P17221: FSAE Composite Tube Fabrication
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Cross Feed

Table of Contents

Inputs to the Design

Associated Risks

The associated risks are derived from the engineering requirements and customer requirements. The risks cover both technical and safety risks.
Cross Feed Associated Risks

Cross Feed Associated Risks

Customer Requirements

The customer requirements are derived from customer interviews as well as the PRP.
Cross Feed Customer Requirements

Cross Feed Customer Requirements

Engineering Requirements

The engineering requirements are derived from translating the customer requirements in to quantitative goals.
Cross Feed Engineering Requirements

Cross Feed Engineering Requirements

Path to the Design

Updated Morphological Chart

The Morph chart shows a benchmarked design, and 5 alternative designs. The designs are all picked with a specific theme to the design.
Updated Morph Chart

Updated Morph Chart

Updated Pugh Chart

The 5 alternative designs are compared to the benchmark datum to best decide the best solution in the Pugh chart. They are weighted on a plus minus scale to find the best solution.
Updated Pugh Chart

Updated Pugh Chart

Feasibility Analysis

First, the precision of the cross feed is found. This is calculated using the smallest diameter tube, as a smallest diameter tube needs the tightest locational accuracy.
Precision Feasibility of Stepper Motor

Precision Feasibility of Stepper Motor

Next, the acceleration of the cross feed has to be found. The acceleration dictates the needed motor torque and the resulting pulley size.

Acceleration Demands of Motor

Acceleration Demands of Motor

The other motor requirements then follow from this torque and pulley size.

Other Motor Requirements

Other Motor Requirements

Once the motor and the pulley are designed, the cross feed mounting can be designed. To ensure that the mounting will not fail, an FEA analysis was done.

FEA Setup

FEA Setup

FEA Stress Results

FEA Stress Results

FEA Deformation Results

FEA Deformation Results

Final Component Selection

The final components were decided on based on the feasibility analysis.
Finalized Cross feed components

Finalized Cross feed components

Torque Curve of Selected Motor

Torque Curve of Selected Motor

Current Model

3-D Model Screenshots

Full Cross Feed Assembly

Full Cross Feed Assembly

Cross Feed Ways

Cross Feed Ways

Cross Feed Tower

Cross Feed Tower

Cross Feed Drive

Cross Feed Drive

Associated Prints

Way Plate

Way Plate

Tower Leg

Tower Leg

Preliminary BOM

Preliminary Cross Feed BOM

Preliminary Cross Feed BOM

Test Plans

Backlash Test Plan

This test plan is to quantify the backlash in the system to ensure that the positional tolerances can be met.
Backlash Test Plan

Backlash Test Plan

Speed Validation Test Plan

This test plan is to validate the designed speed of the cross feed.
Cross Feed Speed Test Plan

Cross Feed Speed Test Plan

Fulfillment of Requirements

Mitigated Risks

The green rows are risks that have been fully addressed. Yellow rows are risks that are in the process of being addressed.
Updated Risks Table

Updated Risks Table

Satisfied Engineering Requirements

The green rows are engineering requirements that have been fully addressed. Yellow rows are engineering requirements that are in the process of being addressed.
Updated Engineering Requirements

Updated Engineering Requirements

Satisfied Customer Requirements

The green rows are customer requirements that have been fully addressed. Yellow rows are customer requirements that are in the process of being addressed.
Updated Customer Requirements

Updated Customer Requirements

Future Tasks

Outstanding Risks

Unfulfilled Engineering Requirements

Unfulfilled Customer Requirements


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