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Introduction
Purposeandapproach Purpose and approach Syllabusreview Courserequirements C i Courseoutline
ME232A:EngineeringDigitalComputationsActivity Syllabus FallQuarter2012 Instructor JosephBerk,jhberk@csupomona.edu,9092049984 Officehoursasannouncedinclass MeetingTimesandLocation Timesasspecified,allmeetingswillbein172660 Prerequisites MinimumgradeofCorbetterinME232 Textbook MATLABforEngineers(2ndEdition)byHollyMoore,PrenticeHall CourseSummary You will utilize ME232 programming skills to develop programs that solve engineering problems. You willbeintroducedtoMATLABandOctaveandlearnusefulfunctionsthatcansolvethesameproblems. ThegeneralapproachinthiscourseislearnMATLAB/Octave,todevelopVBAprogramsforengineering problems assigned in the lab, and to use MATLAB/Octave for checking your solutions to some or all aspects of these problems. There will be very little lecture; most of the lab time will be focused on developingyourprograms.Forthisreason,youmustdoallassignedreadingsandreviewallassigned materials prior to coming to the lab. DO NOT come to the lab session without having reviewed the readingassignmentsandcoursematerialsinadvanceofourtimetogether.Therewillbenoquizzesor tests. Ourschedulewillbe: Weeks1&2 IntroductiontoMATLABandOctave,matrixalgebra,Project1assignment. Weeks3&4: Vectormath,solvingsetsoflinearequations,curvefitting,polynomialregression,interpolation, Project2assignment. Weeks5&6: Numericalintegration,calculatingareaundercurve,numericalintegrationof1storder equations,statisticalanalysis,Project3assignment. Weeks7&8: Linearinterpolation,plotting,morenumericalintegration,findingrootsofnonlinearequations, Project4assignment. Weeks9&10:
Logicalcontrolfunctions,selectionstructures,loops,readingtoandfromfiles,Project5 assignment. Obligations Yourobligationsare: Youmustpurchasethetext. You must work independently on all assignments. All material you prepare must be original. Youmaynotturninmaterialpreparedbysomeoneelseasoriginalmaterial. Youmustcompleteallassignedreadingspriortoattendingeachlabsession(withtheexception ofourfirstmeeting). Youmustcompleteallprojectassignments. Youmustnotuseyourcellphoneortextmessageduringlabsessions.Turnyoucellphonesoff priortocomingtothelab. YoumustnotsurftheInternetordoothercomputerworkunrelatedtolabassignmentsduring labassignments.Ifyoufinishearly,youshouldleave. Youmustattendalllabsessions. Youmustbeontimeforalllabsessions. Youmuststayawake. Projects Youwillberequiredtocompletefiveprojectsforthiscourse.Theseareindividualprojects(notgroup projects)andallpartsoftheproject(programcreation,obtainingresults,andprogramsubmission)must beoriginal.Theprojectsareintendedtoexposeyoutorealworldproblemsfacedbyworking engineers;theyarenotpointlesscomputationalexercises.Theywillbechallengingbothfroma programmingperspectiveandfromanengineeringperspective.Ifyouarehavingissues,usetheoffice hours,email,andthetelephonetocontactmeforassistance.Donotwaituntilshortlybeforethe projectisduetoannouncetomethatyoudontgetit. Grading Therewillbe5projects.Eachwillcountfor20%ofyourlabgrade.Youwillreceiveagradeoneach project.Thegradescaleis: 5=A 4=B 3=C 2=D <2=F YouwillearnanAinthiscoursethroughdemonstratedmaterialmasteryandprofessionalsubmittals. Thismeansyourworkmustnotcontainspellingorgrammarerrors,yourprogramsdonotcrash,your programsdelivercorrectanswers,andallworkissubmittedontime. YouwillearnaBinthiscourseisyourworkisaboveaverage,butnotexemplary.
YouwillearnnohigherthanaCinthiscourseifyourworkisaverageaspertheabovegradescale,orif oneassignmentissubmittedlate. YouwillearnnohigherthanaDinthiscourseifyourworkisbelowaverageaspertheabovegradescale oriftwoassignmentsaresubmittedlate. YouwillearnanFinthiscourseifyouarehabituallylateinarrivingforthelabsession,ifyoudonot attendalllabsessions,ifthreeormoreassignmentsarelate,orifyouraveragegradeonallassignments isbelow2.0. Anylateassignmentwillreceiveagradeof0.Anyassignmentmorethan3dayslatewillresultin coursefailure. Thebottomlinetoalloftheaboveisdonotbelateonanyassignments,donotbelateforanyofthelab sessions,turnyourcellphonesoff,andattendalllabsessions.
