P17665: Rotating Dynamometer for Cutting Tools
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Preliminary Detailed Design

Table of Contents

Team Vision for Preliminary Detailed Design Phase

The main goal of Phase 3 was to select specific components to commit to our design and go through preliminary testing. Many of the physical components meant for the final build of the device were purchased, circuit schematics and analysis were carried out, and CAD designs were made for all mechanical parts being manufactured in house. This phase sets the ground work for the final design.

Required Tasks:

Other Accomplishments:

Electrical

Electrical System Overview

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Click here to download the Electronics overview pdf file.

Wheatstone Bridge Circuit

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Click here to download the wheatstone bridge circuit pdf file.

Amplifier Circuit

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Click here to download the amplifier circuit pdf file.

Filter Circuit

Microcontroller

Program Flow

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Click here to download the microcontroller program flow pdf file.

UART Calculations

Sample Rate Timer Calculations

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Communications Protocol

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Click here to download the communication scheme pdf file.

Wiring Diagram

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Click here to download the wiring diagram pdf file.

Power Consumption Study

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Click here to download Power Calculations in pdf format and here in xlsx format.

Mechanical

Force Equations

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Click here to download the force calculations PDF.

Deflection Analysis

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Click here to download the Deflection Analysis spreadsheet.

Toolholder Adapter & Acceptor

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Click here to download the toolholder adapter inventor part file.

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Click here to download the toolholder inventor assembly file.

Click here to download the toolholder nut inventor part file.

Click here to download the toolholder backstop inventor part file.

Click here to download the toolholder retaining ring inventor part file.

Click here to download the toolholder body inventor part file.

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Click here to download the Tool Acceptor inventor acceptor file.

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Click here to download the toolholder adapter print.

Measurement Structure

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Click here to download the Measurement Legs solid works part file.

Click here to download the Measurement Legs part STEP file.

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Click here to download the Measurement Legs solid works drawing file.

Full Assembly

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Click here to download the full assembly inventor file.

Ansys simulation

Setup

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Mesh

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Stress

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Y deformation

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Z deformation

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Bill of Material (BOM)

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Click here to download the Bill of Materials in pdf format and click here to download in xlsx format.

Test Plans

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Click here to download the Preliminary Test Plan pdf file.

Risk Assessment

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Click here to download the risk assessment pdf file.

Click here to download the risk assessment excel worksheet.

Peer Evaluation Feedback

Project Member Feedback Remediation
Joe Interface with Dr. Liu appropriately to keep him in the loop. Make hard deadlines/due dates for deliverables and team meetings. More meetings and emails with Dr. Liu. Assigned tasks ownership and deadlines after each meeting.
Zac Keep things focused. Contribute more to technical side of ME. Keeps team on track during meetings. Extended help and more hours to Elbert and Brian.
Muhammad Less research during meetings – big improvement from last phase. More prepared to discuss on-topic items with the team during meetings.
Elbert Brings up off-topic items during meetings and discussions often – less frequent. Team members help catch him when on tangents, leads back to discussion.
Brian Upload documents to team’s drive and EDGE by due dates. Has been having more things up on the drive and EDGE when required – making good progress.
Key Takeaways:

Action List Items and Meeting Notes

10-21 Action List

Meeting with Dr. Liu 10-21-16

Plans for next phase

WBS

Download the latest version of the WBS in .mpp format here.

Three Week Plans

Each team member has developed an individual plan for the next three weeks of the Detailed Design. This will help ensure that important tasks are completed and that all milestones are reached on time for the Detailed Design Review.

JA Three Week Plan

EH Three Week Plan

ZR Three Week Plan

MI Three Week Plan

BC Three Week Plan

Design Review Feedback

This section documents the feedback and resulting action items from our third Design Review.

Dr. Liu

Feedback Action Items
Disconnect between customer and team about deflection analysis. Will meet with Dr. Liu to ensure both parties are on the same page.
Need to ensure strain gauges will be able to measure full range of strains. Will continue to investigate methods to validate this.

Gary

Feedback Action Items
Should have contingencies in place if electronic components fail. Ordering backups of major components might be helpful. Will look into purchasing more components based off of importance.
A chart of requirements and how they are validated would be helpful. Will be added to engineering requirements document.
Engineering drawings need more detail (tolerances, material, changeblock). Will complete this in next phase.
Need better documentation on how the electronic components will be mounted. Will detail this in next phase.
Need to fill out Subject Matter Expert (SME) forms. Will do this in next phase.
Need validation testing. Will detail this in next phase.

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