MECE 3420 2019

Senior Design Manual: Fall Semester

Professor Josh Browne
Table of Contents

Assignment # 1 - Forming a Team

Assignment # 2 - Work Contract

Assignment # 3 - Project Proposals

Assignment # 4 - Literature Review & Presentation

Assignment # 5 - Design Review I (Faculty Review)

Appendix A - Forms for Assignments

Appendix B - Rubrics
 Assignment # 1 – Forming a Team

Your first task will be to select a project team. The project teams should consist of 4 members
but can have as few as 3 and as many as 5. Ideally, your team will have, a CAD modeler, a
machinist, a programmer, and an electronics person. Alternatively, four people excited about a
topic will learn whatever skills they need to be successful!

Once your team has been formed, fill out Worksheet 1 in Appendix A.

Considerations in Forming Successful Design Teams

1. The structure is up to you, but all team members are expected to contribute
equally overall

The organizational structure of each design team is the responsibility of the members of
each team. One of the first tasks of the team is to establish roles and responsibilities for
each of its members. In general, there is no specific team structure and delegation of
tasks that works in all situations and each team is encouraged to select the structure
that works best for them. It is the responsibility of the team to ensure an equitable
distribution of work within the team.

2. Be open to working in subject matters you may not currently be proficient in.

Expect to work across disciplines to ensure the success of your design. Successful
product development requires that all team members are aware of the difficulties and
efforts of every other member of the team.

3. Pick people you can work with frequently for TWO SEMESTERS. Maintaining a
good team dynamic should always be a priority.

Be sure to hang out with your team, and always know what everyone else is currently
working on. Once a team is established, it is very, very difficult ​to change a team. It is
possible to fire an individual from a team (see below), but ​this should be an extremely
rare occurrence in this class. The TA and I will work with you to try to make your team
structure work and avoid this situation, if at all possible.

4. Never make an aspect of the project the sole responsibility of one team member

Though you may have a team member who is the most qualified to work on a particular
aspect of your project, be prepared to pick up the slack when this person has conflicts.

5. You are REQUIRED to be on a team

This is not an option. It is a requirement to work as a team on this project.

Firing a Team Member

To fire a team member, you will have to document his/her deficiency as any business would
have to do. You must first meet with me and the TA to discuss the nature of the problem. If
the problem cannot be resolved, you must give the team member written warnings, with
copies to the instructor. After two such warnings, a team member may be fired.

If you are dismissed from a team, you have three choices.

1. You may withdraw from Senior Design and complete your capstone design project
requirement next year. ​If you are fired in the second (Spring) semester, you will
have​ ​to repeat the first (Fall) semester next year.

2. You may complete an entire course project this year by yourself.

3. You may be hired by another team.

Because of the workload involved, it is highly unlikely that you will be able to complete the
courses alone. Your chance of success is very slim. It is also difficult to get hired by another
team (just as it is often difficult to get a new job after being fired). A new team will want to
know what skills and motivations you bring to the job. They may ask for recommendations
from your past team. Pick people you work well with and a project that inspires you the first
time around!

Since Senior Design in Mechanical Engineering at Columbia is a unique course, the

department ​will not accept​ ​a course at another school as equivalent.
 Assignment #2: Work Contract

Your next task after forming a team is to create a work contract. Your work contract should
have four main parts:

1. Definition of primary and secondary roles depending on the needs of your project.
Typical roles include:

● CAD modeler
● Machinist
● Programmer
● Electronics person

2. Agreement on how much time team members are willing to contribute ​outside of
class time.

● Be honest. Do not sign up for more work than you are willing to do.
● Set up a weekly meeting to discuss cumulative progress.

3. Plan for how the team will catch up if they fall behind schedule

4. Decide what to do if someone is not pulling their weight.

Once your work contract is complete, every team member should sign it. In conflicts serious
enough to warrant TA or professor intervention, it will be consulted.
 Assignment # 3 – Project Proposals
Topic Proposals

Overview:
The proposal form is a simple one-page document from each team that provides the ideas or
concepts for the required proof-of-concept prototype and its subsystems. Three proposals are
required, so you will fill out three forms and rank the ideas. This form, called Worksheet 2, can
be found in Appendix A.

The Importance of Picking a Good Idea:

This is a team assignment and all team members should like the project. Ideas should be
collected and discussed by everyone before generating the 3 proposals. Your team’s concept
selection is probably the single most important decision your team will make. Selecting a poor
concept will surely lead to failure, even if your team invests infinite resources.