Effective Fall 2006, any engineering student taking classes may acquire a user name and password to permit use of engineering computers. Once the student has activated their account they will have access to these computers with a courtesy storage quota of 50MB. If the student is enrolled in a class the instructor may activate printing and storage privileges as required by the course. A folder will be created with the name MyEGRClassFolder on the H:drive of the student's computer. Opening the folder will give access to each of the class folders for the courses in which the students is enrolled. The student's user name for the College of Engineering computer account is the same their Cal Poly BroncoName. For the rest of the student's engineering career this user name will remain effective The password for the Engineering computer account is intially based on the student's personal information. You will be required to change the password the first time you logon. You can determine the initial password by using the following criteria: o For the first character of the password use the Upper case letter of the first letter of the first name. If the student has no first name use "X". o For the second character of the password use the Upper case letter of the of the first letter of the last name. If the student has no last name use "X". o For the third character of the password use the lower case letter of the second letter of the last name. If the student has no last name or a single letter last name use "x". o For the next four characters of the password use the 2 digit birth month and 2 digit birth date of the student's birthday. o If the first three characters in the password are the same as the students user name, add a "#" in between the first and second character of the password. o If the password still cannot be resolved contact one of the Engineering IT techs. o Examples: For an example of the above rules assume the student's name is Fred Smith, his Cal Poly e-mail username is fsmith and his birthday is June 5, 1987: His password would be FSm0605 If the student's name is Peter Ng, his Cal Poly e-mail username is png and his birthday is December 12, 1986: His password would be P#Ng1212 The student will be prompted to change the password at the first logon. The password must meet the following minimum requirements: o Not contain the user's BroncoName. o Be at least six characters in length. o Contain characters from three of the following categories: Uppercase characters ( A through Z ) Lowercase characters ( a through z ) Decimal digits ( 0 through 9 ) Non-alphabetic characters (for example, !, $, #, %)
Workspace
Command History Hi t
CreatingDirectories
CreatingFiles
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PerformingMath Operations
ClearingCommandWindow
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CreatingVariables
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15
UseWhocommandtoseeyourvariables
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CharacterVariables
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Chapter3outlinesseveralmorefunctions h l l f
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ClearingVariablesFromMemory
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FormattingHowNumbersAppear
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Comments
In VBA we used an apostrophe InVBA,weusedanapostrophe InMATLAB,weusethe%symbol
W Wecaninsert%symbolanywhereincodeline i t% b l h i d li Alltorightignoredinprocessing
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Matrices
MATLAB shines with matrix operations MATLABshineswithmatrixoperations Cancreatearrayswith
Si l l Singleelements t Rows Rowsandcolumns
Seeexamplesinfollowingcharts
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Createbiggerarrayswithbrackets
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Separaterowsofdatawithsemicolons
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Multiplyingmatrixbyascalar
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Recommendation:Alwaysuseperiodinfrontofoperator
Goodpracticetousemultiplication,division,orexponent operationoneachelementofarray
If we tried to square above matrix by saying c = c^2 we would get Ifwetriedtosquareabovematrixbysayingc=c 2,wewouldget errormessageduetoviolationofmatrixmultiplicationrules Ifwesquareabovematrixbysayingc=c.^2,itworks
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Writingdataonsameline
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Writingdataonsameline(continued)
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Writingdataonsameline(continued)
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ShowingNumbersandStringsOnSameRowinMatrix
Notes
You have to convert everything in matrix to a Youhavetoconverteverythinginmatrixtoa string Once youve done this, you cant perform Onceyou vedonethis,youcan tperform mathematicaloperationsdirectlyandgeta correctanswer Wecanconvertanumberthatweconverted toastringbacktoanumberusingthe str2numfunction Seenextslide
