1. Engineering Design Workshop Quality Design Projects for Engineering Fairs Sponsored by Santa Clara Valley Science and Engineering Fair Association for students

2. Bruce Kawanami2 SCIENCE & ENGINEERING Scientific Process Why? Knowledge

3. Bruce Kawanami3 SCIENCE & ENGINEERING Scientific Process Why? Knowledge Engineering Design Process Prototype Need Specification Science/Technology

4. Bruce Kawanami4 Engineering Design Process 1.Define a need 2.Establish criteria and constraints 3.Research, evaluate alternatives, test plan 4.Construct a prototype 5.Test against established criteria 6.Failure analysis, tweak, and re-test 7.Final documentation

5. Bruce Kawanami5 Step #1 (Beginning) & #7 (End) Generate a Project Book Project data book A complete record All key decisions Good drawings Test plans Results Conclusions Things learned

6. Bruce Kawanami6 Step #1: DEFINE A NEED Have a need, a customer for the project Often stated as bigger, cheaper, faster, lighter Engineering Goal template: The design and construction of a (engineering project) for (user) to do (some function). Project MUST have technical content

7. Bruce Kawanami7 The design and construction of a (project) for (user) to (function). Project: solar powered scooter User: children Function: zip around the block Technical Content: solar energy, energy storage, motor torque, mechanical gear ratios, electronics

8. Bruce Kawanami8 The design and construction of a (project) for (user) to (function). Project: wireless ear pods User: music or radio listeners Function: avoid tangled wires Technical Content: Analog electronics, wireless communications

9. Bruce Kawanami9 The design and construction of a (project) for (user) to (function). Project: kitchen shelving that lowers itself User: short, weak, or disabled persons Function: easily reach items stored high Technical Content: Motor torque, structural design

10. ENGINEERING GOAL STATEMENT EXERCISE

11. Bruce Kawanami11 Step #2: Criteria & Constraints “Design criteria are requirements you specify for your design that will be used to make decisions about how to build the product” Size Appearance Physical Features Performance Use Environment

12. Bruce Kawanami12 Some Design Constraints Cost Time

13. Bruce Kawanami13 Criteria & Constraints for Solar Powered Scooter 1.Transport up to 35 kg rider 2.Speed of at least 8 kph on level surfaces 3.Travels through 10 meters of shade 4.Material cost 5.Testing completed by Feb 28

14. Bruce Kawanami14 Criteria & Constraints for Wireless Earpods 1.Transmits 10 meter radius 2.Receiver weighs < 75 grams 3.No dropouts, ‘good fidelity’ 4.Material cost 5.Testing completed by Feb 28

15. Bruce Kawanami15 Criteria & Constraints for Lowering Shelf 1.All shelves lower 45 cm 2.Safely move 16 kg up and down 3.Shelves will tilt < 10 degrees 4.Material cost 5.Testing completed by Feb 28

16. Bruce Kawanami16 Step #3: List Alternatives Research reveals what has been done Likely to find good alternatives for cheapest, fastest, or lightest Select best alternatives that meet the design criteria and constraints Create a test plan based on the design criteria from Step #2

17. Bruce Kawanami17 Web Researched Alternatives Lowering shelves Electrically powered scooters Wireless earphones

18. Bruce Kawanami18 Solar Powered Scooter Test Plan 1.Transport up to 35 kg rider Test Plan: Transport a 35kg load 2. Speed of at least 8 kph on level surfaces Test Plan: 100m distance should take less than 45 seconds 3.Travels through 10 meters of shade Test Plan: Charge up battery. With 35kg rider, ride through 10m of shade

19. Bruce Kawanami19 Wireless Earpod Test Plan 1.Transmits 10 meter radius Test Plan: Walk receiver in a 10m radius around transmitter 2.Receiver weighs < 75 grams Test Plan: Weigh completed assembly 3.No dropouts, ‘good fidelity’ Test Plan: Survey student peers, likely customers

20. Bruce Kawanami20 Lowering Shelf Test Plan 1.All shelves lower 45 cm Test Plan: Design motor to travel 45 cm 2.Safely move 16 kg up and down Test Plan: Select motor to lift 16 kg 3.Shelves will tilt < 10 degrees Test Plan: Design in leveling guides and careful construction techniques

21. Bruce Kawanami21 Step #4: Construct Prototype Prototype is implementation of chosen design alternative It is a proof of design, production and suitability

22. Bruce Kawanami22 Project Construction

23. Bruce Kawanami23 Step #5: Test it Well Execute the developed Test Plan Learn beyond minimum requirements! Characterize the limits of your project.

24. Bruce Kawanami24 Solar Powered Scooter Testing 1. Transport 35 kg rider. Exceeds Test Plan: Maximum mass transported 2. Speed. Exceeds Test Plan: Measure and plot speed vs. rider mass. 3. Travels through shade. Exceeds Test Plan: Measure and plot distance in shade travel vs. rider mass. Extra Knowledge: solar energy, storing energy, electric motor torque, gears

25. Bruce Kawanami25 Wireless Earpod Testing 1. Transmits 10 meter. Exceeds Test Plan: Measure maximum transmission distance. 2. Receiver weight. Exceeds Test Plan: Know the weight of each component and alternatives. 3. No dropouts, ‘good fidelity.’ Exceeds Test Plan: Higher number of surveys. Extra Knowledge: capacitors, inductors, antenna, ordering free samples, soldering

26. Bruce Kawanami26 Lowering Shelf Testing 1. Moves 45 cm. Exceeds Test Plan: Measure elapsed time 2. Move 16 kg. Exceeds Test Plan: Measure and plot mass vs. elapsed time 3. Tilt. Exceeds Test Plan: Measure and plot degree tilt vs. location of mass. Extra Knowledge: motor torque

27. Bruce Kawanami27 Step #6: Failure Analysis and Tweak/Redesign Iterations Evaluate the test results. Do they satisfy design criteria? If not, can you tweak the process as opposed to a complete redesign? This is the longest step….

28. Bruce Kawanami28 Failure Analysis and Tweak/Redesign Examples Solar scooter: Cannot move 35kg …. Add more solar cells, bigger motor, higher gear ratio, reduce scooter weight Wireless earpods: Range only 4m …. Increase transmitter voltage Lowering shelf: Shelf tilt up to 15°…. Add stabilizing guides

29. Bruce Kawanami29 Step #7: Complete the Project Book (Started at project definition) Project data book A complete record All key decisions Good drawings Test plans Results Conclusions Things learned

30. Bruce Kawanami30 Draw a Good Picture Drawings for project notebook, application, display Photos, sketches, CAD 2-D or 3-D Show assembly, components, materials

31. Summary

32. Bruce Kawanami32 Design Features 1.Meets a need, has a “customer” 2.Design criteria and constraints 3.Evaluate alternatives and generate test plan 4.Build prototype 5.Test/evaluate against test plans 6.Analyze, “tweak” ( ), redesign (  ), retest 7.Project book: record, analyses, decisions, specs

33. Bruce Kawanami33 Best of Luck Engineering is exciting! Use creative problem solving! Ignite your passion!