Sort It Out Critical Load Pulleys and Force Ship the Chip Christopher Lester Yvonne Pelham Moshe Kam D.G. Gorham TISP: Uruguay 9–10 May 2009

TISP: Uruguay 9–10 May 2009

Welcome

Package design and the engineering behind shipping products safely Exercise 1: Ship The Chip

Exercise 1:

Ship The Chip

Ship the Chip Learn about engineering product planning and design Learn about meeting the needs of the customer and society Learn about teamwork and cooperation Objectives

Learn about engineering product planning and design

Learn about meeting the needs of the customer and society

Learn about teamwork and cooperation

Objectives

Ship the Chip Manufacturing Engineering Package design, manufacture and test Material properties and selection Real world application of mathematics Teamwork Students will learn…

Manufacturing Engineering

Package design, manufacture and test

Material properties and selection

Real world application of mathematics

Teamwork

Students will learn…

Ship the Chip Design a package that will securely hold a potato chip and protect it from breaking when dropped Construct the lightest package to get the highest score Overall score based on: Weight of the package Volume of the package Intactness Score The Challenge

Design a package that will securely hold a potato chip and protect it from breaking when dropped

Construct the lightest package to get the highest score

Overall score based on:

Weight of the package

Volume of the package

Intactness Score

The Challenge

Ship the Chip Sketch a design on the worksheet Label your worksheet with Table # and Team Name Construct a model of your package At a test station, drop the package from a height of 1.5 meters Open your package and examine the chip Calculate and record your score Using a second kit, redesign and construct a new package Record the second design on the worksheet Label your package with Table # and Team Name Submit your worksheet and package to the Test Team for overnight testing Procedure

Sketch a design on the worksheet

Label your worksheet with Table # and Team Name

Construct a model of your package

At a test station, drop the package from a height of 1.5 meters

Open your package and examine the chip

Calculate and record your score

Using a second kit, redesign and construct a new package

Record the second design on the worksheet

Label your package with Table # and Team Name

Submit your worksheet and package to the Test Team for overnight testing

Procedure

Ship the Chip Cardboard – 22 cm x 28 cm 10 Craft sticks 6 Cotton Balls String – 91 cm Plastic wrap – 1 sheet of 22 cm x 28 cm 10 Toothpicks Foil – 1 sheet of 22 cm x 28 cm Paper – 1 sheet of 22 cm x 28 cm 1 Mailing label 1 Potato Chip Materials

Cardboard – 22 cm x 28 cm

10 Craft sticks

6 Cotton Balls

String – 91 cm

Plastic wrap – 1 sheet of 22 cm x 28 cm

10 Toothpicks

Foil – 1 sheet of 22 cm x 28 cm

Paper – 1 sheet of 22 cm x 28 cm

1 Mailing label

1 Potato Chip

Materials

Ship the Chip Tools and Accessories

Tools and Accessories

Intactness score : 100: like new, perfect 50 : slightly damaged; cracked but still in one piece 25 : broken in 2 - 5 pieces 5 : broken in 6-20 pieces 1 : broken into more than 20 pieces; crumbled Ship the Chip Scoring

Intactness score :

100: like new, perfect

50 : slightly damaged; cracked but still in one piece

25 : broken in 2 - 5 pieces

5 : broken in 6-20 pieces

1 : broken into more than 20 pieces; crumbled

Scoring

Ship the Chip We will imbed the package in the smallest-volume rectangular prism that contains it We will calculate the volume of the prism; Width x Length x Height For example : 3cm x 4cm x12cm =144 cm 3 in the prism shown below If your package weighed 100g and had a volume of 800 cm 3 and the chip has arrived broken in 3 pieces: Calculating Volume

We will imbed the package in the smallest-volume rectangular prism that contains it

We will calculate the volume of the prism;

Width x Length x Height

For example : 3cm x 4cm x12cm =144 cm 3 in the prism shown below

If your package weighed 100g and had a volume of 800 cm 3 and the chip has arrived broken in 3 pieces:

Calculating Volume

Ship the Chip Sketch a design on the worksheet Label your worksheet with Table # and Team Name Construct a model of your package At a test station, drop the package from a height of 1.5 meters Open your package and examine the chip Calculate and record your score Using a second kit, redesign and construct a new package Record the second design on the worksheet Label your package with Table # and Team Name Submit your worksheet and package to the Test Team for overnight testing Procedure

Sketch a design on the worksheet

Label your worksheet with Table # and Team Name

Construct a model of your package

At a test station, drop the package from a height of 1.5 meters

Open your package and examine the chip

Calculate and record your score

Using a second kit, redesign and construct a new package

Record the second design on the worksheet

Label your package with Table # and Team Name

Submit your worksheet and package to the Test Team for overnight testing

Procedure

The engineering behind industrial sorting processes Exercise 2: Sort It Out!

Exercise 2:

Sort It Out!

Sort It Out Learn about engineering of systems Learn about coin manufacturing processes Learn about teamwork and cooperation Objectives

Learn about engineering of systems

Learn about coin manufacturing processes

Learn about teamwork and cooperation

Objectives

Sort It Out Sorting through History Miners panning for gold Quality control in food and other industries Bottle sorting for recycling

Sorting through History

Miners panning for gold

Quality control in food and other industries

Bottle sorting for recycling

Sort It Out Different Types of Sorting Image Processing: Off-the-shelf cameras, frame grabbers, and image-processing software used to develop a casino-coin sorting system Lighting Digital I/O & Network Connection Frame Grabber Part Sensor Camera & PC platform Inspection software Optics

Different Types of Sorting

Image Processing: Off-the-shelf cameras, frame grabbers, and image-processing software used to develop a casino-coin sorting system

Sort It Out Different Types of Sorting Material Properties of Coin: Current run through left coil, creates magnetic field. Magnetic field passes through and is attenuated by coin Right coil receives magnetic field, creates measurable current with different value depending on the coin Coin in Center Transverse line represents direction of magnetic field

Different Types of Sorting

Material Properties of Coin:

Current run through left coil, creates magnetic field.

Magnetic field passes through and is attenuated by coin

Right coil receives magnetic field, creates measurable current with different value depending on the coin

Mixed coins come from a variety of sources and must be sorted out before they can be redistributed Coins from vending machines Coins from parking meters Also helpful to identify fake or foreign coins Sort It Out Why Coin Sorting is Needed

Mixed coins come from a variety of sources and must be sorted out before they can be redistributed

Coins from vending machines

Coins from parking meters

Also helpful to identify fake or foreign coins

Why Coin Sorting is Needed

Mixed coins are Sorted Rolled Re-circulated through banks and businesses Sort It Out Why Coin Sorting is Needed

Mixed coins are

Sorted

Rolled

Re-circulated through banks and businesses

Why Coin Sorting is Needed

Groups of 2 You are a team of engineers hired by a bank to develop a machine to sort coins that are brought in by customers. Must mechanically sort mixed coins into separate containers. In our experiment we use washers: ½ Inch 1 Inch 1¼ Inch 1½ Inch Sort It Out Your Turn

Groups of 2

You are a team of engineers hired by a bank to develop a machine to sort coins that are brought in by customers.

Must mechanically sort mixed coins into separate containers.

In our experiment we use washers:

½ Inch

1 Inch

1¼ Inch

1½ Inch

Your Turn

Sort It Out How good is it? 1: “Distance” performance index: A washer that does not get sorted has maximum D error = 3 Your Turn 1 Distance from correct bin here, D error = 2 bins 1 1 ½ ½ ½ ½ ½ 1½ 1¼ 1 1 1 1 1¼ 1¼ 1¼ 1¼ 1½ 1½ 1½ ½in 1in 1¼in 1½in

How good is it?

1: “Distance” performance index:

A washer that does not get sorted has maximum D error = 3

Your Turn

Sort It Out How good is it? 2: “Percentage” performance index: Your Turn 1 1 1 ½ ½ ½ ½ ½ 1½ 1¼ 1 1 1 1 1¼ 1¼ 1¼ 1¼ 1½ 1½ 1½ ½in 1in 1¼in 1½in # of washers incorrectly identified Total # of washers to sort 40 5%

How good is it?

