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DR. TAREK A. TUTUNJI REVERSE ENGINEERING PHILADELPHIA UNIVERSITY, JORDAN 2015 Forward Design Example Rev II

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Page 1: Forward Design Example Rev II - Philadelphia University. FWD Design...Forward Design Example Rev II . ... Type of crane ... in order to reduce the speed and increase the torque with

DR. TAREK A. TUTUNJI

REVERSE ENGINEERING

PHILADELPHIA UNIVERSITY, JORDAN

2015

Forward Design Example Rev II

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Introduction

Examples for forward design will be presented and discussed

The objective is to let students think of the seven-steps

and how they are applied to several systems This will allow the students to review their design skills

and later compare the forward design steps with the reverse engineering steps

First, the students are asked to work on two simple

designs. Then, the design for more complex systems are provided.

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Example: Pen

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Pen Design

What is the need?

What are the specifications?

What options are available?

Design a pen in class with your group!

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Example: AC-DC Converter

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

AC-DC Converter Design

What is the need?

What are the specifications?

What options are available?

Design an AC-DC converter in class with your group!

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Case Study: Crane Design

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

1. Define the Problem

The objective is to build a small prototype crane that can translate a weight in three dimensions by manual joystick.

Specifications:

Load = 5 kg

Speed = 0.11 m/s

Constraints

Time 8 months

Budget: $800

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

2. Gather Information

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

2. Gather information

An overhead crane is a crane where the hook-and-line mechanism runs along a horizontal beam that itself runs along two widely separated rails.

Also a hoist is used to lift the items, the bridge, which spans the area covered by the crane, and a trolley to move along the bridge.

Its purpose is to move objects automatically between two locations in a factory

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

2. Gather Information

Main Components

Bridge

Rail

Trolley

Beam

Hook

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

2. Gather Information

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

2. Gather Information

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

2. Gather Information

Electrical components Motors

Electronics

Controller

Sensor

Mechanical components Shafts

Gears

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

3. Propose Solutions

Type of crane

Tower

Overhead

Type of actuators

Electric: DC, AC, or Stepper

Pneumatic

Type of sensors

Optical

Limit Switches

Type of controller

PC

Microcontroller

Analog

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

4. Study the Solutions

Overhead crane works better than Tower for our purpose

Microcontroller

Cheaper than PC

More accurate than analog

DC Motor

Cheaper than AC and easier to control

Easier than pneumatic

Sensors

Limit switch for linear end position

Optical encoder for motor position

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

4. Study the Solutions: Choose

Single girder overhead crane with dimensions: 2 m length, 1.2 m width, and 1 m height

Three DC motors for xyz-directions

PIC microcontroller

Limit switches, three positioning sensors, control and drive circuits

Keypad. The user can specify the desired position by entering the coordinates on the keypad

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

5. Analyze & Design: Block Diagram

Controller Power

Electronics Interface

Limit Switch Sensors

Crane Plant Electrical Motors

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Analysis: Weight Calculations

Motors weight = 1.5kg ×2 = 3kg

• Shaft and bearing =4kg

• U- Shape steel bar and steel sheet = 2kg

• Screws and roundels = 0.25kg

• Teflon wheels = 0.25 kg

• Other parts = 0.5 kg

Total weight of Trolley = 10 kg

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Analysis: Power Calculations

F = M × g F = 5 kg × 9.81 m/s² = 49.05 N

T = F × R T = 49.05 N × 0.025 m = 1.23 N.m

Pm = T × ω Pm = 1.23 N.m × 4.7 rad/s = 5.8 watt.

P actual = 5.8 watt × 1.6 = 9.6 watt

Pe = 9.6Watt /0.8 = 12 Watt

Pe = I × V

We chose DC motor with V = 12 V, I = 3 A.

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Analysis and Design: Simulation

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Design: Mechanical Drawings

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Design: Flow Chart

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Final Design

The mechanical components were composed of the frame, the girder, and the trolley.

The frame used bars of hot roll steel AISI 1020: two parallel tracks of 2m length, six vertical columns of 1m length, and sixteen side holding bars.

The girder consisted of two parallel girder tracks of 1.2 m length mounted to side rolling bases.

The trolley part had two 36 watt DC motors with internal worm gear assembly mounted to side rolling bases.

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Final Design

Actuators:

Three DC motors as: Hook motor to lift the load, trolley motor to move the trolley above the girder, and girder motor to move the girder above the bridges. Each dc motor (3 A, 12V) had internal gears in order to reduce the speed and increase the torque with a gear ratio 1/140.

Sensors:

Two linear optical encoders were used as displacement sensors for the x-y positioning with a resolution 1pulse/cm. The tracks were made from plastic and fixed to the frame. For the z-direction, rotational optical encoders were placed on the shaft of the pulley with a resolution of 20pulse/revolution.

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

6. Implement: PCB

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Implementation: Mechanical

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

7. Evaluate

The crane was tested in the labs

Equipment used: Scopes and multi-meters

Different loads (up to 5 Kg) were used

Speed of movement was measured using stopwatch

Microcontroller was damaged during testing.

Limit switches were calibrated.

The load cable was re-packaged

Added support to the skeleton frame

Insulated the controller using the opto-coupler.

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Final Prototype

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Acknowledgement

The crane project work was the effort of two student design teams:

Team 1:

Abd Al-hafez Suleiman

Yosef Abo Hurira

Team 2:

Hassan Abu Zahra

Moafeq Alkhateeb

Fadi Darweesh

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Aircraft Elevator Design

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Aircraft Elevator Design

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Dr. Tarek A. Tutunji Engineering Skills, Philadelphia University

Conclusion

Design examples were provided to show the 7-design steps

The examples included Pen

Electrical Converter

Overhead Crane

Aircraft Elevator