DESIGN 2 (MMM 235) FBS COURSE INFORMATION UINRNCASTIAS 2000/2001 et antataing arts 1. Desir Dre P PURPOSE OF THE COURSE ‘The purpose of the DESIGN 2 course is to enable you to design assemblies for real machines to fulfill a customer's need. The means that your machines must, at least:- () meet the customer's requirements, (i.e. work well !) (ii) be safe (even when subjected to rough environments) and (ill) be designed with the manufacturing and assembly processes in mind. (i make). cheap to COURSE DESIGN PROJECT The course is centred around a design projact and the teaching will be structured to provide information and direction at times appropriate to the project. The project is the design of a range of high quality long life and compact hand operated wire rope winches. These winches ere used widely in industry, in theatres and wherever loads have to be lifted easily by hand. In addition to the design project, a Class Test worth 15% of the module will be organised during week 11 of ‘Semester 2 (71/6/2001) to assess understanding of the course. PROJECT ORGANISATION The project will be conducted in Teams of four students with each student working individually. Each student is expected to produce an individual design based on his/her own work. However, conferring within Teams is encouraged: itis likely to be essential ! ‘The work to be presented at the end of the project includes a complete layout drawing with supporting drawings so that all details of the design are specified fully. Each student Is required to keep a “Design Log Book’ in which will appear all the design work done: this will inelurle all the rough caiculations and sketches, ts. This book will be inspected disring each design class ard wil be taken into account for the assessments. The Log Bookis to be an A4 size note book into which the sheets are permanently bound: no adding or removal of pages is allowed. ALL work, including the rough work, must be in the fog book Itis intended that the design will evolve each week as it is extremely unlikely that you (or |) will get all the dimensions correct first ime! Therefore do not be surprised when a considerable amount of redrawing is needed: this may be an excellent time to use AutoCAD/Mechanical Desktop. But, on no account, allow yourself to spend longer doing the design with AutoCAD/Mechanical Desktop than you would by hand drawing: we are attempting to teach you to design not just to produce beautiful drawings. Design 2 runs for one Semester: it counts as one full module, Itis, therefore, intended to require approximately 100 Rours of stucient effort. The total number of hours in class for this module is likely to be in the range 30 - 40, 80 students will be expected to work on the module for 60 - 70 in their own time: {.¢. approx. 7- 10 hours of (proper) work per week, It is intended that no detailed analysis is done before a satisfactory layout design is achieved: however basic mechanical science is required to establish the layout. Itwill be impossible to make satisfactory progress on this course without constant reference to a large format (A1 size minimum) layout drawing: A4/AS size CAD laser printer check plots may be used for weekly submissions if all details are clear. Ripzasert44 42 43 44 45 48 47 48 49 4.40 4.12 PROJECT REMIT Each Team Member is to produce a design for a hand operated wire rope winch: the design will be unique and wil be presented individually. Each member of the class will be given a different specification from the table below. The design will be based upon a frame holding both a shaft with 2 winch drum and spur gear and also a shaft with spur pinion and ratchet wheel driven by a hand crank. Run back of the winch is to be prevented by the ratchet mechanism: this mechanism is will be released by hand but must self engage. All specifications of winch set out below can be implemented by one stage of speed reduction gearing: but although more compact designs ‘may be achieved with two stages of speed reduction gearing in conimercial designs, use only a single stage for this project. Atl components are to be built into one compact unit with the gears fully enclosed and lubricated