Tips for Generating Novel Ideas:

Throw your net wide and try to bring in as large a catch of ideas/concepts as possible. There is
no such thing as a stupid idea, but there is definitely such a thing as a missed good idea. You
will discuss your concept selection strategy eventually in your final report. You can pick
something that has been done before if you think you can do it better. Try asking your friends
and family who aren’t engineers for ideas. Sometimes they will have great ideas for problems
that you can try to solve. When you have an idea, have a look at similar products on the market.
If something exists, don’t be discouraged; try to come up with a useful improvement. Can you
add a new feature? Make it cheaper to produce? Increase efficiency?

Project Constraints​:
In order to be approved by the Instructor and TA’s a project must:

● Be something related to MECHANICAL ENGINEERING DESIGN.

● Have significant engineering content.
● Be of the proper scope for the time available (i.e., neither too big, nor too small).
● Result in a working prototype.
● Consider and demonstrate issues related to product safety and durability.
● Have fewer than 10 unique parts requiring time from the lab staff to fabricate.
● Ideally, fit inside a 3 square foot box. Projects involving larger structures may be
approved as is or require scaling.
● Not include gasoline power, except if the gasoline engines are set up in appropriate lab
space with ventilation.
● Be capable of being demonstrated at the Design Expo.
● Be novel. Making a significant improvement on an existing product is also acceptable.
The Types of Projects

You have to select the type of project that you will attempt. The selection affects how your work
is graded by the Design Expo Committee. For example, for a Design Project Type, the “Quality
of the Prototype” is weighted more heavily than the “Engineering Approach”. For an Analytical
Project Type, the reverse is true. The team has to decide which type of project it will attempt so
grading can be determined.

Types of projects fall into 3 broad areas.

1. Analytical: ​Address an Engineering Problem

Analytical type projects address a particular engineering problem in one of the

mechanical engineering disciplines. The project will be judged based on the level of
difficulty of the task relative to the level of success. Analytical type projects should
require some engineering analysis, modeling, and simulation. The task is essentially a
demonstration that the analysis is correct and the model is valid. While the prototype
should certainly have a finished look, more emphasis is placed on performance and the
difficulty of the task over appearance. The final report should include all the analyses
performed and the modeling simulation results.

2. Design:​ Create a Product

Design type projects address a particular product. The product should serve a
perceived need for a real or assumed customer. The prototype is essentially a
demonstration of the operation of the product. The prototype should look finished and
be very near the final version of the product for introduction into the marketplace. The
operation of the prototype should be at a level for demonstration to a venture capital
firm for funding.

3. Experimental: ​Design Experimental Apparatus

Experimental type projects address a particular engineering experiment. It should be a

novel way to make a particular measurement or an experimental procedure capable of
being added to an undergraduate lab course. The prototype should be rugged and
easily repaired. The experiment should be interesting and teach some aspects of
mechanical engineering. The sensitivity of the measurement equipment has to be
analyzed. If the experiment is to be performed using LabVIEW or MATLAB, the software
interface has to be well documented and easily understood. In addition, a preliminary
experiment manual must be written and included in the final report. For experimental
type projects, durability and scientific appeal should be the primary emphasis.
 Assignment # 4 - Literature Review & Presentation
Overview:
You must perform a literature search on your concept to determine if anyone has done
something similar. ​This task is ​extremely important as it can show you what has and hasn't
worked in the past. You are looking for references associated ​with the mechanical design of
your prototype. Do not refer to references that relate to your topic but say nothing about the
mechanical design. You can read these for your own edification but they should not be included
in your report or presentation. Feel free to consult with the librarian in the Engineering Library
for additional resources.

Essential Literature Search Components:

1. Internet Keyword Search

Peruse google for articles, videos, and similar commercial products

2. Technical Journal Review

Pull journal articles from, ​Engineering Village, Web of Science, ​or another
literature search engine available from the library

3. Patent Search
Investigate patents related to the overall or key component design of your
project. The ​Derwent Innovations Index is a patent search engine available from
the library. Google Patents is also very useful.

Written Report Structure:

● Part 1: Summary
Condense your idea for a project topic and what similar ideas were found in the
literature search.

● Part 2: Overview of the Internet, Journal, and Patent Searches

Review what was turned up for each of the 3 searches. Include (but do not dwell
on) dead ends. Describe any ideas that you will use in your project.