ExampleUserInputs
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ReferringtoSpecificMatrixLocations
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ChangingSpecificMatrixValues
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OperationsUsingSpecificMatrixValues
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PerformingOperationsonMatrices
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PerformingOperationsonMatrices
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PerformingFunctionsonMatrices
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TransposingMatrices
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Usedforextractingpartsofanarray
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CreatingMatriceswithStepSizes
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ExtractingPortionsofArrays
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ExtractingPortionsofArrays
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EndCommand
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SizeCommand
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Numel Command
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a b e f ae bg af bh c d g h ce dg cf dh
ScalarMultiplication
Multiplication
a b wa wb w wc wd d c d
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MatrixAddition/Subtraction
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VectorMagnitude
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VectorDotProducts
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VectorCrossProducts
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Homework
Continue Project 1 ContinueProject1 ReadChapters1through4
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UsingMatricesToSolveLinear IndependentEquations
ME232A Weeks3and4 Weeks 3 and 4
Save file
File runs
S Supposewehave h
3x1 +5x2 =10 7x1 +15x2 =23
Approach
Set equations in matrix form Setequationsinmatrixform Writematrixequationasx=inv(A)*b AllowOctaveorMATLABtosolveforvariables ll O l f i bl
3 5 x1 10 7 15 x 23 2
x = B
Caveats
Touseprecedingapproach,equationsmustbe p g pp , q linear
Variablestofirstpower No unknowns multiplied by each other Nounknownsmultipliedbyeachother Squarematrices(onlywayyoucanhaveinverse)
CantTakeInverseOfMatrixwithDeterminant=0
SolvingStaticsProblemsWithMatrices
1000lb 3.2ft 75o F2 9.9ft 71o F3 7.3ft 70o F1
Verticalforces: F1 sin70o F2 sin75o F3 sin71o +1000=0 Horizontalforces: F1 cos 70o F2 cos 75o + F3 cos 71o =0 F +F 0 Moments: 20.4F sin70o 3.2F sin72 20 4 F1 sin 70o 3 2 F2 sin 72o 13 1 F3 sin 71o =0 13.1F sin71 0
=
1
0 0
1000 0 0
cos 70o
LetscreatethematricesinOctave
LetssolveforF1,F2,F3
Project2 Project 2
Supposeyouhaveamemberattachedtowall pp y
Wallforce D1 1 F1 D2 2 F2 D3 3 F3
WriteaMATLABprogramthatallowsusertoenter resultantverticalforceatwall,D1,D2,D3,1,2,3 Program returns F1,F2,andF3 ProgramreturnsF F and F Emailmfiletoinstructornotlaterthanspecified submittaltime NamefileyourlastnamefirstinitialP2.m
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Introduction
Twodimensionalplotting Subplots Polarplots Logarithmicplots Barcharts Histograms Functionplots Threedimensionalplotting Statisticalfunctions Editingfrommenubar g Savingplots Project3 Summary y
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SimplexyInputs
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SimplexyInputs(continued)
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AddingTitlesandLabels
Tosavefigures, seenextslide
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ReadingSpecificExcelData
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AssigningSpecificExcelDatatoMatrix
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AssigningSpecificExcelDatatoMatrix
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AssigningSpecificExcelDatatoMatrix
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PlottingPrecedingExcerptedExcelData
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xandyRangescanbeinrowsorcolumns
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Wecanexcerptdirectlyintoplotcommand
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PlottingTrigonometricFunctions
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PlottingTrigonometricFunctions
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PlottingMultipleLines
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PolarPlots
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PolarPlots
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PolarPlots
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semilogx(x,y)
Logarithmicxscale,linearyscale
semilogy(x,y)
Linearxscale,logarithmicyscale
loglog(x,y)
Logarithmicxandyscale
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TheNormalDistribution
Assignsdatatocategories Usuallyreferredtoashistogramor frequencydistribution frequency distribution Curvecanbedescribed mathematically Distancefrommeancorrelateswith Distance from mean correlates with probabilityofoccurrence
So,howcanweusetheabove?
