Senior Design I: Multi-Disciplinary Senior Design I

Course Deliverables

Objective: Following the product development process, develop customer needs and engineering specifications, evaluate concepts, resolve major technical hurdles, and employ rigorous engineering principles to design an alpha prototype. Develop a design verification plan and fully document design.

  1. Phase 0 Planning: Team norms and values; SDI project plan / schedule including specific deliverables and due dates. (wks 1-3)
  2. Phase 1 Concept Development: Detailed, quantitative target specifications mapped to customer needs. (wks 1-3)
    • EE / CE: Power, voltages, current, cost, size, environmental conditions, noise, detailed performance specifications. All functionality should be defined with quantitative specifications.
    • ME: Horsepower, torque, rpm, mass flow rate, temperature, heat flux, lift, drag, cost, size, weight, factor of safety, number of cycles, expected life.
    • ISE: Throughput, Weeks of Supply, Lead Time, Capacity, Cycle Time, Throughput, Work-in-Process, Service Levels, Footprint, Cost, Safety, Defect Rates, MTBF, MTTS, Scarp rate, Machine/Operator Utilization
  3. Phase 1 Concept development: Develop multiple concepts (on paper) and select most feasible. Update specifications. Customer Feedback. (wks 3-4)
    • EE / CE: High level block diagrams, rough schematics, power budget, space budget, critical component requirements.
    • ME: Basic functionality, estimates of size/capacity of major components, connections/links between components considered, basic parts list, cost estimates.
    • ISE: Factory Layout, Process Flow Diagrams, Work Flow Maps, Supply Chain Maps, Quality Control Plan, Supply Chain Management & Ordering Policies, Inventory Holding Locations, Ergonomic Design, Serviceability & Maintainability Design, DFX
  4. Phase 2 System-Level Design: System design including architecture, sub-system definition, interface definition, and more detailed specifications. Appropriate engineering analysis including hand calculations and simulation / modeling. Determine greatest challenges / risks to project. Concept/System Design Review (partial). (wk 5-6)
    • EE / CE: More detailed block diagrams, schematics, SPICE simulations, matlab modeling, memory requirements, processor speed calculations.
    • ME: Analysis of components, stress/deflection determination for major components, fatigue analysis, heat flow calculations, control system laid out.
    • ISE: Linear Programming, Queuing Theory, Discrete Event Simulation, Lean Analysis, SPC, Inventory Analysis, Physical Workload Assessment
  5. Phase 2 System-Level Design: Proof of concept breadboard, brassboard, or simulation of high risk technologies defined in 4. Use appropriate discipline specific methods to demonstrate confidence in selected architecture / design approach. Risk assessment for technology / cost / schedule. Concept/System Design Review (completed). (wks 6-7)
    • EE / CE: Physical hardware of key / high risk sub-systems, development board evaluation of DSP algorithms, etc.
    • ME: Finite element analysis of key / high risk components, simulation of control systems.
    • ISE: Mostly simulation-based or mock-up models
  6. Phase 3 Detail Design: Detailed design to meet all customer needs. All long lead items should be identified for ordering. Detail Design Review. (wks 8-9).
    • EE / CE: Final ORCAD schematics, BOM, detailed SPICE, Matlab, etc. simulations.
    • ME: 3D CAD drawings, mechanical simulations, detailed BOM.
    • ISE: Finalize the items in 3) with supporting analysis in 4) & 5) coupled with implementation plans, particularly project schedules and risk assessments
  7. Phase 3 Detail Design: Project Review (wk 10).
  8. Phase 3 Detail Design: Develop detailed test plan with linkage to engineering specifications and customer needs. The results of this plan should demonstrate the design meets all customer needs and translated engineering specifications (both high level specifications and cascaded sub-system specifications). (wks 10-11)
    • EE / CE: Step by step plan to fully characterize developed electronic system against all specifications and customer needs.
    • ME: Step by step plan to fully characterize developed mechanical system against all specifications and customer needs.
    • ISE: Step by step plan to fully characterize developed implemented system against all specifications and input requirements.
  9. Phase 3 Detail Design: Design Documentation: update Design History File on EDGE (all design documents, final drawings, design review materials); BOM sufficiently detailed to define source, cost, and lead time; Test Plan; Project Plan for SDII. (wk 11).

See the MSD I deliverables timeline for an overview of week-by-week deliverables.

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