Forward Design Example

Dr. Tarek A. Tutunji Philadelphia University, Jordan

Engineering Skills, Philadelphia University

Dr. Tarek A. Tutunji

1. Define the Problem

The objective is to build a system 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
Types of cranes Tower Truck Mounted Overhead

Travelling bridge Gantry Jib Monorail

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

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
Electrical components Motors Electronics Controller Sensor
Mechanical components Shafts Gears
Engineering Skills, Philadelphia University Dr. Tarek A. Tutunji

3. Propose Solutions
Type of crane Tower Overhead Type of actuators Electric: DC, AC, or Stepper Pneumatic Type of sensors Optical Limit Switches Type of controller PC Microcontroller Analog

Engineering Skills, Philadelphia University

Dr. Tarek A. Tutunji

4. Study the Solutions

Overhead crane works

better than Tower for our purpose

Microcontroller Cheaper than PC More accurate than analog

DC Motor Cheaper than AC and easier to control Easier than pneumatic Sensors Limit switch for linear end position 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

Controller Power Electronics Interface

Limit Switch Sensors

Crane Plant

Electrical Motors

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/s = 49.05 N T = F R T = 49.05 N 0.025 m = 1.23 N.m Pm = T 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

Design: Schematic Diagram

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 Equipment used: Scopes and multi-meters Different loads (up to 5 Kg) were used Speed of movement was measured using stopwatch
Engineering Skills, Philadelphia University

damaged during testing. Limit switches were calibrated. The load cable was repackaged Added support to the skeleton frame Insulated the controller using the opto-coupler.
Dr. Tarek A. Tutunji

Final Prototype

Engineering Skills, Philadelphia University

Dr. Tarek A. Tutunji

Acknowledgement
This 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

Conclusion
A design example was provided to show the 7design steps
In this design project, students used the 7-step design process to build an overhead crane model

Engineering Skills, Philadelphia University

Dr. Tarek A. Tutunji