1 Module I: Problem Solving

Problem Solving: Applying Prior Knowledge and Skills

Elissa Ledoux; Nicholas Matta; and Matthew Sheppard

ABET Student Outcomes

ENGR Student Outcome 1: an ability to identify, formulate, and solve complex engineering problems by applying principles of engineering, science, and mathematics

ET Student Outcome 1: an ability to apply knowledge, techniques, skills and modern tools of mathematics, science, engineering, and technology to solve broadly-defined engineering problems appropriate to the discipline

Problem Solving is the most important skill for an engineer.  This module includes theory and design practices focusing on the basics of mechanical and electrical systems.  Much of the material is review and highlights from discipline-specific courses that students can reference.  Students should review all material relevant to their portion of the project, to start the project off on the right track and avoid delays caused by designing or building something in a less-than-ideal manner.

 

I.0) Capstone Project Course Overview

As a student in an engineering capstone course, you will work in teams to design, prototype, and program machines.  This is the most important course of your academic journey, where you prove that you are ready to be an engineer by applying prior knowledge plus independent research to solve open-ended problems as part of a team.  In addition to producing a functioning prototype, deliverables include a complete technical documentation package and oral presentation to a panel of judges.  Success will require coordinating with your teammates, your sponsor, your instructor, and participating in person.  This is a very time-intensive course, and you should plan to spend an additional 10-15 hours each week outside of class so your team will have a functioning prototype and quality documentation by the end.

Sample downloadable introductory slides for instructors are provided below in editable formats:
ETSU Capstone Introduction & Syllabus
Overview of ENGR 4950 4960

I.1) Construction Refresher

A construction engineer plays a pivotal role in the planning, designing, and executing construction projects, ensuring that structures are built safely, efficiently, and within specified budgets. They collaborate with architects, project managers, and other professionals to translate design plans into tangible constructions, overseeing the entire building process. Construction engineers are responsible for selecting materials, coordinating schedules, and implementing construction methodologies. Their expertise covers a wide range of engineering disciplines, encompassing structural, geotechnical, and environmental considerations. Additionally, construction engineers must adhere to building codes, safety regulations, and sustainability practices, contributing to infrastructure projects’ successful and sustainable development.

Information

  • Construction estimating involves predicting the total cost of a construction project by accounting for all potential expenses, including both direct costs like labor and materials, and indirect costs such as permits and overhead. Accurate estimates are essential to ensure projects remain within budget and are completed profitably. This process includes reviewing bid documents, conducting site visits, and meticulously accounting for every known cost.
  • Access the information on Construction Estimating by clicking the hyperlink below
  • Surveying involves making precise measurements of the Earth’s surface to determine the relative positions and distances between points. It is crucial for construction, land development, and mapping, providing accurate spatial data for engineering and infrastructure planning. This practice uses specialized instruments and techniques to gather, process, and interpret measurement data.
  • Access the information on Surveying by clicking the hyperlink below
  • The pdfs below contains in-depth information on calculating measurements.
    • Topographic maps use contour lines to represent the Earth’s surface, showing elevation and terrain shape. Contour lines connect points of equal elevation, with close lines indicating steep slopes and spread-out lines indicating gentle slopes. These maps are crucial for construction, land development, and outdoor activities.
    • Differential leveling measures the vertical distance between points to determine their relative elevations. Using a level instrument and a leveling rod, surveyors take readings from a known elevation point to the point of interest. The difference between these readings provides the elevation of the new point.
    • A compass rule traverse computation worksheet is an essential tool in surveying used to adjust the coordinates of a traverse to account for measurement errors. The compass rule, also known as the Bowditch rule, is based on the principle that errors in a traverse are proportional to the lengths of the traverse legs. This method helps ensure the accuracy and reliability of the survey data.
        • Traverse Data: This section includes the measured angles and distances between each pair of traverse points. These measurements are the raw data collected during the field survey.
        • Initial Coordinates: The starting coordinates of the traverse points, often based on a known reference point or benchmark. These coordinates serve as the baseline for the computations.
        • Error Calculation: This step involves determining the total error in the traverse by comparing the measured coordinates with the known or calculated coordinates. The total error is the discrepancy between the starting and ending points of the traverse.
        • Error Distribution: The compass rule distributes the total error proportionally to the length of each traverse leg. This means that longer legs will receive a larger portion of the error correction. The formula used is:
        • Adjusted Coordinates: After distributing the errors, the worksheet provides the corrected coordinates for each traverse point. These adjusted coordinates are more accurate and account for the measurement errors identified.

I.2) Manufacturing Refresher

A manufacturing engineer focuses on creating, refining, and optimizing manufacturing processes and systems to achieve efficient and cost-effective production. Collaborating with other engineering fields like mechanical, electrical, and industrial engineering, they work to enhance production methods, boost product quality, and lower costs. Their duties encompass analyzing workflows, integrating automation, choosing suitable equipment, and ensuring that manufacturing processes comply with safety and quality standards. By emphasizing process improvement and innovation, manufacturing engineers are essential in boosting productivity and maintaining a competitive edge across various industries.

