Faculty of Engineering & Applied Science

Memorial University of Newfoundland Faculty of Engineering & Applied Science

MECHANICAL ENGINEERING DESIGN PROJECT HANDBOOK

2002 1.0 OBJECTIVE

One of the main objectives of the engineering program is the preparation of technically competent entry-level engineers for industry. The design project provides each senior mechanical engineering student with an opportunity to operate as part of a small design team in an unstructured, problem-solving environment. In addition to strengthening the student's analytical ability, the design project is also intended to build on the many months of practical experience gained through work-term placements. It presents the student with an opportunity to select and employ proper development skills and tools.

2.0 PROJECT SELECTION AND OPERATION

During the fall of 2001, the course instructor will solicit ideas for design projects from clients in university, government and industry. Students may choose a project from the client solicitation list, or propose a design problem of their own. No project will be allowed that is even remotely dangerous. Final selection must be approved by the course instructor. Selection must be done before 1 week into the semester. Problems selected for consideration are expected to be multi-component, broadly based projects involving typically thermo/fluids, hydraulics, pneumatics, structures, dynamics, electronics, controls and/or other technical considerations. Some of the non-technical issues that must be addressed in the design project are safety, economics, ethics, and aesthetics. A prototype of the design or a critical component of it must be constructed.

Each design group will consist of 2 people: under exceptional circumstances 3 people per group will be allowed. Each design group will have a project advisor. This will be someone with technical expertise in the subject area. The course instructor, after consulting with the group, will assign the advisor. The advisor will meet on a regular basis with the group. The main role of the advisor is to act as a resource person on tough technical issues related to his/her area of expertise and to provide guidance on effective approaches to design. Having said this, each design group is ultimately responsible for its project. Each group will be allotted a budget of $150 for materials and supplies.

. 3.0 PROJECT MILESTONES

3.1 Brief Project Proposal

Following the project selection process, each design group must submit a written proposal that defines the problem being tackled and identifies the group and its advisor. A simple timeline for all identifiable project activity should be included. Where possible, requirements for special equipment, facilities, support personnel, or project funding should also be addressed in the proposal. It is anticipated that the proposal will be no more than 6 pages in length. The proposal format should include the following: (1) Group Identification (2) Project Advisor (3) Identification Problem Statement / Specification (4) Plan of Approach / Design Methodology (5) Personnel / Facilities Requirements (if known) (6) Time Schedule (as detailed as possible) (7) Budget (preliminary) (8) References (if appropriate) (9) Sketches. The course instructor and advisors will be interested in knowing that the design group properly understands the client problem. As well, the client will want to know that the design group is working on the correct problem (i.e. no interpretation errors). Therefore, it is highly advisable that the design group restate the client problem as it sees it, to ensure that all parties have a common understanding.

The Problem Statement should refine or correct the problem background, identification of need, and definition of goals. The problem should be clearly identified to provide context and/or purpose for the project. Sufficient information must be presented so that any individual reading the proposal can grasp the significance of the problem and can identify equipment and concepts referred to in the proposal. A graphic description of the problem is a valuable aid to understanding the nature of the problem.

The design group must establish an explicit objective, or goal, for itself. This goal must be related to solving the identified problem. The design solution resulting from achieving this goal must satisfy the need. In some cases, the design group may have several goals, or may state an overall goal with several sub-goals.

The success of the design work can be measured by comparing the results of the design against the target specifications, design criteria, or design expectations. This is why the

. target specifications must be stated at the beginning of the design process. The target specifications should be expressed in measurable terms in order to facilitate design evaluation, but some qualitative statements can be included as necessary.

3.2 Design Review

Each design group is required to give a 20 minute design review (including 5 minutes for questions). This review will occur approximately 6 weeks into the semester. The design review is a way to report on design progress and get critical feedback from others outside the group. It is mainly an oral presentation which is organized and presented by the entire design group. Visuals will consist primarily of overhead viewgraphs, but may include other types of presentation materials. The lead visuals should present an outline of the approaching presentation. A smooth transition between presenters should be part of the presentation. A summary of the results and/or progress, and a projection of near- future plans should conclude the review. A 2 page report based on the summary must be handed in at the presentation.

3.3 Technical Design Report

The technical design report gives the details of the design work undertaken. It contains technical information collected and used in solving the design problem. It is important that the report be constructed to clearly present the findings of the group in a succinct and professional manner. The report should include all information necessary to support the chosen design, but must be organized in such a way that readers can quickly learn the nature of the proposed design without having to sort through unnecessary detail. It is anticipated that the main body of the report will be fairly brief: approximately 20 pages. This does not include appendices.