● Part 3: Compilation of Most Useful Resources

Mention the sources that you found to be the most useful.

Presentation:

In addition to the report, your team will prepare a presentation on your search where you will
describe what you feel are the most important references. Create a slide for each one of the
essential literature search components. The order of these slides may be decided by you, but
it is recommended to begin with your internet keyword search to provide a general basis for
your search and then elaborate with your technical journal articles and patents. Additionally,
include one slide at the end including your resources.
 Assignment # 5 - Design Review I
(Faculty Review)
Overview:
At Design Review I, you will present your design to the Mechanical Engineering department
faculty. You cannot proceed with your topic until you receive faculty approval. Your instructors
and TAs will ensure that you are adequately prepared for the review. Your presentation should
be around 20 minutes long. Faculty will ask questions at the end.

The Eight Essential Presentation Elements:

1. Detailed Project Description

We are more interested in what you are trying to do than why you are doing it. Briefly
explain project motivation, but focus on the engineering design. However, be prepared
to answer questions for more details of why you want to attempt this project if asked.

2. Literature Search Summary

Include a presentation of the results of the literature search task (internet, patent,
articles). Try to describe the results with pictures rather than text. Also, describe the
concept selection method (exactly how and why you settled on this particular prototype
when there may be multiple ways to achieve the same objective).

3. 3D CAD Model of your Prototype

Generate at least, a CAD layout of the base system. O ​ ther drawings may include
how you intend to test the prototype (what the test setup will look like). Animate
prototypes involving motion. Drawings must be dimensioned and your 3D model
must indicate size and scale.
Presenters should stress the overall design with a conceptual drawing CAD layout
rather than focus on the design of specific parts (unless the particular part is a key
element to the design). Fabrication and joining methods should also be generally
described.

4. The Engineering Analysis

Describe the quantitative justification ​for the decisions made during the design
process but do not go into extensive detail at this design review (save it for Design
Review II). Demonstrate the design team’s ability to develop analytical models, the
appropriateness of these models, and the ability to provide quantitative reasons for
design decisions. You should then give high-level results.
The results of the analysis must be obtained based on engineering principles and
modeling. These considerations should also include manufacturing consideration,
cost analysis (especially for purchased parts), material (component) selection, and
the incorporation of engineering drawings.
 The engineering analysis need not be complete for this review (for example, it may
need details from the detailed design) but it should have enough aspects to show that
success is feasible. Describe what information needs to be added to the analysis to
make it more accurate and when you expect to get this information.

5. Gantt Chart
Outline a group schedule for the work for the remainder of the fall semester and the
spring semester. Include the review dates on your Gantt chart, but this is not enough
to describe your work. Detail key issues that you intend to address and schedule key
milestones for the remainder of the project. Consider that difficult projects will require
you to finish elements prior to the average.

6. Levels of Success
Break up your project into at least 4 levels of success. Think about how to divide up
your realistic and stretch goals to make them achievable. The minimum level of
success will form the basis of the definition of “working” for the In-House
Demonstration. It is generally poor to propose a project that either works or does not
and very risky for your grade.

7. Acknowledge Potential Risks

Discuss risk management, and how you intend to design the parts of your prototype
to mitigate risks.

8. Codes and Standards

Provide an overview on engineering, materials, safety etc. standards that need to be
considered to make your product safe to use and produce.

Notes on Grading and Feedback:

Your grade for Design Review I from the faculty will depend on the completeness and
technical competence of your design. A sample grading rubric is shown in Appendix B. The
faculty will decide officially whether or not you can proceed with your work. Projects can be
rejected for either being too simple (meaning not worth 4 undergraduate credits for 4 or 5
people) or too hard (meaning that we do not believe that you can finish by May).
Every team is encouraged to discuss their project with instructors, TAs and faculty prior
to the Design Review I presentation to get feedback.​ ​The Review should be an opportunity for
you to​ ​describe your work during the semester to the faculty and other students.
Appendix A: Forms for Assignments
 Worksheet 1: Team Roster Form

Enter the name of each member of your team and a team name (don’t worry, you can change
your team name later).

Team Name: ___________________________

Name UNI

1.

2.

3.

4.