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HistogramExamples
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HistogramExamples
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Selectapproachyoufeelisappropriateandbe abletoexplainwhy able to explain why Basedonbinsizeandminandmaxdatapoints, selectnumberofcategoriesforuseinMATLAB select number of categories for use in MATLAB hist(x,a)function
Numberofcategories=(max min)/(binsize)
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FunctionPlots
Plotsfunctionswithoutdefiningarrays
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AnotherfplotExample
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Project3:HistogramProgram
CollectweightsofmalesinME232Alab C ll t i ht f l i ME232A l b WriteaVBAprogramthatallowsuserstoenterweightsonaform VBAprogramshouldwriteweightstoa.csvfile VBAprogramshouldreadweightsfroma.csvfile p g g VBAprogramshouldcalculateweightmeanandstandarddeviation Researchapproachesfordeterminingnormaldistributionbinsizes,select approach,haveVBAprogramdeterminebinsize VBAprogramshouldwriteweights,mean,standarddeviationtoExcelspreadsheet VBA program should write weights mean standard deviation to Excel spreadsheet MATLABprogramshouldtakeweightsandbinsizeanddisplayhistogram ProvidefollowinginWordreport: Yourname VBAcode(moduleandform) Excelspreadsheet Yourbinsize,andyourrationaleforyourbinsizeselectionapproach MATLAB code MATLABcode MATLABgeneratedhistogramwithappropriatetitleandaxislabels NameyourWorddocumentyourlastnamefirstinitialP3.docx NameyourMATLABfileyourlastnamefirstinitialP3.m NameyourExcelfileyourlastnamefirstinitialP3.xlsm Submitabovenotlaterthanspecifiedsubmittaltime
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Introduction
Interpolationandcurvefitting Interpolation and curve fitting Differencesandnumericaldifferentiation Numericalintegration i li i Project4 Summary
Interpolation
Linear interpolation Linearinterpolation
Assumesstraightlinebetweentwoknownpoints
LinearInterpolation
Useinterp1function f Consider
MultipleInterpolations
PlottingMultipleInterpolations
PlottingMultipleInterpolations
CubicSpline vsLinearInterpolation
CubicSplinevsLinearInterpolation
RefertoChapter12foradditionalinterp1optionsand3dimensionalinterpolation
LinearRegression
Bestfittingstraightline
y=2.1905x+15.9167
LinearRegression
Bestfittingstraightline
PolynomialRegression
MATLABdifffunctionfindsdifferencesbetween vectorvalues
Canuseabovetofindslopebetweendatapairs Seenextslide
NumericalDifferentiation
10ysegments
Averagevaluebetweenupper andloweryineachsegment
quadl
UsesadaptiveLobatto quadrature
quadandquadl
function (noteapostrophes)
lowerlimit
upperlimit
IntegratingPrecedingFunction
Project4 Project 4
Findequationdescribingnormaldistribution UsemeanandstandarddeviationfromProject3(mensweights) U d t d d d i ti f P j t3( i ht ) Plotnormaldistributionwithabovemeanandstandarddeviationusing
Excelschartingfeatures MATLABsplotfeatures
UseMATLABtofindareaundercurvefrom f d d f
1 to+1 2 to+2 3 to+3 6 t 6 6 to+6
Summary
Interpolationandcurvefitting Interpolation and curve fitting Differencesandnumericaldifferentiation Numericalintegration i li i Project4
LogicalFunctionsandControl Structures
ME232AWeeks9and10
Introduction
Relationalandlogicaloperators Relational and logical operators Logicalfunctions Selectionstructures S l i Loops Project5assignment Summary
MATLAB LogicalFunctionsandControlStructures i l i d l
Similar in concept to other languages Similarinconcepttootherlanguages SimilarinconcepttoVBA
S Sequentialstructure ti l t t Conditionalstructure(orselectionstructures) Repetitivestructure(loops) ( )
all
Checks to see if logical condition true for all matrix Checkstoseeiflogicalconditiontrueforallmatrix elements
any y
Checkstoseeiflogicalfunctiontrueforanymatrix elements
RefertoMATLABhelpformoreinformation
If/Else
SimilartoIfThenElseEndIfinVBA
SeeChapter8fordiscussionofcomparisonswithmatricesversusscalars
Loops
for loop forloop
Usedwhenyouknowhowmanytimestoloop
Showshowmanytimesscores>90
Project5 Project 5
Anacidetchprocessremoves1%(by weight)ofanaluminumstructure i ht) f l i t t eachtimeitisdipped.Thestructure isrepeatedlydippeduntilitsweight approaches10lbs,buttheweight cannotbeallowedtodropbelow10 t b ll dt d b l 10 lbs.CreateaMATLABprogramthat allowstheusertoenterstructures weightpriortothefirstdip,andthen returns:
Howmanythetimestheproduct needstobedippedsuchthatits weightapproachesbutdoesnotdrop below10lbs. below 10 lbs Theproductsfinalweight
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Summary
Relationalandlogicaloperators Relational and logical operators Logicalfunctions Selectionstructures S l i Loops Project5assignment
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ME232AProject1 HydraulicAccumulatorReliabilityPrediction Hydraulicaccumulatorsareusedinaircraftandotherapplicationstodampenhydraulicpressure fluctuationsandtoprovideresidualhydraulicpressureforshortperiodsifthehydraulicpressuresource (e.g.,ahydraulicpumps)failtopressurethehydrauliccircuit.Inthisregard,theyarethehydraulic systemequivalentofacapacitorinanelectricalcircuit. Thetypicalhydraulicaccumulatorisapressurized,sealedcylinder,withaslidingpiston.Pressurized hydraulicfluidisononesideofthepiston;pressurizednitrogengasisontheotherside.Ashydraulic pressurefluctuationsoccurandthepistonmovesbackandforth,thenitrogengasiscompressedor decompressedslightlytoaccountforthehydraulicpressurefluctuations. Thisistheaccumulatorengineeringassemblydrawingforthisassignment,alongwithanassociatedbill ofmaterials:
ReliabilityisalsoexpressedasMeanTimeBetweenFailures,orMTBF,whichmeanstheaverage numberofhourstheproductwillworkpriortofailing.