Access the PowerPoint Refresher material covering the rules for using machine workspaces below:

These rules are general guidelines to provide a safe working environment.

I.3) Electronics Refresher

An electronics engineer focuses on designing, developing, testing, and maintaining electronic systems, circuits, and components. They leverage principles from electrical engineering to create technologies that manipulate electrical signals for various applications. Working in diverse fields such as telecommunications, consumer electronics, and control systems, electronics engineers drive technological advancements by designing and optimizing devices like microprocessors, sensors, and integrated circuits. Their responsibilities include system design, circuit design, prototyping, testing, and ensuring quality and reliability. By emphasizing innovation and efficiency, electronics engineers play a crucial role in shaping modern technology and enhancing everyday life.

Information

  • AC (Alternating Current) circuits feature currents that periodically reverse direction, usually following a sinusoidal pattern. They are widely utilized in residential and industrial power systems because they efficiently transmit energy over long distances.

Clicking on the following PowerPoint refresher links below provides in-depth material covering AC circuits:

  • DC (Direct Current) circuits feature currents that move in one steady direction. They are frequently employed in battery-operated devices and electronics because they provide a reliable and constant voltage.

Clicking on the following PowerPoint refresher links below provides in-depth material covering DC circuits:

  • Digital circuits handle and transform digital signals, which correspond to binary values (0 and 1). These circuits are essential to modern electronics, facilitating tasks such as arithmetic calculations, logic operations, and data storage.

Clicking on the following PowerPoint refresher links below provides in-depth material covering Digital circuits:

  • Semiconductors possess electrical conductivity that falls between that of conductors and insulators, making them crucial for modern electronics. They are integral to devices like computers and smartphones, where they regulate electrical flow and enable functions such as amplification, switching, and energy conversion.

Clicking on the following PowerPoint refresher links below provides in-depth material covering Semiconductors:

I.4) System Salvation

Best practices for electronics and control for a reliable system that doesn’t burn up. 

Video: Sensor Redundancy

Video: Feedback Controls

Video: Microcontroller Protection

I.5) Actuator Specification

Information

An actuator is the prime mover for a mechanical system.  The most common actuators are motors (electromechanical), and cylinders (pneumatic or hydraulic), although other types of actuators such as solenoids and pumps are also possible.  How many actuators and what types are needed for a system depends on the application, available power sources, size and weight constraints, budget, and types of motion required.  Motion can be linear or angular, continuous or discrete, and transmissions can be used to convert from one to the other.  It is easiest to use as few actuators as necessary to reduce complexity, cost, and weight, although one actuator per degree of freedom is required.  For similar reasons, it is also advisable to stick to one energy domain (either mechanical or fluid power).  In senior design projects, pneumatics are preferred over hydraulics due to their lighter-duty applications and lower mess.

Actuators are selected based on effort and flow.

  • motor: effort = torque, flow = angular velocity
  • cylinder: effort = force, flow = linear velocity or displacement

These specs will be listed on manufacturers’ websites in the product information pages.  To determine the required effort and displacement for the actuator, calculations are required.  These calculations should take into account the mass or inertia of the system, the resistance caused by friction and damping, and the effects of system position.  The following materials explain how to calculate required motor torque and speed for an application.

Motor Specification Handout: written version

Activity

For your project, determine how many actuators you need for your system, and what kinds they should be (motors, cylinders, solenoids, pumps, etc.).   Using the worksheet below, calculate the required effort and flow for each actuator.  You will need to use the information from the above video and handout, as well as your knowledge of dynamics, and for more advanced systems, you may need to search online for additional information.

Actuator Specification Worksheet

I.6) Sensors

Information

Sensors are used to provide feedback on a system’s internal or environmental conditions.  They increase consistency and quality of data, and save time for humans by helping to close the loop in system operation.  The following videos provide an introduction to sensors, types, pros and cons, and redundancy.

Sensor Intro explains sensor purposes and categories.

Sensor Types describes various types of sensors and their applications.

Sensor Pro and Con discusses the pros and cons of using sensors.

Sensor Redundancy details the practice and benefits of using multiple sensors to measure the same signal.

Activity

Use the worksheet below to help identify what types of sensors and how many of each your project needs.  Choose the sensors based on what functions your system does, how it interacts with its environment, and what data must be shown to the user.

Sensor Identification Worksheet

I.7) Controls

Controlling your system can be done in different ways.  Open loop control uses no sensors, while closed control loop does.  Bang-bang control is simplest, and PID control is smoothest, but there are other options, too.  This video playlist explains different types of control and how the choice of sensors and mathematical parameters affect your system.

Videos: in Controls Playlist

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Engineering Capstone: A Guide to Senior Design for Engineering and Technology Copyright © by Elissa Ledoux, Moin Uddin, Nicholas Matta, Matthew Sheppard is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License, except where otherwise noted.

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