5.
 Worksheet 2: Individual Topic Proposal Form
Submit 3 per team outlining 3 separate project ideas

Team Name:​ ________________________ Proposal Rank: ​_____ out

of 3

Team Members:
______________________________________________________________________

____________________________________________________________________________
________

Briefly describe your proposed project:

Type of project (circle one):

Analytical Design Experimental

Levels of success for the Design Expo:

Level 1 (the minimum that we expect to have working): __________________________

________________________________________________________________________

Level 2: ________________________________________________________________
________________________________________________________________________

Level 3 ________________________________________________________________
________________________________________________________________________

Level 4 (the most that we would expect to have working): ________________________

________________________________________________________________________

What do you see as the major risks with the work?

Appendix B: Grading Rubrics
 Rubric 1: Literature Search Grading
Grading performed by TA’s and Course Instructor

Design Team Name: ​_______________________________________​_ Team #:​___________

Score:​ __________________ ( 100 points max )

Literature Search Report Required Elements (2 pages maximum)................................ ___/50

● Internet search completed? Anything found? …....................................................... ___/5

● Journal Search (20 pts total)

○ Were appropriate journals searched? ......................................................... ___/10
○ Did the search seem complete? ………………...……………………………. ___/10

● Patent Search (20 pts total)

○ Were appropriate patent categories searched?.......................................... ___/10
○ Did the search seem complete?................................................................. ___/10

● Report Formatting (5 pts total)

○ Were complete sentences used? Is the report readable? ………………... ___/1
○ Did the team justify which journals and patents were searched?.............. ___/2
○ Do the references listed seem reasonable? ……………………………….. ___/2

Literature Search Presentation - located documents…………………………………….. ___/50

● Journal Search
○ Did the team find a reasonable journal article or book? ………………….. ___/10

● Patent Search
○ Did the team find at least 3 reasonable patents?...................................... ___/10

● Are all provided documents directly relevant?....................................................... ___/10

○ Points deducted for articles and patents not related to the mechanical design of the
proposed topic

● Time Usage (10 pts total)

○ Did all members of the team speak?...........................................................___/5
○ Presentation under 15 minutes ……………………………………………….. ___/5

● Presentation quality………………………………………………………………………. ___/10

○ Was the information on the slides legible and presented in a logical order?
 Rubric 2: Design Review I Grading
Grading performed by TA’s and Course Instructor

Design Team Name:​ ________________________________________ Team #​ ___________

Score:​ __________________ ( 25 points max )

Required Presentation Elements……………………………………………………………… ___/3

● Project Summary…………………………………………………………………………. ___/ ½
○ A very brief description of what is in the project and an explicit statement of
specifications and constraints for the project
● CAD Layout of the Concept……………………………………………………………… ___/ ½
● Analyses to Be Performed………………………………………………………………. ___/ ½
● Levels of Success…………………………………………………………………………. ___/ ½
● Risks Associated with the Project ……………………………………………………… /½
● Schedule for completion (Gantt Chart).................................................................... ___/ ½

Presentation Content: …………………………………………………………………………….. ___/22

● Discussion of Motivation………………………………………………………………….... ___/1
○ Limited discussion​ of why it is being done, limited to 1 slide.
○ Max of 10 pts will be subtracted if too much time is spent.

● Levels of success …………………………………………………………………………… ___/1

○ Outline 4 reasonable levels of success that build on each other.
○ The minimum level of success should be achievable.

● Project Description (2 pts) ………………………………………………………………….... ___/2

○ The discussed design problem is clear, the project goal is outlined
○ Multiple ideas for the proposed prototype, system, and, where applicable, control strategy
were discussed

● 3D CAD Layout or Sketch (7 pts total)

○ Multiple views of concept design and subsystems are depicted….............. ___/5
○ CAD layout animated includes at least 1 relevant animation……................ ___/2

● Drawing Quality (5pts)

○ Drawings are neat and clear ……................................................................ ___/2
○ Drawings appropriately indicate scale…………........................................... ___/2
○ Drawings adequately describe the idea and are labeled effectively………….. ___/1

● Analyses to Be Performed …………………………………………………………………. ___/2

○ Proposed analyses address potential issues with the project
 ○ Team has a plan to complete the analyses and learn relevant software if applicable
○ Acknowledgment of additional analysis that might become necessary as the project
progresses.

● Awareness of Risks…………………………………………………………………………. ___/2

○ Key issues with the fabrication and operation of the proposed design and how they will be
handled are discussed.
○ What do you see as the major difficulties in designing the prototype?
■ Tight tolerances, special materials, Need for precise control critical alignments,
Special tooling, etc
● Schedule…………………………………………………………………………………….. ___/2
○ The schedule is reasonable and major steps are represented
○ Course milestones such as design reviews are indicated