Presentation on theme: "If you can remember seven passwords to get into your computer to do your job but forget your second wedding anniversary, you could be an engineer. Mei-Chuan."— Presentation transcript:
If you can remember seven passwords to get into your computer to do your job but forget your second wedding anniversary, you could be an engineer. Mei-Chuan S Haverkamp
Jim Haverkamp Senior (Ancient) Mechanical Engineer
Disclaimer In this presentation I am going to mention some of the things that has molded me into the engineer that I am. My mold is only one of many and just because you dont exactly fit in my mold does not mean that you cannot become an outstanding engineer. Saying the word engineer is like saying vehicle, the next question is usually What kind?
History From a young age I have always been intensely interested in how things worked. I would get excited when thing broke This would extend to my toys This became such an obsession that I would actually weigh the difference between having the toy and finding out how it worked Finding out how it worked usually won I got to be good with the disassembly process
My mother labeled me the worlds most destructive kid in the world!
Why Mechanical? Found in the basement as an old TV that was not working. I plugged it in and confirmed that it, in fact, was not working properly. Before I did anything I unplugged to. Cant be too careful, right? I took the back off and was immediately in heaven! I discovered capacitance! Cleaned up
United States Navy When in the Navy I was eventually assigned to R division. R is for Repair. Take thing apart Put them back together The are supposed to work When on a ship at sea one cannot run to the local Osh store. Have to make out own tools and I became very interested in tool design and why. Leaving the navy I found work in the sheet metal industries.
Digressing just a bit Part of the reason I left the navy is that I objected to being forced to wear a uniform like everybody else I went from this …..
To this ….. I think I lost that round
The following are sanitized slides from and actual project that I ran Phase 1 is to produce a conceptual design The first step is to clarify the objective What is causing the need? Some function that does not meet a requirement. What is the scope of the problem? When is a solution needed? What is the budget? The second step is to create a specification that I will design to. Finally I will come up with some conceptual designs and demonstrate how they fulfill the specifications
Product / Project Name / Date of Review / Name of Presenter XXXXXXXX Window Pry tool, 3/7/13, Jim Haverkamp Objective of this Design Review Obtain permission to purchase newly designed pry tool XXXXXXXXX and test fixture Identify EPL Item Driving This Activity PR XXXXXXXX Problem statement The XXXXXXX tool has two windows that stick together due to adhesion from the two O-rings. A tool is needed to pull the windows apart. Previous tool does not fit well and requires the removal of several parts Earlier tool failed after 4 uses
Project Objective Specifications Pry the top window from the bottom window During the removal the gas distribution plenum with remain attached to the top window Material from the tool will not contaminate or damage either window Will not require the removal of the Plastic alignment brackets that are attached to the pinnacle Cost - Targeting $1260 Time / Schedule Design complete 2/28/13 Receive parts 3/11/13 Release 3/15/13 Success Criteria Confirmation that will provide 2X the force or the XXXXX before failure on the upper window Confirmation that it will perform equally as well as the XXXXX1 on the lower window Scope 10 customers currently own a this tool including our lab. Potential need for the tool is between 20 and 30. This tool is not legacy, there is a potential for more customers Summary of Design Change Tool foot designed to fit into gap between the two windows Material changed from polycarbonate to 40% glass filled polycarbonate SS Helicoil changed to Nitronic 60 gall resistant Helicoil An Aluminum plug insert is designed to provide support for the polycarbonate Frame members were thickened to aid in managing the load
This is the part that I designed
The part in position
Addition specifications that I found during the design process
Finite Element Analysis was used to confirm that the part could match the forces
Example of a risk table
Phase 2 involves buying parts and breaking them!
Take notes and document lessons learned During the breaking phase there is nearly always a surprise or two that requires redesign. Question your results! In this case the Finite Element Analysis was bit applicable Review and update risks
Phase 3 get it ready for a customer Lock down the design Create a Bill of Materials (BOM) Create instruction on how to use it or install it What to do with the old parts MONITOR CUSTOMER FEEDBACK!!!!! Be proactive! When the customer returns with positive feedback ….
After positive feedback Go Kayakingand have a beer In that order!