The appendices should contain all of the supporting information such as drawings, sketches, raw data, letters, computer output, photographs, and other general information that supports, but is not appropriate for inclusion in, the main body of the report. The preliminary idea generation methods and decision matrix tables for selecting the best solution should be included in the appendices. These early steps in the design process

. form important decision points upon which the entire design solution is based. The appendices must be organized such that this material is accessible.

A summary of the Design Reports will be presented at a series of open meetings at the end of the term. These presentations will provide an opportunity to demonstrate prototypes, show videos of construction or testing programs, and so forth. The format for the presentations will be the same as for the Design Review presentations.

3.4 Engineer’s Log Book

An Engineer’s Log Book must be maintained by each student. In industry, such log books are used to document the contributions of individual engineers to a development project. The log book, which serves as a technical diary, must contain an account of the work performed and time spent on the project. In many industrial projects, the client is billed (e.g. monthly) based on the time spent by the contractor's staff.

In general, the engineer’s log book is intended to serve as a record of new ideas and engineering research and developments, whether or not they materialize into commercial usage. The primary purpose and reason for maintaining a complete log book is that it will serve as evidence to prove inventorship, establish the date of conception and reduction to practice of an invention, and to show that the inventor has used diligence in advancing the invention to completion.

The engineer’s log book is the official record of all design project work. All work done by the design group should be recorded in the log book following the Engineer's Log Book Guidelines given on the last page of this manual. It is expected that changes and mistakes will occur during engineering work. The important thing is that these errors are found and corrected before it is too late.

In addition to the log book serving as the official record of design work, it performs other uses. The review of the work in the log book aids in the writing of progress reports and technical reports, and in preparation of design reviews. The record of design work also documents the thought process used in reaching a solution. In some cases, a review of this process will illustrate more efficient thinking patterns.

. The date and approximate time period of each work activity must be recorded at the beginning of each entry. There must be a distinction between group work and individual work. When work is accomplished by more than one group member, the names of all individuals contributing to the work must be included. The most important entries must be witnessed by one or more persons. They must sign the entry and state that they have understood it. Hours spent on each activity must also be indicated.

The log books may be collected periodically during the semester and evaluated by the course instructor. The instructor will give 24 hour notification prior to the collection of the log books. Log books must also be submitted with the Technical Design Report.

4.0 PROFESSIONALISM

The student’s maturity and professionalism, as demonstrated in the approach to the design project, is very important. Some of the factors considered are: (1) the systematic and logical approach to the project (2) sustained and thoughtful work towards the solution to the project (3) seeking all available information and assistance during the course of the project (4) ability to make good engineering decisions to accomplish the work (5) willingness of the group members to work together (6) professional attitude of the group members toward the project advisors and support personnel. A portion of the grade for all parts of the course will be allotted to this.

5.0 EVALUATION

A breakdown of the final mark for 8936 for 2002 is as follows:

Project Proposal 15% Design Review 30% Final Design 50% Log Book 5% Total 100%

. ENGINEER’S LOG BOOK GUIDELINES

An Engineer’s Log Book documents the contributions of an individual engineer to a development project. Ideas, calculations, experiments, tests and anything else which may have a bearing on project developments should be entered in the Log Book. There must be a distinction between group work and individual work. When work is accomplished by more than one group member, the names of all individuals contributing to the must be included. When a work activity is completed, there must be a notation of the time spent by the engineer on the activity. A second entry must be made to show the total time spent by the engineer on the project to date. All entries should be in ink. Margins should be maintained in order to provide for ease of reproduction. No pages should be left blank. If a page, or part of a page, is not used , draw a line down through whatever is not used. Do not tear out pages Each page should be signed and dated on the day of entry, pages being used in consecutive order. All entries should be periodically and routinely witnessed by at least one witness, preferably two. The witnesses should be persons capable of understanding the entries. The witnesses should endorse each sheet, "read and understood". Where tests are made, the witness must have observed what was done, and not merely read the Log Book entry. Preferably, the witness should note on the document, "witnessed tests, read and understood this page". Photos, graphs, drawings, etc., should be used liberally. They must be dated and signed by the engineer and witnesses. Preferably, these are attached to the Log Book using staples. If a change is made, draw a line through the original entry and add the new material so as to clearly indicate what the change is and why it was made. Also, note the date when the change was made. Where possible, make a new entry rather than alter an existing one.