Mechanical Systems Design

Syllabus: Spring 2021
A Junior-level course that develops experience and confidence with:
(1) An approach to mechanical systems design that incorporates ideation, back-of-the-envelope analysis, computational analysis, and prototyping, iteratively and with an appropriate balance for the domain.
(2) Designing custom mechanical components, finding and selecting common machine elements, and selecting electric motors and transmission elements to meet performance, efficiency and reliability goals.

First Module:
The first project introduces the structure of projects in this course; introduces the design approach; reviews and begins to apply statics and stress analysis skills from prerequisite courses to design; introduces finite-element analysis; and provides an opportunity to work out any issues with fabrication methods.
Project 1: Description | Launch Video - 15 min.
Topic Video 1: Introductions - 10 min.
Topic Reading 1: Teaching Philosophy - 20 min.
Topic Reading 2: Design Approach - 10 min.
Topic Video 2: Course Overview - 10 min.
Topic Reading 3: Simple Models - 10 min.
Topic Video 3: Simple Models - 20 min.
Topic Reading 4: Free-Body Diagrams - 25 min.
Topic Video 4: Free-Body Diagrams - 35 min.
Topic Reading 5: Stress Analysis for Design - 35 min.
Topic Video 5a: Simplified Stress Analysis in Design - 25 min.
FEA in SolidWorks: Modeling Video | FEA Video | Tip Sheet | Example Part File - 25 min.
FEA in Fusion 360: Modeling Video | FEA Video | Tip Sheet | Example Part File - 25 min.
Topic Video 5b: Detailed Stress Analysis in Design | Vise Grip Example - 20 min.
Topic Reading 6: Technical Writing for Design - 15 min.
Topic Video 6: Technical Writing for Design - 30 min.

Second Module:
The second project comprises a challenging, open-ended problem: design of a single component for mass efficiency. Success requires sophisticated application of the design approach, including statics analysis using free-body diagrams; stress, deflection and buckling analysis using simplified models and finite-element analysis; and testing of both low-fidelity and functional prototypes.
Project 2: Winter 21: Description | Launch Video - 10 min.
Spring 21: Description | Launch Video - 10 min.
Topic Reading 7: Failure Analysis for Design - 15 min.
Topic Video 7: Failure Analysis for Design - 25 min.
Analyzing 3D-Printed Parts: Tip Sheet | Video - 15 min.
Topic Reading 8: Mass-Efficient Design - 25 min.
Topic Video 8a: Mass-Efficient Design - 120 min.
Topic Video 8a: Mass-Efficient Design II - 60 min.
Topic Video 8a: Prototype Testing - 25 min.
Wrap-Up Video: Project 2 Debrief - 25 min.

Third Module:
The third project introduces simple models of electric motors and gears; applies these models to selection of a motor operating point and gear ratio; and introduces the design of experiments to identify important system characteristics.
Project 3: Description | Launch Video - 25 min.
Gearbox Build: Tip Sheet | Walk-Through Video - 20 min.
Capstan Model: SLDPRT | F3D
Topic Reading 9: Electric Motors - 40 min.
Topic Video 9: Electric Motors - 60 min.
Topic Reading 10: Gears - 45 min.
Topic Video 10: Gears - 45 min.
Wrap-Up Video: Project 3 Debrief - 15 min.

Fourth Module:
The fourth project comprises the challenging, open-ended design of a motor-driven machine to maximize electromechanical performance. It requires application of the Design Approach to complex problems in a team setting; effective incorporation of multiple custom and catalog components into an assembly; and sophisticated use motor and gear models, power analysis, and mass-efficient component design.
Project 4: Winter 21: Description | Launch Video
Spring 21: Description | Launch Video
Spur Gear Model: SLDPRT
Topic Reading 11: Assemblies - 25 min.
Topic Video 11: Assemblies - 75 min.
Topic Reading 12: Catalog Parts - 60 min.
Topic Video 12: Catalog Parts - 90 min.
Topic Reading 13: Energy Loss - 35 min.
Topic Video 13: Energy Loss - 90 min.
Thoughts on: Pacing | Process | Uncertainty | Uniqueness
Wrap-Up Videos: Project 4 Debrief | Quarter In Review - 35 min.

Optional Topic Readings:
These are intended as resources for students who wish to take their designs beyond the intended scope of the fourth project, or who wish to apply similar methods to extracurricular design problems.
Optional Topic Reading: Material Selection
Optional Topic Reading: Manufacturing and Cost
Optional Topic Reading: Costing Appendix
Optional Topic Reading: Design for Manufacture
Optional Topic Reading: Geometric Dimensioning and Tolerancing

Other Resources:
All Videos: YouTube Playlist
Personal 3D Printer Program: Info Sheet | Step-by-Step Guide
Fusion 360 - Free Student Version: Download Software