P20603: 3D Braiding Machine
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Systems Design

Table of Contents

Your website should document your journey through MSD, so include work-in-progress as well as latest results. Use pdf's for display whenever possible so that information is easily viewable without the need to download files and open applications. (Your EDGE file repository should still contain original editable files).

Content linked here should go in the Systems Level Design Documents directory. This directory is pre-populated with a variety of templates that are designed to help you through this phase of the design.

All template text must be removed from this page prior to your System Level Design Review

Team Vision for System-Level Design Phase

By the end of this phase we would like to have finished research and benchmarking, understand why the bottle braiding team’s machine didn’t work, refine engineering requirements (OSHA, quantitative), brainstormed a variety of feasible designs (electrical, mechanical, and control scheme), and selected a design to move forward to detailed design with.

During this phase, we have selected concepts for our sub-systems, we understand the drawbacks of the bottle braiding machine, and are ready to move on to detailed design.

Functional Decomposition

Functional Decomposition Tree

Functional Decomposition Tree

This Functional Decomposition Tree helps uncover function details in a structured format and ensure that all engineering requirements are being addressed and satisfied by our system.

Benchmarking

Metric Benchmarking

Metric Benchmarking

Note: Due to the nature of our project as an exploration into relatively unknown technology, it is challenging to apply standard metric benchmarking. While a few industry braiding machines exist, they are vastly more expensive and thus have near incomparable metrics, compared to our expected design.

Feasibility: Prototyping, Analysis, Simulation

Prototypes

Literature review did not reveal common tension values for 3D braiding, so we set up a prototype to determine if the motor we had could handle what we deemed as qualitatively appropriate amount of tension in string. The cardboard represents the horn gear in our design. Based on this testing, we determined that motors with higher torque ratings were needed.

Moving Torque

Moving Torque

Mechanical Calculations

Torque Estimates

Torque Calculations

Torque Calculations

Bobbin Scalability

Bobbin Scalability Calculations

Bobbin Scalability Calculations

Fiber Length

Length of String Calculations

Length of String Calculations

Morphological Chart and Concept Selection

Morphological Chart 1

Morphological Chart 1

Morphological Chart 2

Morphological Chart 2

Tensioning Decision Matrix

Tensioning Decision Matrix

Orientation Decision Matrix

Orientation Decision Matrix

Bobbin Passing Decision Matrix

Bobbin Passing Decision Matrix

Mandrel Moving Decision Matrix

Mandrel Moving Decision Matrix

Mandrel Moving Decision Matrix

Mandrel Moving Decision Matrix

Concept Selection

Transmission Decision Matrix

Transmission Decision Matrix

Connector Decision Matrix

Connector Decision Matrix

Zigbee\Xbee is recommended for future, larger scale

Driver Decision Matrix

Driver Decision Matrix

Controller Decision Matrix

Controller Decision Matrix

Systems Architecture

This Transformation Diagram helps identify and illustrate interactions between our system and the environment as well as internal interactions. In particular, it has been helpful to see the interactions between our mechanical, electrical, and control systems.
Transformation Diagram

Transformation Diagram

Designs and Flowcharts

Control System Flow

Control System Flow

Risk Assessment

Risk Management_1

Risk Management_1

Risk Management_2

Risk Management_2

Click the following link for the Risk Management active working document

Preliminary Test Plan Overview

Engineering Requirement and Constraint Updates

Changed Engineering Requirements

Changed Engineering Requirements

Our target number of bobbins decreased from 16 to 9 since preliminary cost estimates (of motors in particular) showed that a 4x4 matrix would not be feasible within the budget. This still adheres to the customer requirement.

We added tension force estimates to our engineering requirements.

Multiple items originally on our engineering requirement list were actually constraints, so we updated both lists accordingly.

Updated Constraints

Updated Constraints

We added a constraint of fiber not loosening during braiding. This directly relates to ER20 (fiber tension)

Design Review Materials

Presentation for Review #2

Action Items from Review:

Plans for next phase

Team Plan

Individual Plans

Brandon

Allison

Isaac

Shehaab

Angus

Asa

Ryan


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