Forward Design Example

Rev II

DR. TAREK A. TUTUNJI

REVERSE ENGINEERING
PHILADELPHIA UNIVERSITY,
JORDAN
2015
 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.

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Example: Pen

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Pen Design

 What is the need?

 What are the specifications?

 What options are available?

 Design a pen in class with your group!

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Example: AC-DC Converter

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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!

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Case Study: Crane Design

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 2. Gather Information

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 2. Gather Information

 Main Components
 Bridge

 Rail

 Trolley

 Beam

 Hook

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 2. Gather Information

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 2. Gather Information

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 2. Gather Information

 Electrical components
 Motors
 Electronics
 Controller
 Sensor

 Mechanical
components
 Shafts
 Gears

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 3. Propose Solutions

 Type of crane  Type of sensors

 Tower  Optical
 Overhead  Limit Switches

 Type of actuators  Type of controller

 Electric: DC, AC, or  PC
Stepper  Microcontroller
 Pneumatic  Analog

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 4. Study the Solutions

 Overhead crane works  DC Motor

better than Tower for our  Cheaper than AC and
purpose easier to control
 Easier than pneumatic
 Microcontroller  Sensors
 Cheaper than PC  Limit switch for linear end
position
 More accurate than analog
 Optical encoder for motor
position

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 5. Analyze & Design: Block Diagram

Power
Controller Electronics
Interface

Limit Switch
Crane Plant Electrical Motors
Sensors

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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.

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Analysis and Design: Simulation

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Design: Mechanical Drawings

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Design: Flow Chart

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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.

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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.

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 6. Implement: PCB

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Implementation: Mechanical

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 7. Evaluate

 The crane was tested in  Microcontroller was

the labs damaged during testing.
 Equipment used: Scopes  Limit switches were
and multi-meters calibrated.
 Different loads (up to 5  The load cable was re-
Kg) were used packaged
 Speed of movement was  Added support to the
measured using skeleton frame
stopwatch  Insulated the controller
using the opto-coupler.

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Final Prototype

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 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

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Aircraft Elevator Design

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Aircraft Elevator Design

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

 Conclusion

 Design examples were provided to show the 7-

design steps

 The examples included

 Pen
 Electrical Converter
 Overhead Crane
 Aircraft Elevator

Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji