P17221: FSAE Composite Tube Fabrication
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Problem Definition

Table of Contents

Team Vision for Problem Definition Phase

Project Summary

Composite tubes are an integral part of creating a lightweight car. Many structures on the car require composite tubes including the steering shaft, drive shafts, wing mounts, and suspension arms. These tubes were fabricated at RIT in the past using hand layup techniques, but it was found that this technique was not suitable for creating robust tubes. The Formula SAE team is currently buying tubes from a third party. However, these tubes are expensive and overbuilt for the team's needs, resulting in both a cost and weight penalty. Having an improved filament winding process in-house would greatly help the Formula SAE team by providing the opportunity to manufacture optimized, quality composite tubes for the car at an affordable cost. This automated filament winding machine would eliminate the need for low-quality hand layup techniques while also not forcing the team to purchase expensive and overbuilt tubes.

This project is a machine that will wrap carbon fiber tubes in-house for the Formula SAE team. The machine will be adaptable, allowing the team to create tubes of various wall thicknesses and diameters. Being able to fabricate tubes in-house will save the team money and allow custom tubes to made. An assembled and operational filament winder will be provided for the Formula SAE team including tooling to produce FSAE driveshafts. A detailed user manual with troubleshooting information along with a training session for composites team members will also be provided. The machine must meet OSHA safety standards that ensure operator safety. It must also meet a maximum physical footprint requirement and stay under a power draw limit requested by the team. Lastly, the cost of the machine must stay below a limit set by the team and preferably be near an ideal target.

Our Project Readiness Package

Use Cases

Our team has identified three use cases:
Use Scenario 1

Use Scenario 1

Use Scenario 2

Use Scenario 2

Use Scenario 3

Use Scenario 3

Project Goals and Key Deliverables

Below are the key deliverables to be given to the customer at the end of this project.

Customer Requirements

Below are the customer requirements generated both from our team and from interviewing members of the FSAE team. 5 is the highest priority and 1 is the lowest priority.

Customer Requirements (Priority 5 = Highest)

Customer Requirements (Priority 5 = Highest)

Link to the current customer requirements: Customer Requirements.

Customer Interviews

We conducted an interview with Nate from the RIT FSAE team. The interview is located here.

Stakeholders

Stakeholder Position Major Concern
RIT MSD Sponsor Completion of Project
RIT Formula FSAE Customer Functionality of machine
Collin Cragon Future team management Robustness of machine
Nate Bierman Composites Manufacturing Lead Compatibility with current manufacturing
Jon Washington F25 Project Manager Budget
Gary Werth Project Guide Completion of Project
MSD Team Design Team Graduation

Engineering Requirements

Engineering Requirements

Engineering Requirements

Link to the current engineering requirements: Engineering Requirements.

Mapping Engineering Requirements to Customer Requirements

Mapped Engineering Requirements

Mapped Engineering Requirements

Link to the current mapped engineering requirements: Mapped Engineering Requirements.

Team Requirements

The chart below clarifies the breakdown of responsibilities between the Formula team and the MSD team.
Breakdown of responsibilities between the Formula team and the MSD team

Breakdown of responsibilities between the Formula team and the MSD team

Benchmarking

Benchmarking Matrix

Benchmarking Matrix

Link to the current benchmarking matrix: Benchmarking Matrix

Comet Filament Winder

Comet Filament Winder

Little Hornet Filament Winder

Little Hornet Filament Winder

Mini Winder

Mini Winder

Material Test Winder

Material Test Winder

2X-23 Filament Winder

2X-23 Filament Winder

4X-23

4X-23


Plans for next phase

Team Setup

Member Team Role Duties
Andrew Derhammer Project Lead Ensure team completes deliverables. Scheduling and Agenda
Daniel Wu Edge Manager Ensure deliverables are uploaded to edge
Ryan Willsey Editor Edit and format documents before final submission
Matthew Hendler Manufacturing Manager Review Designs from manufacturability standpoint.
Patrick Burke Team Facilitator Keep team on task during meetings, take meeting notes
Jon Washington Financial Manager Coordinate purchasing and budget

Team Conflict Resolution Plan

The following 5 step process will be utilized when conflicts arise on the team, including but not limited to: missed deadlines, over/underallocation of workload, missed meetings, etc.

Escalate - The problem is brought to the attention of Project Team as soon as it is known about.

Discuss - The team discusses the issue at the next meeting and how it will affect the project overall.

Plan - The Project Team decides upon a plan and path forward to resolve.

Execute - The plan is put into action by the team.

Review - The team reviews if the plan was successful.

Team Values and Norms

Team Norm and Values

Team Norm and Values

The team norms and values can be found here

Project Plans & Schedules

Work Breakdown Structure

Work Breakdown Structure

The current work breakdown structure can be found here
Gannt Chart

Gannt Chart

The current Gannt Chart can be found here

Systems Design Phase Team Goals

Motors Selected for All Major Axes

Equations of Motion Determined

High Level Geometry and Packaging Completed

Load Paths Determined

Risk Assessment and Growth Curves

Risk Management Table

Risk Management Table

The current risk management document can be found here

Other Team Resources

Storage and Work Space: The RIT Formula SAE Team is offering part of their workspace for storage

Meeting Location: Default meeting space is the Gordon Atrium in Building 9

Peer Reviews

Problem Definition Phase

PDR Peer Review

PDR Peer Review

Pat's Review

Andrews's Review

Matt's Review

Jon's Review

Ryans's Review

Dan's Review

Project Reviews

Preparation, notes and actions, etc. Refer to Gate Reviews page, as well.

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