2: “Percentage” performance index:

Your Turn

Materials: glue, tape, paper or plastic plates, cardboard, scissors or hole punch, foil, paper, cardboard tubes washers Design (draw) a mechanical sorter that can separate the ½in, 1in, 1¼in, 1½in washers Input: either Parallel – all washers are inserted at start of your sorter together; or Serial – washers are inserted at start of your sorter one at a time Output: Each size of washer in its own physical container Sort It Out Your Turn

Materials:

glue, tape, paper or plastic plates, cardboard, scissors or hole punch, foil, paper, cardboard tubes

washers

Design (draw) a mechanical sorter that can separate the ½in, 1in, 1¼in, 1½in washers

Input: either

Parallel – all washers are inserted at start of your sorter together; or

Serial – washers are inserted at start of your sorter one at a time

Output: Each size of washer in its own physical container

Your Turn

Sort It Out At your table, choose 2 groups to build a parallel sorter; the other 2 groups will build a serial sorter You will have 45 seconds to allow your sorter to operate Predict the value of the two performance indices for your design Construct your sorting mechanism Test it! Can you do better? Your Turn

At your table, choose 2 groups to build a parallel sorter; the other 2 groups will build a serial sorter

You will have 45 seconds to allow your sorter to operate

Predict the value of the two performance indices for your design

Construct your sorting mechanism

Test it!

Can you do better?

Your Turn

Sort It Out Did your sorting mechanism work? If not, why did it fail? What were your performance index values? What levels of error would be acceptable in: Medical Equipment manufacturing? Nail manufacturing? What redesigns were necessary when you went to construct your design? Why? Conclusion

Did your sorting mechanism work? If not, why did it fail?

What were your performance index values?

What levels of error would be acceptable in:

Medical Equipment manufacturing?

Nail manufacturing?

What redesigns were necessary when you went to construct your design? Why?

Conclusion

All about force and how pulleys can help reduce it Exercise 3: Pulleys & Force

Exercise 3:

Pulleys & Force

Pulleys & Force Learn about pulleys and pulley systems Learn how using multiple pulleys can dramatically reduce required force Learn how pulley systems are used in machines and impact everyday life Learn about teamwork and problem solving in groups Objectives

Learn about pulleys and pulley systems

Learn how using multiple pulleys can dramatically reduce required force

Learn how pulley systems are used in machines and impact everyday life

Learn about teamwork and problem solving in groups

Objectives

Fixed Pulley Movable Pulley Pulleys & Force Basics of Pulleys: Two orientations

Fixed Pulley

Movable Pulley

Basics of Pulleys: Two orientations

The tension in the rope, T , is always the same everywhere Fixed pulley allows for change in direction of applied force Sum of the forces: vertically 2 T = 100 N T = 50 N Compound Pulley Pulleys & Force Basics of Pulleys

The tension in the rope, T , is always the same everywhere

Fixed pulley allows for change in direction of applied force

Sum of the forces: vertically

2 T = 100 N T = 50 N

Compound Pulley

Basics of Pulleys

Pulleys & Force Mechanical Advantage Mechanical Advantage (MA) is the factor by which a mechanism multiplies the force or torque put into it. Ideal MA: Actual MA: This movable pulley system has a mechanical advantage of 2

Mechanical Advantage

Mechanical Advantage (MA) is the factor by which a mechanism multiplies the force or torque put into it.

Ideal MA:

Actual MA:

Work is the amount of energy transferred by a force acting through a distance Work = Force x Distance Work = Force x Distance A bigger mechanical advantage decreases the force required, but increases the distance over which it must be applied The total amount of work required to move the load stays the same Pulleys & Force Work

Work is the amount of energy transferred by a force acting through a distance

Work = Force x Distance Work = Force x Distance

A bigger mechanical advantage decreases the force required, but increases the distance over which it must be applied

The total amount of work required to move the load stays the same

Work

The ratio between Actual and Ideal mechanical advantage is Efficiency Frictionless system = 100% Efficiency Pulleys & Force Efficiency

The ratio between Actual and Ideal mechanical advantage is Efficiency

Frictionless system = 100% Efficiency

Efficiency

Pulleys have long been used on sailing ships to handle the rigging and move the sails Even with large mechanical advantages, it still takes many people to do the work! Pulleys & Force Pulleys in the World

Pulleys have long been used on sailing ships to handle the rigging and move the sails

Even with large mechanical advantages, it still takes many people to do the work!

