P17521: Kodak Dry Ink Station Coupling Test Bed
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Detailed Design

Table of Contents

Recap of Previous Preliminary Detailed Design Phase

Prototype - View 1

Prototype - View 1

Team Vision for Detailed Design Phase

So far, team P17521 has moved through defining the problem based on Kodak requirements, brainstorming solutions, conceptualizing/prototyping a selected solution, and finally managing major risk(s) involved in the project.

The test fixture portion of the project is currently on track. No issues are currently holding the project milestones back, however, a high-risk issue may become more prevalent once detailed electrical design begins.

The main goals of this Detailed Design Phase were to solidify the detailed CAD drawing and narrow down options for purchasing parts throughout summer/fall. The team was also able to complete a full risk assessment for the electrical component knowledge risk, which will play a much larger role going into the next phase.

Detailed Design Phase Project Plan

Detailed Design Phase Project Plan

To the left is a screen capture of the project plan for this phase.

Progress Report

A progress report was created by Ryan Mraz on 4/26/2017 outlining the Detailed Design phase of the project thus far.

The report can be accessed by clicking and downloading the link here.

A progress report reviewing the entirety of MSD I and outlining MSD II was created by Ryan Mraz on 5/09/2017 for the End-of-Semester review.

The report can be accessed by clicking and downloading the link here.

Prototyping, Engineering Analysis, Simulation

Detailed Design

Detailed Design

The above design allows for testing of the rotational motion translated through the desired coupling and includes the following features.

Misalignment Testing

Angular Misalignment

Angular Misalignment

Features

Sliding Carriage Track - Side View

Sliding Carriage Track - Side View

Sliding Carriage Track - Top View

Sliding Carriage Track - Top View

Drawings, Schematics, Flow Charts, Simulations

Top Level Assembly

Top Level Assembly

The top level assembly can be found here 20010-1000-01.

The BOM for the top level assembly can be found here 20010-1000-01 BOM.

Coupling Test Fixture, Base Assembly

Coupling Test Fixture, Base Assembly

The base assembly can be found here 20010-1010-01.

The BOM for the base assembly can be found here 20010-1010-01 BOM.

Coupling Test Fixture, Coupling Carriage Assembly

Coupling Test Fixture, Coupling Carriage Assembly

The carriage assembly can be found here 20010-1020-01.

The BOM for the carriage assembly can be found here 20010-1020-01 BOM.

Coupling Test Fixture, Base Assembly

Coupling Test Fixture, Base Assembly

The carriage assembly can be found here 20010-1030-01.

The BOM for the base assembly shown above can be found 20010-1030-01 BOM.

The overall part database can be found here Part Number Database.

Coupling Test Fixture, Base Assembly

Coupling Test Fixture, Base Assembly

Bill of Material (BOM)

The Bill of Material drawn up for the previous phase was amended and is included below:

Final BOM

Final BOM

The live copy of the spreadsheet can be found here.

The preliminary requirements for a power supply were compiled in the following pseudo-circuit diagram to determine the type of power supply required:

Electrical Draws for Power Supply

Electrical Draws for Power Supply

Test Plans

First and foremost, engineering requirements were re-evaluated to best suit the test fixture. Below are the updated engineering requirements, along with the changes made.

public/Photo Gallery/ER-Coupling.PNG
A copy of the live document of Engineering Requirements can be found here

Changes:

Preliminary test plans for test fixture engineering requirements are linked below:

ER 1
ER1 Test Plan.
ER 2
ER2 Test Plan.
ER 3
ER3 Test Plan.
ER 4
ER4 Test Plan.
ER 5
ER5 Test Plan.
ER 6
ER6 Test Plan.
ER 7
Engineering requirement 7 is as follows:
Engineering Requirement 7

Engineering Requirement 7

Testing to ensure the product meets these requirements is simply to measure the maximum protruding dimensions of the fixture (in x, y , & z) and compare them to the above specifications. A passing test occurs if and only if the measurements are less than the specified dimensions.
ER 8
ER8 Test Plan.
ER 9
ER9 Test Plan.

Design and Flowcharts

The current project flowchart is displayed below:

Test Fixture Use Flow Chart

Test Fixture Use Flow Chart

A copy of the live document of the Testing Fixture Use Flow Chart can be found here.

Risk Assessment

Updated Risk Assessment

Updated Risk Assessment

A copy of the live document of Risk Management can be found here.

Following customer notes from the previous phase's gate review, a plan was drafted as a reaction to the very high importance (81/81 possible) of the first risk noted on the risk management tracker, above. The plan can be downloaded and viewed by clicking the link here.

Plans for next phase

First and foremost, any changes/updates borne from the end-of-phase or end-of-semester review need to be added to EDGE. Throughout the summer, team members will be responsible for retaining information relevant to the current status of the project. Given the time and opportunity, members are encouraged to continue any individual work that will set up the team for success upon returning to RIT in the fall.

Following the summer break, MSD II will begin with the Subsystem Level Prep phase, which will encompass two parts. The test fixture portion will see a focus on any/all electrical subsystems that will be used. All test plans created in previous phases will need to be revisited and polished such that preliminary analyses of sample or dummy data can be carried out. The second portion of the project focuses on coupling analysis. Any couplings selected for benchmarking in the previous phase will be purchased for future testing. The preliminary work breakdown structure is located in MSD II Schedule, below.

The main variable that lies in anticipation of MSD II is the possibility of adding an electrical engineer to the team. Having this opportunity would allow for a less intensive learning curve for the remaining group members, and therefore a more productive team in the creation of the project deliverables.

MSD II Preliminary Project Plan

MSD II Preliminary Project Plan


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