Senior Design An Overview Dr. Kamal Sarkar University of Texas – Rio Grande Valley May 11, 2015 Dr. Kamal Sarkar University of Texas – Rio Grande Valley

Senior DesignAn Overview

Senior DesignAn Overview

Dr. Kamal SarkarUniversity of Texas – Rio Grande

Valley

May 11, 2015

Dr. Kamal SarkarUniversity of Texas – Rio Grande

Valley

May 11, 2015 Copy Right of Dr. Kamal Sarkar May 2015

Copy Right of Dr. Kamal Sarkar May 2015

11

What is Design?What is Design?

“A” Definition of Engineering Design

A systematic approach of identifying

an optimum solution for a complex engineering problem with real-life constraints using established scientific and engineering principles.

“A” Definition of Engineering Design

A systematic approach of identifying

an optimum solution for a complex engineering problem with real-life constraints using established scientific and engineering principles.



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What is Senior Design?

What is Senior Design?

Last opportunity to prepare our students for real-life scenarios using their own strengths

Preparing our students to be “Engineering Professionals” in a multi-cultural world

Make the students “more employable” OR “more prepared” for Grad

School or Technopreneurship

Last opportunity to prepare our students for real-life scenarios using their own strengths

Preparing our students to be “Engineering Professionals” in a multi-cultural world

Make the students “more employable” OR “more prepared” for Grad

School or Technopreneurship



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Senior Design: THE Bridge Between The Profession & EducatorsSenior Design: THE Bridge

Between The Profession & Educators

Senior Design

IndustryGrad SchoolTechnopreneurship

STEMCore Engg. Courses

Advanced Engg. Courses



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Structure of the Senior Design Course

Structure of the Senior Design Course



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Five Phases of DesignFive Phases of Design

Phase One: Problem Formulation Phase Two: Concept Development Phase Three: Design Embodiment Phase Four: Design Validation Phase Five: DHF (Design History

File)

Phase One: Problem Formulation Phase Two: Concept Development Phase Three: Design Embodiment Phase Four: Design Validation Phase Five: DHF (Design History

File)



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Five Phases of DesignPhase One: Problem

Formulation

Five Phases of DesignPhase One: Problem

Formulation “Elevator Speech” “The Challenge”

Competitive Product Solution Strategy (Identify & Organize

Disciplines)

Impact Background Research Quality Function Deployment (QFD)

“Elevator Speech” “The Challenge”

Competitive Product Solution Strategy (Identify & Organize

Disciplines)

Impact Background Research Quality Function Deployment (QFD)



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Five Phases of DesignPhase Two: Concept

Development

Five Phases of DesignPhase Two: Concept

Development

Concept Selection Functional Decomposition Develop alternatives

Develop Design Criteria (from Objectives and Constraints)

Identify Concept Variants

Final Selection (Decision Matrices) Screening Method of Pairs Over-riding Factors

Concept Selection Functional Decomposition Develop alternatives

Develop Design Criteria (from Objectives and Constraints)

Identify Concept Variants

Final Selection (Decision Matrices) Screening Method of Pairs Over-riding Factors



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Five Phases of DesignPhase Three: Design

Embodiment

Five Phases of DesignPhase Three: Design

Embodiment Design Calculations Design for Manufacturability Design/Process Failure Modes and

Effects Analysis (D-FMEA or P-FMEA)

Bill of Materials Economic Analysis Develop Plans for Tests & Data

Collection Create Manufacturing Process Document

Design Calculations Design for Manufacturability Design/Process Failure Modes and

Effects Analysis (D-FMEA or P-FMEA)

Bill of Materials Economic Analysis Develop Plans for Tests & Data

Collection Create Manufacturing Process Document



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Five Phases of DesignPhase Four: Design

Validation

Five Phases of DesignPhase Four: Design

Validation Design Validation * System Level Validation (“Sanity Check”)

* Test Protocols Data Collection & Analysis * Modify Design and/or Test Methods As

Needed * Validate Design w/Additional Experimental

Data

Design Documents * User’s Manual

* Operations Manual * Maintenance Manual

Design Validation * System Level Validation (“Sanity Check”)

* Test Protocols Data Collection & Analysis * Modify Design and/or Test Methods As

Needed * Validate Design w/Additional Experimental

Data

Design Documents * User’s Manual

* Operations Manual * Maintenance Manual



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Five Phases of DesignPhase Five: DHF

Five Phases of DesignPhase Five: DHF

Documentation

* Formalize the Design via Design History File

Lab Note Book

Reports

Presentations

Background Data/Info

Test Protocols & Data

Raw Data

Design Details (All Revs of Design Info)

Videos & Pictures

Flash Drive !!!