Engineerspreparereliabilitypredictionsbyworkingfromthepartleveluptotheassemblylevelinthe followingmanner: Eachpartisaassignedafailurerate,typicallyinfailurespermillionhours.Forexample,ifthe partshistoryisthatitfailsonceeverymillionhours,itsfailurerateis1x106.Thesefailure ratescanbefoundinpublishedsources,online,fromthecomponentsupplier,theycanbe basedonthecompanyshistorywiththepart,ortheengineermaymakeanestimateofthe failurerate.WeusuallyusetheGreekletterlambda()torepresentfailurerate.Forthis assignment,thefailureratesareprovidedtoyou. Afterfailureratesareassignedtoeachpart,thefailurerateforeachpartismultipliedbythe numberofpartsintheassemblytoprovideatotalfailurerateperpart.Inotherwords,iftwoof aparticularpartareincludedtheassemblyandthefailurerateis1x106,thetotalfailurerate forthatpartis2x106. Thefailureratesforallpartsarethensummedtoprovideatotalfailureratefortheassembly: assembly= TheassemblyMTBFissimplytheinverseoftheassemblyfailurerate: MTBFassembly=1/ Thereliabilityoftheassemblyisgivenbythefollowingequation: Reliabilityassembly=et Where e=baseofthenaturallogarithm,orapproximately2.71828183 isequaltoassembly tisequaltoassemblyoperatingtime(frequentlyreferredtoasmissiontime) Similarly,theassemblysprobabilityoffailureis1minusthereliability,or: ProbabilityofFailure=1et Heresyourassignment: CreateaVBAprogramthatallowstheusertoenter(onaformorinaninputbox)eachparts partname,partnumber,andquantityfortheaccumulatorshowninthisassignment. TheVBAprogramshouldcreateheadingsinColumnsA,B,C,D,andEofRow1inthe spreadsheetthataretitledPartName,PartNumber,Quantity,FailureRatePerEachPart,
TheVBAprogramshouldtransfertheinformation,whencommandedtodoso,showingpart name,partnumber,partquantity,failurerate,andtotalfailurerateforeachpart,placingthe appropriateentryintorowsbelowtheheadingsdefinedabove.Useonerowforeachpart. TheVBAprogramshouldsumtheentriesforallofthepartfailureratestoprovideatotalfailure ratefortheaccumulatorassembly. TheVBAprogramshouldallowtheoperatortoinputanoperating(i.e.,mission)time. TheVBAprogramshouldcalculateanddisplayinthespreadsheet(withappropriatelabels),the accumulatortotalfailurerate,theaccumulatorMTBF,theaccumulatorreliability,andthe accumulatorprobabilityoffailure.Theaccumulatorreliabilityandprobabilityoffailureshould bebasedontheoperatingtimetheuserinputs. CreateaMATLABmfilethatincludesamatrixshowingthepartname,partquantity,partfailure rate,andtotalpartfailurerateforeachpartusedintheaccumulator(youshouldenterthis data,nottheuser).TheMATLABfileshouldsumthefailureratestoprovideatotalfailurerate fortheaccumulator.Assuminganoperatingtimeof2.5hours,theMATLABprogramshould displaytheaccumulatorsreliabilityandtheMTBF.ThiswillserveasacheckonyourVBA programsresults. NameyourVBAprogramyourlastnamefirstinitialP1.xslm.NameyourMATLABprogram yourlastnamefirstinitialP1.m. EmailboththeVBAandMATLABprogramstotheinstructor(jhberk@csupomona.edu)bythe assignedprojectcompletiontime.