Pulleys in the World

Pulleys are used in elevators to change the direction of the tension in the cable, reduce power required of lift motor Pulleys & Force Pulleys in the World

Pulleys are used in elevators to change the direction of the tension in the cable, reduce power required of lift motor

Pulleys in the World

Industrial cranes lift large loads for construction and transportation Pulleys & Force Pulleys in the World

Industrial cranes lift large loads for construction and transportation

Pulleys in the World

Pulleys & Force Measuring Tension Spring Scale Calibrate: Hold spring scale at eye-level and turn adjustment screw until the internal indicator is precisely aligned with the top zero line Measure: Create a loop in the end of the rope you want to measure tension in; attach spring scale to loop. Hold the spring scale steady and read off the tension measurement.

Measuring Tension

Spring Scale

Calibrate: Hold spring scale at eye-level and turn adjustment screw until the internal indicator is precisely aligned with the top zero line

Measure: Create a loop in the end of the rope you want to measure tension in; attach spring scale to loop. Hold the spring scale steady and read off the tension measurement.

Groups of 2 Develop 2 systems to lift a filled soda bottle 10cm with 1 pulley 2 pulleys Build your systems Measure the distance the soda bottle moves and compare it to the distance you had to pull What is the actual mechanical advantage? Measure the force you must exert on the string and compare it to the force that is finally transmitted to the soda bottle What is the ideal mechanical advantage? Calculate the efficiency of each system Pulleys & Force Your Turn

Groups of 2

Develop 2 systems to lift a filled soda bottle 10cm with

1 pulley

2 pulleys

Build your systems

Measure the distance the soda bottle moves and compare it to the distance you had to pull

What is the actual mechanical advantage?

Measure the force you must exert on the string and compare it to the force that is finally transmitted to the soda bottle

What is the ideal mechanical advantage?

Calculate the efficiency of each system

Your Turn

Now join with one other group at your table Develop 2 different systems to lift a filled soda bottle 10cm with all 4 pulleys Build both systems What are their actual mechanical advantages? Ideal? Which one has a better efficiency? Why do think that is? Pulleys & Force Your Turn

Now join with one other group at your table

Develop 2 different systems to lift a filled soda bottle 10cm with all 4 pulleys

Build both systems

What are their actual mechanical advantages? Ideal?

Which one has a better efficiency? Why do think that is?

Your Turn

Pulleys & Force Which system required the least amount of force to lift the bottle? How did this system rank in its mechanical advantage? Do you think the size of the pulley makes a difference in the ideal mechanical advantage? Actual? How could you further increase the efficiency of your most efficient pulley system design? What other engineering problems were solved with pulleys or pulley systems? Conclusion

Which system required the least amount of force to lift the bottle? How did this system rank in its mechanical advantage?

Do you think the size of the pulley makes a difference in the ideal mechanical advantage? Actual?

How could you further increase the efficiency of your most efficient pulley system design?

What other engineering problems were solved with pulleys or pulley systems?

Conclusion

End of Saturday Exercises

TISP: Uruguay Sunday, 10 May 2009

Sunday, 10 May 2009

Structural engineering and how to reinforce the design of a structure to hold more weight. Exercise 4: Critical Load

Exercise 4:

Critical Load

Critical Load Learn about civil engineering and the testing of building structure Learn about efficiency ratings and critical load Learn about teamwork and the engineering problem solving Objectives

Learn about civil engineering and the testing of building structure

Learn about efficiency ratings and critical load

Learn about teamwork and the engineering problem solving

Objectives

Millau Viaduct Millau, France World’s Tallest Bridge 2460m long 434m pylon height 270m road height December, 2004 Critical Load Great Structures of the World

Millau Viaduct

Millau, France

World’s Tallest Bridge

2460m long 434m pylon height 270m road height

December, 2004

Great Structures of the World

Yokohama Landmark Tower Yokohama, Japan Japan’s Tallest Office Building 296m tall 70 floors including office and hotel July, 1993 Critical Load Great Structures of the World

