ES1050 – Introductory Engineering Design and Innovation Studio Practical Prototyping Prof. K. McIsaac.

ES1050 – Introductory Engineering Design and Innovation Studio

Practical Prototyping

Prof. K. McIsaac

Prototyping in the MDP

Part of the MDP is a development of the prototype.

This will play two roles:

•Prototypes are presented in the design showcase

•Prototypes are modeled and tested using

experiments you design

http://en.wikipedia.org/wiki/Prototype

Prototype Goals

When we introduced prototypes, we discussed the

following uses:

•Answer simple questions (will it work?)

•Obtain feedback from customers

•Aid in visualization

•Realistic models for marketing and advertising

•Study the look and feel of the product

•Functional testing and evaluation

Proof-of-concept Prototypes

Demonstrate feasibility Simple construction Often only a part or

subsystem Usually not fully

functional! Not sufficient for design

validation!

http://me118.stanford.edu/pictures/Win01Projects/TooShort/images/2nd%20prototype.JPG

Experimental Prototype Intended for

physical experiments and testing

Often only a subsystem

Prototype of shock-absorbing casterTest results

Prototype Goals

Focus on proof-of-concept and experimental prototypes It is not necessary to create something that does all of

what your project is about The goal is to create something you can test and model

that illustrates a key part of the project Make sure your prototype fits within your skill set

An illustrative example

Last year’s theme was “improve student life”. One of

my studio teams wanted to make the automated

breakfast maker:

1.Could be set on a timer

2.Would start making toast at a set time

3.A robot arm would remove the toast and move it to a

conveyor

4.A syringe would extrude jam onto the toast

5.A spreader would spread the jam evenly

Some problems

1. AC power is dangerous (banned) and difficult to

work with

2. Robot arms are expensive and complex

3. Conveyor belts are expensive and hard to build

yourself

4. How to make a powered jam syringe?

5. The team had limited software skills. How to

program and synchronize all these operations?

Some solutions!

1. Just plug in the toaster to a power bar, then use

the power bar’s ON switch instead of a timer

2. Tip the toaster on a ramp so the toast just falls out

3. Instead of a conveyor belt, buy an old record

player at the surplus store

4. The “jam syringe” was a metal can with a plunger

and a hole cut in the bottom

5. Synchronize by hand

Modeling and experimentation

What to test and model in all this?

• Torque and power requirements to lift the toaster?

• Torque and power requirements to smear the jam?

• Others?

Prototype Construction in ES1050

Inexpensive Easy No special

tools Quick

http://www.ben.com/LEGO/rcx/picoscout/breadboard.jpg

Common Prototyping Materials in ES1050 Wood Plastic

Plexiglass Cardboard and

paper Metal

http://www.riscx.com/pyramac/proto_pics/proto_3_600.jpg

Prototyping Tools in ES1050

Simple hand tools Scissors Screwdrivers Wrenches

Simple joining methods Glue Duct tape Screws

Construction kits you may want to use in ES1050 Lego Meccano Others

http://www.sentex.net/~mwandel/legos/legos.html

Lego Many mechanical

and electrical parts

Inexpensive and easy

No tools required

http://www.hamster.dk/~purple/robot/iBOT/lego_robot_prototype.jpg

http://www.cs.rhul.ac.uk/eca/micromouse/lego/shakey/images/parts.jpg

Meccano Uses metal parts Simple tools

www.meccano.com

http://webperso.easyconnect.fr/esteve.jeanmax/j.e.o/fotopi%E8ces/MarklinPiecP.jpg

UMS Machine Shop Support

Scrap, off-cut materials One hour of machining/consulting time

(consult with TA A. Ho to set this up) Rapid Prototyping (Fused Deposition

Modeling only) Be careful of what you spend!

Workshop Facility

There is student design space in CMLP (only qualified people can use the machine tools)

We are working to have it ready It would include hand tools and benches

only All of these resources are limited so don’t

wait too long!

Select the correct statement MDP prototyping

A Looks are the most important factor

B Using advanced materials is necessary

C UMS can do whatever you need

D It must be subject to modeling and testing

E It must implement all components of the proposed design