture of a part by an outside contractor, writing a software code, interfacing sensors to a computer, making a part in the DML, etc.
11. Make sure your team can deliver what you promise in the MPCOD. An overarching objective here is quality of product and process rather than quantity.
12. Maintain your design notebook to record your test data/results, and any other useful information.