Leaks
Historically,ADominantFailureMode... Hi i ll A D i F il M d
Mosthardwaresealedinsomemanner O rings Orings Gaskets Metaltometalseals Epoxiesandsimilarsealants Structure Valves Leakstypicallymanifestedas yp y Pressureloss Fluidloss(oildrops,etc.) Testfailuresw/leakdetectors
Let'sexamineafewcommoncauses....
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ORingsandGaskets
CommonCausesofLeakage... g
Toomuchsqueeze Nonconforminghardware GaskOSeal Designdeficiencies Toolittlesqueeze RubberSeal ubbe Sea Nonconforminghardware f h d Designdeficiencies Interferencewithmatingparts Nicksorcuts Installationerrors p ( j gp g) Sharpsurfaces(adjoiningpartsortooling) Packagingerrors ORing Surfaceimperfections Moldingerrors Rolledortwistedsealingsurface Installationerror Improperapplication Improper application Fluidtosealincompatibilities Nobackupwhenneeded,orbackuppresentwhennot needed Contaminantsonsealingsurfaces Dryrot Backup
MetalSealFrame
Gasket Gasket
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MetaltoMetalSeals
CommonCausesofLeakage Common Causes of Leakage
Metaltometalsealstypicallyusedforconduits orpressurizedlines i d li Nonconformingcomponents Eccentric(angledoroffset)connections Designdeficiencies Design deficiencies Nonconforminginstallationorcomponents Contaminantsonsealingsurfaces Overtorquing Humanerror(assemblyormaintenanceerror) Inadequateassemblyinstructions Undertorquing Humanerror(assemblyormaintenanceerror) Human error (assembly or maintenance error) Inadequateassemblyinstructions
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EpoxiesandSimilarSealants
CommonCausesofLeakage... Common Causes of Leakage...
Impropermixratios Humanerror Inadequateassemblyinstructions I d t bl i t ti Improperenvironmentalapplication Toohot Toocold Shock/vibrationtoohigh Sh k/ ib ti t hi h Improperstorage Toohot Toocold Opencontainer(contaminants,UVexposure,air O t i ( t i t UV i exposure,etc.) Improperapplication Contaminatedsurfaces Toolittleapplied T littl li d Movementpriortocuring Incorrectepoxy/sealantspecified Expiredshelforpotlife Storagelife Storage life Applicationwindow
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Structure
CommonCausesofLeakage Common Causes of Leakage
Porosity Processincapable Process incapable Humanerror Inadequateprocessdefinition IdealTaguchiapplication Cracks Processincapable Inadequatedesign Inadequateprocessdefinition adequate p ocess de t o Humanerror PotentialTaguchiapplication
Impactdamage
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Valves
CommonCausesofLeakage g
Wearout Inadequatepreventivemaintenance Lifeexpectancyexceeded Life expectancy exceeded Closedtootightly Humanerrororovertorquedbymotor Inadequateoperating/maintenance/assemblyinstructions Closedtooloosely Closed too loosely Humanerrororundertorquedbymotor Inadequateoperating/maintenance/assemblyinstructions Missingcomponents Schradervalvecap h d l Contaminants Fluidcontaminated Metalorotherparticlesinducedduringvalvemanufacture Metalorotherparticlescreatedelsewhereinsystem Overpressurized Humanerror Testequipmentanomalies q p Inadequateassemblyortestinstructions
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Compensatingprovisionsinclude
Appropriatematerial Appropriatecoatings Freedomfromcorrosiveenvironment Freedomfromsharpcorners Freedom from sharp corners StresscyclingatappropriatepointonSNcurve
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Compensatingprovisionsinclude p gp
Addressingallabove Toleranceanalysis y
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MechanicalInterferenceOrWear
Fractures
Stressedmemberscanfailasaresultof St essed e be s ca a as a esu t o
Brittlefailures Ductilefailures Stresscorrosioncracking Fatiguefailures
Compensatingprovisionsinclude
Appropriatedesignmargin A Appropriatematerialhardness i t t i lh d Freedomfromcorrosiveagentsorappropriate coatings
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MetallurgicalEvaluations
CommonFailureCauses Common Failure Causes
Mechanicalinterferenceorwear Tensilefailures Indicatedbystretchingand"necking" Commoncauses Common causes Tensileoverload Exceedingelasticlimit Inadequatedesign Incorrectmaterial Brittlefailures Brittle failures Indicatedbysharpfracture Commoncauses Materialtoohard Incorrectheattreat Inadequatedesign I d t d i Incorrectmaterial Fatiguefailures Indicatedby"beach"marks Commoncauses Highstressandcyclicloading Inadequatedesign Incorrectmaterial Stresscorrosioncracking
