Team Vision for Problem Definition Phase
- Our team planned to complete all assigned deliverables for this phase to present at the Problem Definition review. This includes things such as team values, a problem statement, customer requirements, and engineering requirements.
- Because four of our six team members are on the RIT Formula SAE team, the team has intimate knowledge of the specific requirements and final deliverables.
Project SummaryComposite 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.
Use CasesOur team has identified three use cases:
- Standard FSAE Team Usage
- Usage by Students in Composites Class
- Routine Maintenance/Repair.
Project Goals and Key DeliverablesBelow are the key deliverables to be given to the customer at the end of this project.
- Assembled and running Filament Winder
- Tooling to produce FSAE driveshafts
- Documented user manual with troubleshooting advice
- Training session for composites team members
- Print book for replacement parts
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.
Link to the current customer requirements: Customer Requirements.
Customer InterviewsWe conducted an interview with Nate from the RIT FSAE team. The interview is located here.
|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|
Link to the current engineering requirements: Engineering Requirements.
Mapping Engineering Requirements to Customer Requirements
Link to the current mapped engineering requirements: Mapped Engineering Requirements.
Team RequirementsThe chart below clarifies the breakdown of responsibilities between the Formula team and the MSD team.
Link to the current benchmarking matrix: Benchmarking Matrix
Plans for next phase
|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
The team norms and values can be found here
Project Plans & Scheduleshere
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
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