1. Laboratory Development
1.1 Actualize innovative IDEAWorks layout in remodeled GJ
115.
1.2 Add two new dual processor machines to existing lab
equipment.
1.3 Organize and sustain software licensing with help of ME
department.
The Gauss Johnson design suite is a hallmark of the UI
capstone program and magnet for recruiting engineering students
and engaging industry visitors. This is facilitated by 5000 ft2
layout that includes a CNC equipped machine shop, project
assembly area, CAD laboratory, conference/study area, and
graduate student offices. We take pride in our shop and strive
to maintain high levels of organization and cleanliness. The
shop is on display for all to see through windows at the end of
the building entryway. We seek to establish an equally
attractive area across the hall from the shop that is dedicated
to engineering analysis and design visualization.
2. Knowledge Management
2.1 Conduct next generation ME 504 class to recruit and
further train over a dozen graduate students and four
faculty members on IDEAWorks tools.
2.2 Define best practices for data exchange between
programs.
2.3 Create SnagIt videos, tutorials, and web posters JIT
learning.
With inexpensive video, screen capture, and home editing
equipment, engineering students can efficiently and effectively
integrate technical principles with practical demonstrations of
skills in a library of short SnagIt clips, videos, and web
posters. Our experience with the
Mindworks laboratory that focuses on machine design and
local manufacturing capabilities is that new or revised JIT
learning objects can be produced in less than four hours. Our
development process insures technical quality and
learner-centeredness through peer review of story boards by
peers, faculty, and staff.
Beliefs about adult learning put forward by the Greenfield
Coalition will guide our development of JIT learning resources.
These beliefs include:
- Learning is a shared responsibility between learner and
teacher.
- Faculty should play a key role in guiding the learning
process.
- Whenever possible, real-world linkages should be used to
enhance learning.
- Learners must take time to prepare for learning
activities.
- Learning is social, requiring group processing of new
ideas.
In order to realize these beliefs, three different audiences
will be engaged in resource creation and maintenance—graduate
students authors, new software users, and faculty/staff
consultants. The value of the resource is enhanced by
customizing it for our local computing, manufacturing, and
testing context and having a local community of practitioners
vested in its ongoing development.
3. Implementation in Transportation
3.1 Hybrid Transmission Design (Hybrid FSAE) Selection of
Materials Selection of Mechanical Components Selection of
Electrical Components Selection of Controls 3.2 Drawing
Package Realization for Large-Scale Projects Templates &
File structures Dimensioning & Tolerancing conventions
Standard call-outs for ME shop fabrication Animation of
Mating Parts
3.3 Optimal Structural Design (Hybrid FSAE) ESOP Shear
Element Capability ESOP User Interface Validation with
Genesis
3.4 Optimal Fluid Design (Hybrid FSAE and CSC) Intake Design
Exhaust Design Sound Abatement
Hybrid Transmission Design
Hybrid technology is one of the newest and fastest growing
segments of the automotive industry. Hybrid technology allows
for lower fuel consumption and lower emissions compared to
conventional drive systems. The FSAE Hybrid competition is based
around the idea of a hybrid powered formula style race car. The
University of Idaho is an ideal research institution due its
background in hybrid vehicle development as well as its
involvement in FSAE competition. An area for high leverage
research is right-size transmission development that could yield
power train configurations that are much lighter and more
efficient than series hybrids. Current parallel technology
involves ultra thin electric motors, planetary gear systems,
high efficiency, lightweight batteries, and the possible use of
ultra capacitors. Research, evaluation, and synthesis of these
technologies will lead to the selection of right-sized
electrical controls. Genesis and Working Model will be used to
size mechanical components in the drive system.
Drawing Package Realization for Large-Scale Projects
Recurring issues in capstone design projects revolve around
misunderstanding of manufacturing processes as well as
frustration over the learning curve associated with SolidWorks.
This leads to prolonged detail design as well as parts that are
extremely difficult to manufacture and assemble. A set of
mentor-directed and self-directed resources for using SolidWorks
with a design for manufacturing mindset will be created in this
work. Special attention will be given to drawing standards and
drawing package maintenance. Artifacts produced locally in the
ME shop will be the focus of case studies that combine
engineering graphics, machine design, and manufacturing
principles. Work products will include drawing templates, a set
of UI standards for dimensioning drawings and using call-outs
for manufacturing in the ME shop. Special attention will be
given to animating assemblies, rendering parts, and interfacing
between SolidWorks and MasterCam (CNC coding). This work should
also enable a next generation engineering drawing course at the
sophomore level that is better aligned with the demanding needs
of large-scale vehicle projects in capstone design.
Optimal Structure Design
This work will continue development of the evolutionary
structures program (ESOP) created by Brian Auer. Shear element
capability will be added to existing capability for truss
members. Both features are necessary for maximum torsional
rigidity and minimum weight in state-of-the-art frame design.
Program input from a worksheet environment rather than command
line format will also be explored as a more user-friendly
interface. A set of simple test cases will be defined and
program output will be verified against solutions by Genesis.
Previous FSAE frame designs will be studied and guidelines for
efficient frame configurations will be formulated for use in
future vehicle design projects.
Optimal Fluid Design
The engine modeling package, Ricardo WAVE, together with the
thermofluid modeling package, FlowWorks/Fluent, have great
potential for advancing engine system design at the University
of Idaho. Using these tools, one is able to more easily design
an integrated intake/engine/exhaust system. Nearly half of the
modeling effort comes from empirical data and measurements. This
requires that we have facilities such as a flow bench available
in the small engine lab. A parallel modeling effort with a Penn
State graduate student is underway in which we are seeking to
develop as high a torque as possible across a broad speed band
for a motorcycle engine while meeting stringent sound
limitations. Ricardo WAVE and FlowWorks/Fluent will also be used
to assist the Clean Snowmobile team in its development of a
turbocharged direct injection two stroke engine.
UTC funds dedicated to this project are
$57,545.80.
Jason Sagen, MS graduate, ½: RA Optimal Hybrid Transmission
Design
Phil Arpke, MS graduate, ½ RA: Drawing Package Realization,
Prototype Visualization, and Design for Manufacturing
Charles Dean, MS graduate, ½ RA: Optimal Intake/Exhaust
Design
Chris Huck, MS graduate, ½ RA: Optimal Structural
Design for Lightweight Vehicles