by a (sealed) oil bath. ‘The winches must perform as required by the specification set out below, continuously at full load for 1000 hours. without requiring any attention. The winches are to withstand, without failure or permanent damege, overloading to 2 times the safe working load ‘occasionally. ‘The breaking load of the wire ropes is to be at least fiye times the SWL (Safe Working Load) of the winch . pt The laput to the winches is by hhand.crenk. The crank hands should be easly removed from the winches without tools but should not present a ‘coming detached accidentally during use The output from the winches is by wire rope. The design of the winches should permit the direction cof the wire ope to vary as much as is practical but should prevent the wire rope rubbing on any component of the winch. The winches are to be capable of being mounted with grade 4.6 bolts to a flat surface perpendicular to the axis of rotation of the handle and are to be capable of operating in any orientation ‘The Winches shouid be robust, compact, eusy to mount, light, of attractive shape minimum maintenance. They are not to have any sharp comers or edges. Possible) and sequire All threaded fasteners must be ISO Metric (Coarse). The shaft bearings are to be rolling slement bearings. ‘The winches are intended to be produced in batches of 10 to 1000 by a company specialising in mechanical hrandling equipment. All components are to be toleranced to give full interchangeabilty Rinz3ser2[5.__ WINCH SPECIFICATIONS Specification numbers shown in [TALICS | Safe [Height | Crank [Spec. ‘Safe | Height] Crank |Spec. |, Safe Height] Crank [Spec | ‘Working | Load | input | No. Werking | Load | input | No. ‘Working | Load | input | No. Load | Lifted | torque Load | Lifted | torque Load | Lifted | torque (egf)_|_(m)_| (Nr) (kgf) | (mm)_| (Nm) (kgfl_|_ tm) _| (my a 1a; s| S| 28 500] 5] 10|__ 3) a 10|__5| 18] 29] 300] | __ 20] 59) sof 5,6) 3 so] 5| 27] 20] S00] | _30| 87) so; 40) 2|_— iso 70] 9] af 500} io} 10] sal so] 10,4 160|__i0} 18] 22 500] 10/20/69) ‘sof 10) 6 50[ 0] 27] 33) 500/10] 30] 60) so] 152] 7] 150] 15| 3] 34 500] 15| 10] 67 eo, 15|___4[_a| 750] 15{ __18| 36] ‘500| 15] 20| 62) so] 15] 6] 9 750] 18] 27] 26) 300] 15|__30] 3] wm] 5| _3|__10 200f5|__ io] a7) 7e0| 5} 10] = 6a [5] 6| 77 200} 5|__20| 28] 70] 5| 20/68) 7] 5] 3|_7 200| 5] 30] 29) 70; S| 30] 66] | i0| 3] 13] 300] 70|__ 70] a0 7s0| io} 10) 67] 7; 106) _14 200[ 10] 20] __47 750] 10} 20] 6a] 710] 8} 7 200; to] 0] 750/10] 30f 69] | 15|__3|__16 200{15|__ 10] 43 70|#5|__t0[ 79] 715] 6|_ 17] 200[75|__20|__ 44 7s0[i5| 20] 74] 75|__15| __3|__74| 200|__75| 30] 4 70 i5| 30] 72] 0) a I) 300] 5|__10| 46 jo00f— 5|_ tof al wool _5|__ 42] 20] 200] 5| 20) _47| 000] 5| 20] 7a yoo S| __18] 27 300] 5], a8 Ee) a CY soo! io] 6] 22 300] 70] 70] _ 49] yooof fof sof 76} a 200] to] 2050 7000| tof zo 77] oat to] 18) 2a) 300] 10] 30] 57 7000} 10} 30h 74] ‘oof is} 6] 23) 300] 45|_ 10/89] cL) a YZ] Too] ts[ 12) 26 300] 15|_20( 53] ooo] 15| 20 ac ool 5] 18] 27 300] 451 30) 54 ooo] 15[ 30] 87 6. FORMAT OF MATERIAL TO BE HANDED IN 61 62 63, 64, 65, All work must have a front cover givin oOooooe Full name of student Course for which work is being submitted (MMM 235) Date of submission. Member of Staff to whom the work is submitted Title of Exercise/Project. Group Number, Team Letter (where applicable). Names of other contributors (if any) the work 1g at least the following information: Final Layout drawings are to be on A1 sheets in black only. Other drawings may be done on Ad, A3, A2 or At sheets. Before submitting your work, check with your supervisor how large drawings are to be presented. All written work must be fixed firmly together in such a manner that all sheets can be read easily but that they cannot accidentally come loose. All sheets (every one except those of the log book) must have the student's name. |f additional packaging (e.g, folders or envelopes) are used to submit work, the information listed above must be visible without removinglopening the packaging, ‘Work must be self explanatory and demonstrate clearly that the requirements have been fulfilled and that the specification has been met. Rup23503