Yokohama Landmark Tower

Yokohama, Japan

Japan’s Tallest Office Building

296m tall 70 floors including office and hotel

July, 1993

Great Structures of the World

Beijing National Stadium – “Bird’s Nest” World’s Largest Steel Structure 258,000 square meters 5 years to construct 110,000 tons of steel used in construction 3,000,000 cubic meters Opened June, 2008 Critical Load Great Structures of the World

Beijing National Stadium – “Bird’s Nest”

World’s Largest Steel Structure

258,000 square meters

5 years to construct

110,000 tons of steel used in construction

3,000,000 cubic meters

Opened June, 2008

Great Structures of the World

Crystal Cathedral Garden Grove, California, USA World’s Largest Glass Building 12 stories tall 12,000+ panes of glass 16,000-pipe organ Opened 1980 Critical Load Great Structures of the World

Crystal Cathedral

Garden Grove, California, USA

World’s Largest Glass Building

12 stories tall 12,000+ panes of glass

16,000-pipe organ

Opened 1980

Great Structures of the World

Skyscraper of Cards 2007 World Record House of Cards Over 7.5 meters tall No glue or tape; just cards Built by Bryan Berg in 2007 Critical Load Great Card Structures of the World

Skyscraper of Cards

2007 World Record House of Cards

Over 7.5 meters tall

No glue or tape; just cards

Built by Bryan Berg in 2007

Great Card Structures of the World

Bryan Berg at Work A “cardstacker” from Santa Fe, NM, USA

Force is placed on a structure Structure can support up to a certain force created by the weight At a certain point, the structure will fail, breaking The maximum force the structure can sustain before failure is known as the “Critical Load” Critical Load What is Critical Load? Force Force

Force is placed on a structure

Structure can support up to a certain force created by the weight

At a certain point, the structure will fail, breaking

The maximum force the structure can sustain before failure is known as the “Critical Load”

What is Critical Load?

Critical Load A high critical load is not the only parameter to consider Is the best bridge made by filling a canyon with concrete? It certainly would have a high critical load! Consider also the weight of the structure Lighter is better, given the same critical load These two parameters are combined in an “Efficiency Rating”: Efficiency

A high critical load is not the only parameter to consider

Is the best bridge made by filling a canyon with concrete? It certainly would have a high critical load!

Consider also the weight of the structure

Lighter is better, given the same critical load

These two parameters are combined in an “Efficiency Rating”:

Efficiency

Groups of 2 Up to 12 cards + 1m tape Devise a plan to build a load bearing structure Should have a flat top Support load with base area of 10 x 10cm at least 8 cm above the table No altering of cards allowed – just tape! No wrap-ups of tape Tape is used to connect cards only Critical Load Your Turn

Groups of 2

Up to 12 cards + 1m tape

Devise a plan to build a load bearing structure

Should have a flat top

Support load with base area of 10 x 10cm at least 8 cm above the table

No altering of cards allowed – just tape!

No wrap-ups of tape

Tape is used to connect cards only

Your Turn

Example: Supports load Load is at least 8cm above table Cards failed after load of 2.4kg Structure made with 4 cards Efficiency rating: 2.4 kg / 4 cards = 0.6 kg/card Critical Load Your Turn 8.5 cm height

Example:

Supports load

Load is at least 8cm above table

Cards failed after load of 2.4kg

Structure made with 4 cards

Efficiency rating: 2.4 kg / 4 cards = 0.6 kg/card

Your Turn

Critical Load Your efficiency rating: [Load at Failure] / [# of cards used] Predict what the rating of your design will be Build your design Test it! Discuss improvements, then repeat exercise for a second design Your Turn

Your efficiency rating: [Load at Failure] / [# of cards used]

Predict what the rating of your design will be

Build your design

Test it!

Discuss improvements, then repeat exercise for a second design

Your Turn

Critical Load What was your efficiency rating? How close were you to your prediction? How was your design different from the best design? How would you change your design? Why? What other factors would you need to take into consideration if your Card House were a real office building? Conclusion

What was your efficiency rating? How close were you to your prediction?

How was your design different from the best design?

How would you change your design? Why?

What other factors would you need to take into consideration if your Card House were a real office building?

Conclusion

End of Sunday Exercises