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ATypicalTensileFailure
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Stressraisers(notches,corners,etc)notrequired
Corrosioncreatesstressraisers
Stresscorrosioncrackingshouldbeconsideredif crackingoccursinnormallyductilematerial
Especiallyifcorrosioninducingconditionspresent
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Manyweldscontaindefectsbutdonotfail Welds fail for same reasons as other metals fail Weldsfailforsamereasonsasothermetalsfail
Stressesexceedstrength Stresscyclinginducesfatiguefailure
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Cohesive C h i
Adhesive Adh i
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Composite/AdhesiveFailures
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ExcessClearance/Interference/Lubrication Failures il
Usuallyinducedby
Poortolerancing/dimensioning Poormaterialselection Inadequatelubrication q
Compensatingprovisionsinclude
Appropriatetolerancing Questions
Whoassignstolerances Howdoyouassigntolerances
Compensatingprovisionsinclude
Adequaterequirementsdefinition duringdesignprocess d d Appropriatedesigns
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Compensatingprovisionsinclude
Appropriate torque specifications Appropriatetorquespecifications Training Appropriatedesigns
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Compensatingprovisionsinclude
Training Processcontrol Appropriatedesigns
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Sometimes
Shortcircuitsduetosolderspatter Opencircuitsduetocontaminationorothersolderdefects d h ld d f Opencircuitsduetodefectivesoldertechniques Inadequate/incorrectwavesolderingprocess Contamination Othersoldertechniqueissues
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TypicalDefectiveSolderJoints
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Electronic&ElectronicFailures
Disconnects Arcing Connectionsplatter Corrosion/aging Mechanicalfailures Mechanical failures
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1 1
See below 0.40000 0.40000 Mechanical or corrosive damage, overtorqued. Mechanical or corrosive damage to sealing surface. Mechanical or corrosive 0.23200 NPRD-95, Pg. 2-118 g
58.00%
D a
20.00%
0.08000
M l
0.50%
0.00200
I l
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Usuallyexpressedasfailurespermillionhours
Examples
6.23x106 1.55x106 Etc.
Mayalsobeexpressedasfailurespermillion miles
AsdoneinNPRD
OftenrepresentedbyGreekletterlambda() p y ( )
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191
Weshouldconsiderfailureeffects
Butassignratesbasedonabove
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Probability
Likelihoodsomethingwilloccur
0<P<1.0 0<P<100%
Reliability
Probability part/subassembly/system performs intended function Probabilitypart/subassembly/systemperformsintendedfunction whencalledupontodoso
0<R<1.0 0<R<100%
Reliability=et Probabilityoffailure=1 et
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MILHDBK217F
Primarysourceforelectronicsfailureratedata Excellentinformationonsomemechanicaldevices Voluminous Free(www.sre.org/pubs/MilHdbk217F.pdf)
NonelectronicPartsReliabilityData 2011
Availableforpurchasefromhttp://theriac.org/ Premiersourcefornonelectronicdata
USNavyMechRelsoftware
Free(http://www.navsea.navy.mil/nswc/carderock/pub/mechrel/products/software.aspx) Modifiesfailureratesforenvironments
Google g Companyspecificfailureratedatabase
Yourorganization Yoursuppliers
Component/subassemblymanufacturers p / y
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TypicalMILHDBK217Data(continued)
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Recommendedapproach
Use your database (if you have one) Useyourdatabase(ifyouhaveone) or Selectsimilarcomponentsfrompublishedsources
Usefailureratesforsimilarcomponents
Makeobjective/reasonable adjustmentsbasedon
Designmargin/loads Loadstandarddeviationversusstrength Application pp Otherfactors
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AWordOn
AndWhereWereGoingWithIt
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Weuseabovetoadjustfailurerateupor down
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Suggestedrange:0.5to102 (50%to1%)
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Specificresearchtoquantifylongtermeffects
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