Documentation

* Formalize the Design via Design History File

Lab Note Book

Reports

Presentations

Background Data/Info

Test Protocols & Data

Raw Data

Design Details (All Revs of Design Info)

Videos & Pictures

Flash Drive !!!Copy Right of Dr. Kamal

Sarkar May 2015Copy Right of Dr. Kamal

Sarkar May 2015

1111

Key ConceptsKey Concepts “Elevator Speech” QFD Functional Decomposition Design Criteria & Concept Variants Concept Selection by Pairing Method DFM (Design for Manufacturing) D-FMEA & P-FMEA Project Management Economic Analysis

“Elevator Speech” QFD Functional Decomposition Design Criteria & Concept Variants Concept Selection by Pairing Method DFM (Design for Manufacturing) D-FMEA & P-FMEA Project Management Economic Analysis



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Key TrainingsKey Trainings

Safety Training including Nanomaterials

Machine Shop Safety Intellectual Property Rights & Issues Literature Search including Patents iShop Trainings Working in Team Environment

Safety Training including Nanomaterials

Machine Shop Safety Intellectual Property Rights & Issues Literature Search including Patents iShop Trainings Working in Team Environment



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Project Formats & ExamplesProject Formats & Examples


14

Types of Senior Design Projects

Types of Senior Design Projects

• National Competitions Mini Baja, NASA, HPV, etc.

• Faculty Sponsored Background Research for Funding Opportunity

Prototype Development for Teaching Tools Exploratory work for IP’s

• Industry Sponsored Small Local Business

National Corporates

• National Competitions Mini Baja, NASA, HPV, etc.

• Faculty Sponsored Background Research for Funding Opportunity

Prototype Development for Teaching Tools Exploratory work for IP’s

• Industry Sponsored Small Local Business

National Corporates



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Typical Senior Design Projects

Typical Senior Design Projects

Design & Development Homeostatic Environmental Chamber Biomechanical Harvester for Health Monitoring Systems

Design of a Knee Replacement Implant

Design of a Light Flexible Bulletproof Vest using Smart Materials

Developing Next Generation DrywallsA Personal Polycopter with Built-in Battery Charger & Stability

Pulsed Jet Propulsion: A High Thrust Propulsion System for Aerospace Vehicles

Building & Demonstrating of A Half HP Low Temp Stirling Engine

Design & Implementation of a Module for Automated Work Measurement System

Pink Zebra Production Research: Feasibility for Automation Development of a Drying Oven for Polymeric Fibers to Achieve High Quality

Multifunctional Carbon FibersExploring Applications of Evaporative Cooling for Air Conditioners

Applications of Controlled Pore Recycled Glass Structures for Liquid Waste Management

Thermal Applications of Porous Glass Structures by Controlling Crystalline and Amorphous Phases

Development of Safe Transportation Techniques for Combustible and/or Hazardous Materials using Controlled Pore Glass Structures

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Some Mentionable Outcomes (Last Five Years)

Won NASA Micro-gravity CompetitionWon NASA Micro-gravity Competition Helped funding ($400K) from Air ForceHelped funding ($400K) from Air Force Built Wire Winding Machine for Local Built Wire Winding Machine for Local

EntrepreneurEntrepreneur Developed Patent(s) on Glass NanoparticlesDeveloped Patent(s) on Glass Nanoparticles Built several lab equipment for teachingBuilt several lab equipment for teaching Working on multiple patentable technologies Working on multiple patentable technologies


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Examples of Recent Projects


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INSTRUMENTED PULSE JET ENGINE680 C, PRESSURE 22 PSIA TO 12 PSIA & PULSING @260 HZ

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NASA Lunabotics Mining Competition (May 2012)NASA Lunabotics Mining Competition (May 2012)



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