1. Senior Design An Overview Dr. Kamal Sarkar University of Texas – Rio Grande Valley May 11, 2015 Dr. Kamal Sarkar University of Texas – Rio Grande Valley May 11, 2015 Copy Right of Dr. Kamal Sarkar May 2015 1

2. What is Design?  “A” Definition of Engineering Design  A systematic approach of identifying an optimum solution for a complex engineering problem with real-life constraints using established scientific and engineering principles.  “A” Definition of Engineering Design  A systematic approach of identifying an optimum solution for a complex engineering problem with real-life constraints using established scientific and engineering principles. Copy Right of Dr. Kamal Sarkar May 2015 2

3. What is Senior Design?  Last opportunity to prepare our students for real-life scenarios using their own strengths  Preparing our students to be “Engineering Professionals” in a multi- cultural world  Make the students “more employable” OR “more prepared” for Grad School or Technopreneurship  Last opportunity to prepare our students for real-life scenarios using their own strengths  Preparing our students to be “Engineering Professionals” in a multi- cultural world  Make the students “more employable” OR “more prepared” for Grad School or Technopreneurship Copy Right of Dr. Kamal Sarkar May 2015 3

4. Senior Design: THE Bridge Between The Profession & Educators Senior Design Industry Grad School Technopreneurship STEM Core Engg. Courses Advanced Engg. Courses Copy Right of Dr. Kamal Sarkar May 2015 4

5. Structure of the Senior Design Course Copy Right of Dr. Kamal Sarkar May 2015 5

6. Five Phases of Design  Phase One: Problem Formulation  Phase Two: Concept Development  Phase Three: Design Embodiment  Phase Four: Design Validation  Phase Five: DHF (Design History File)  Phase One: Problem Formulation  Phase Two: Concept Development  Phase Three: Design Embodiment  Phase Four: Design Validation  Phase Five: DHF (Design History File) Copy Right of Dr. Kamal Sarkar May 2015 6

7. Five Phases of Design Phase One: Problem Formulation  “Elevator Speech” “The Challenge” Competitive Product Solution Strategy (Identify & Organize Disciplines) Impact  Background Research  Quality Function Deployment (QFD)  “Elevator Speech” “The Challenge” Competitive Product Solution Strategy (Identify & Organize Disciplines) Impact  Background Research  Quality Function Deployment (QFD) Copy Right of Dr. Kamal Sarkar May 2015 7

8. Five Phases of Design Phase Two: Concept Development Concept Selection  Functional Decomposition  Develop alternatives  Develop Design Criteria (from Objectives and Constraints)  Identify Concept Variants Final Selection (Decision Matrices)  Screening  Method of Pairs  Over-riding Factors Concept Selection  Functional Decomposition  Develop alternatives  Develop Design Criteria (from Objectives and Constraints)  Identify Concept Variants Final Selection (Decision Matrices)  Screening  Method of Pairs  Over-riding Factors Copy Right of Dr. Kamal Sarkar May 2015 8

9. Five Phases of Design Phase Three: Design Embodiment  Design Calculations  Design for Manufacturability  Design/Process Failure Modes and Effects Analysis (D-FMEA or P-FMEA )  Bill of Materials  Economic Analysis  Develop Plans for Tests & Data Collection  Create Manufacturing Process Document  Design Calculations  Design for Manufacturability  Design/Process Failure Modes and Effects Analysis (D-FMEA or P-FMEA )  Bill of Materials  Economic Analysis  Develop Plans for Tests & Data Collection  Create Manufacturing Process Document Copy Right of Dr. Kamal Sarkar May 2015 9

10. Five Phases of Design Phase Four: Design Validation  Design Validation * System Level Validation (“Sanity Check”) * Test Protocols Data Collection & Analysis * Modify Design and/or Test Methods As Needed * Validate Design w/Additional Experimental Data  Design Documents * User’s Manual * Operations Manual * Maintenance Manual  Design Validation * System Level Validation (“Sanity Check”) * Test Protocols Data Collection & Analysis * Modify Design and/or Test Methods As Needed * Validate Design w/Additional Experimental Data  Design Documents * User’s Manual * Operations Manual * Maintenance Manual Copy Right of Dr. Kamal Sarkar May 2015 10

11. Five Phases of Design Phase Five: DHF Documentation * Formalize the Design via Design History File Lab Note Book Reports Presentations Background Data/Info Test Protocols & Data Raw Data Design Details (All Revs of Design Info) Videos & Pictures Flash Drive !!! Documentation * Formalize the Design via Design History File Lab Note Book Reports Presentations Background Data/Info Test Protocols & Data Raw Data Design Details (All Revs of Design Info) Videos & Pictures Flash Drive !!! Copy Right of Dr. Kamal Sarkar May 2015 11

12. Key Concepts  “Elevator Speech”  QFD  Functional Decomposition  Design Criteria & Concept Variants  Concept Selection by Pairing Method  DFM (Design for Manufacturing)  D-FMEA & P-FMEA  Project Management  Economic Analysis  “Elevator Speech”  QFD  Functional Decomposition  Design Criteria & Concept Variants  Concept Selection by Pairing Method  DFM (Design for Manufacturing)  D-FMEA & P-FMEA  Project Management  Economic Analysis Copy Right of Dr. Kamal Sarkar May 2015 12

13. Key Trainings  Safety Training including Nanomaterials  Machine Shop Safety  Intellectual Property Rights & Issues  Literature Search including Patents  iShop Trainings  Working in Team Environment  Safety Training including Nanomaterials  Machine Shop Safety  Intellectual Property Rights & Issues  Literature Search including Patents  iShop Trainings  Working in Team Environment Copy Right of Dr. Kamal Sarkar May 2015 13

14. Project Formats & Examples Project Formats & Examples Copy Right of Dr. Kamal Sarkar May 2015 14

15. Types of Senior Design Projects National Competitions Mini Baja, NASA, HPV, etc. Faculty Sponsored Background Research for Funding Opportunity Prototype Development for Teaching Tools Exploratory work for IP’s Industry Sponsored Small Local Business National Corporates National Competitions Mini Baja, NASA, HPV, etc. Faculty Sponsored Background Research for Funding Opportunity Prototype Development for Teaching Tools Exploratory work for IP’s Industry Sponsored Small Local Business National Corporates Copy Right of Dr. Kamal Sarkar May 2015 15

16. Typical Senior Design Projects Design & Development Homeostatic Environmental Chamber Biomechanical Harvester for Health Monitoring Systems Design of a Knee Replacement Implant Design of a Light Flexible Bulletproof Vest using Smart Materials Developing Next Generation Drywalls A Personal Polycopter with Built-in Battery Charger & Stability Pulsed Jet Propulsion: A High Thrust Propulsion System for Aerospace Vehicles Building & Demonstrating of A Half HP Low Temp Stirling Engine Design & Implementation of a Module for Automated Work Measurement System Pink Zebra Production Research: Feasibility for Automation Development of a Drying Oven for Polymeric Fibers to Achieve High Quality Multifunctional Carbon Fibers Exploring Applications of Evaporative Cooling for Air Conditioners Applications of Controlled Pore Recycled Glass Structures for Liquid Waste Management Thermal Applications of Porous Glass Structures by Controlling Crystalline and Amorphous Phases Development of Safe Transportation Techniques for Combustible and/or Hazardous Materials using Controlled Pore Glass Structures 16

17. Some Mentionable Outcomes (Last Five Years) Won NASA Micro-gravity Competition Won NASA Micro-gravity Competition Helped funding ($400K) from Air Force Helped funding ($400K) from Air Force Built Wire Winding Machine for Local Entrepreneur Built Wire Winding Machine for Local Entrepreneur Developed Patent(s) on Glass Nanoparticles Developed Patent(s) on Glass Nanoparticles Built several lab equipment for teaching Built several lab equipment for teaching Working on multiple patentable technologies Working on multiple patentable technologies Copy Right of Dr. Kamal Sarkar May 2015 17

18. Examples of Recent Projects Copy Right of Dr. Kamal Sarkar May 2015 18

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20. INSTRUMENTED PULSE JET ENGINE 680 C, PRESSURE 22 PSIA TO 12 PSIA & PULSING @260 HZ COPY RIGHT OF DR. KAMAL SARKAR MAY 2015 20

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22. NASA Lunabotics Mining Competition (May 2012) Copy Right of Dr. Kamal Sarkar May 2015 22

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