P17665: Rotating Dynamometer for Cutting Tools

Systems Design

Table of Contents

Team Vision for System-Level Design Phase

The main goal of Phase 2 was to fully comprehend the concepts generated during the Systems Design. Similar set points had to be reached as in the Problem Definition phase like detailing an outline of the device, what the device will look like, and how all the subsystems will come together.

Required Tasks:

Other Accomplishments:

Functional Decomposition

The functional decomposition documents all of the functions and subfunctions the final product will need to perform. The functions are sourced from the engineering requirements and customer requirements.

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Click here to download the Functional Decomposition PDF.


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Click here to download the pdf file for the materials benchmarking.

Click here to download the pdf file for the adhesives benchmarking.

Click here to download the pdf file for strain gauge benchmarking.

Click here to download the pdf file for HBM Strain Gauge Datasheet.

Click here to download the pdf file for microcontroller benchmarking.

Click here to download the pdf file for bluetooth tranceiver module benchmarking.

Click here to download the pdf file for bluetooth receiver benchmarking.

Click here to download the excel file for battery benchmarking.

Concept Development, Morphological Chart, and Concept Selection

Using the morph table above, we devised several concepts outlined below.

After developing our three concepts displayed in the summary table we created an engineering decision matrix to help select what we felt would be the best concept.

Click here to download the engineering decision matrix PDF.

Then our ME lead made preliminary schematics of the sensor support structure for the strain gauges with help from the Lead Process Engineer and supplemental research that are displayed below.

Click here to download the preliminary drawings of the sensor support structure PDF.

Feasibility: Prototyping, Analysis, Simulation

Document Description
Rotating Dynamometer for Milling Processes Documents the structural design of an existing, strain gauged-based dynamometer.
Natural Frequency Minimum Requirement Documents the minimum natural frequency allowed by the material components of the rotating dynamometer.
Analysis of Thermal Effects on Strain Provides evidence that thermal effects on the strain gauge will be negligible.
Sampling Rate Analysis Analyzes the sampling rate needed for sufficient resolution of force data.
Toolholder Feasability Analysis Outlines a decision matrix that supports our decision to purchase rather than manufacture the toolholder we will need for the project.
Preliminary Rotational Testing of Electronics Documents rotational testing of MSP430 to test the power supply connections.
EE SME Meeting Notes Summary of meeting with Carlos Barrios (EE department) about use of microcontroller, and what sort of wireless protocol to use for the project.
UART Bit Rate Calculations Outlines calculations involved to come up with necessary bit rate for a given sample rate.
MSP430 UART 115.2kbps Feasibility Prototype Provides evidence based on prototype that the MSP430G2553 can send data at ~115k bps.

Systems Architecture and Design Flowcharts

The purpose of the Systems Architecture document is to ensure that the power, information, and forces flow as intended. It also helps define subsystems functions and interfaces.

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Click here to download the Systems Architecture PDF.

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Click here to download the Microcontroller Flow Diagram PDF.

Test Plan

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Click here to download the Test Plan PDF file.

Risk Assessment

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Click here to download the risk management PDF file.

Administrative Materials

Action List Items for Each Week

9-18 Action List

9-29 Action List

10-4 Action List

10-5 Action List

Peer Evaluation Feedback

Project Member Feedback Remediation
Joe Slow down when talking and presenting. Limited contribution in meetings without laptop. Been aware of slowing down. Has brought laptop for every meeting since.
Zac Makes minor changes to things without updating team on documents and EDGE. Always notifies in Slack when making changes or updating EDGE.
Muhammad Contribute more to discussions and leave research to time outside meetings. Laptop closed for most of the meeting and only on it when viewing documents with the whole team.
Elbert Brings up off-topic items during meetings and discussions often. Team members help catch him when on tangents, leads back to discussion.
Brian Talk louder and ensure that points are heard and understood by team members. Upload documents to team’s drive more often. Talks more during team meetings and updates documents
Key Takeaways:

Plans for next phase


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 Preliminary Detailed Design. This will help ensure that important tasks are completed and that all milestones are reached on time.

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 second Design Review.

Dr. Liu

Feedback Action Items
Most risky component is the structural design (stiffness bounds). Performed detailed stiffness and deflection analysis.
Low frequency noise will also need to be filtered, not just high frequency. Use a band-pass digital filter.
Strain gauges are too expensive. Found alternate vendor.
Concerns about natural frequency analysis. Detailed analysis to be performed this upcoming phase (once design is more finalized).
Need more information about how money is being spent Detailed BOM created and maintained


Feedback Action Items
Better identify risks and how they are being managed. Assigned risks dates and owners and created a risk reduction graph.
Need to better utilize Subject Matter Experts. Conferred with Professor Slack for feedback on electrical components.

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