product readiness review...technical analysis (ogp): the selected design for the ez tabber was...

Product Readiness Review

MAE 491/492 - 01: Fall 2010

Course Instructor: Dr Christina Carmen

Team # 2 - Optical Guitar Pickup: 11/11/2010

Team Members: Jared Nelson, Ben Fowler, Chris Kirchner, Samuel Hobbs, and Stephanie Buckner.

Team Lead: Jared Nelson

Customer: Mr. Tim Blackwell, UAH Center for Applied Optics

Overview Purpose of the PRR Slide 3 Mission Statement Slide 4 Product Design Specifications Slide 5-6 Detailed Drawings Slide 7-10 Technical Analysis Slide 11-23 Verification Testing Slide 24-28 Cost Analysis Slide 29-30 Manufacturing Slide 31 Assembly/Installation Slide 32-37 Problems and Solutions Slide 38 Lessons Learned Slide 39 Customer Response Slide 40 Summary Slide 41 Acknowledgements Slide 42 Product Demonstration Slide 43-45

Purpose of the PRR Review the results of verification process

• Product testing

• Technical analysis

Provide final cost analysis and information

Demonstrate product

• Verify product meets Product Design Specifications

• Verify customer satisfaction

3Team 2 - Product Readiness Review

Mission Statement Team 2 is designing an Optical Guitar Pickup. The team’s goal is

to design and fabricate a product that will be able to temporarily or permanently attach to both acoustic and electric guitars.

Once attached, the EZ Tabber will be able to write out the musical notes in the form of tablature.

The EZ Tabber will work by using small light diodes and motion sensors to determine the individual frequency of each string. The frequency values will be measured and recorded in real time as the musician is playing them. The string vibration will be seen by the motion sensors and be converted into a frequency input that will be sent to a computer.

The computer will determine the frets that are being played for the given frequency input, based on the tuning of the guitar. The computer will write out the tabs for each note that is being played.

The invention and production of the EZ Tabber could revolutionize and improve the way musicians play their guitars.


Product Design Specifications

Team 2 - Product Readiness Review 5

Product Design Specifications


Design DrawingsEZ Tabber with mounting plate

1/27/2011 7Team 2 - Interim Design Review

Design DrawingsEZ Tabber: Base Plate

1/27/2011 8Team 2 - Interim Design Review1/27/2011 8Team 2 - Interim Design Review

Design DrawingsEZ Tabber: Acoustic Mounting Plate


Design DrawingsEZ Tabber: Diode/Sensor Housing


Technical Analysis (OGP): The selected design for the EZ Tabber was imported into Patran via a step file

and meshed using TET 10 solid elements.

Rather than a loads model, which will produce stress and strain data, Team 2 ran a Eigen Vector solution to determine the normal modes of the system.

By knowing the modes of the system, the frequency bands that may cause problems with vibrations can be predetermined.

This normal modes analysis will allow Team 2 to predict the deformation shapes that the system is most likely to be subjected to at various frequency ranges.

Patran and Nastran were used to solve for the first 30 modes of the selected design because the first 30 modes encompass the frequency range that our product will be subjected to.

In this analysis, ABS-M30 plastic was used as the OGP material.

Material Properties were taken from ABS-M30 spec sheet. Properties are seen below:

• Modulus of Elasticity: E = 350000 psi.

• Poisson’s Ratio: V = 0.33.

• Density: p = 0.036 lb / in^3.


Technical Analysis (OGP):Meshed Geometry: TET 10 Plate

Elements:GEL = 0.1 in

RBE2 Elements:

RBE 2 Elements:

Top View:

Right Side View:


CBAR Elements: RBE2 Elements:

Technical Analysis (OGP):

The first normal mode of the system was at 11.603 Hz.

A deformation plot from Patran is given to the right.

Normal Mode 1: 11.603 Hz


Technical Analysis (OGP):Normal Mode 1: 11.603 Hz



The second normal mode of the system was at 25.006 Hz.





The third normal mode of the system was at 27.867 Hz.




Technical Analysis (OGP)

Summary From this analysis, Team 2 determined that

the effects of vibration at the normal modes of the system are negligible.

It was determined that the loads and vibrations that the EZ Tabber will be subjected to during normal use will not cause any fatigue or plastic deformation concerns.

It can be concluded with low risk that the structural integrity of the EZ Tabber will be acceptable over the lifecycle of the product.


Technical Analysis (Guitar): The pressure load from the clamping mechanism of the EZ Tabber is

applied to the face of a standard Acoustic Guitar.

The stress in the Face of the guitar faces will be measured and discussed.

The guitar face will be modeled with a paver mesh of CQUAD 4 Plate elements.

The pressure load will be modeled with a uniform pressure of 5 psi over the contact area of the clamping mechanism.

A 15in. by 15in. guitar face size is chosen to ensure that the Fixed SPC’s on the edge of the guitar face will not interfere with the analysis of the clamping mechanism.

In this analysis, Sugar Maple was used as the guitar material.

(material properties from Matweb:(http://www.matweb.com) seen below.

• Modulus of Elasticity: E = 18e5 psi.

• Poisson’s Ratio: V = 0.349.

• Density: p = 0.0315 lb / in^3.

• Shear Strength = 1.38 ksi

• Compressive Yield Strength = 3.12 ksi


Technical Analysis (Guitar):Guitar FEM Thickness Plot:


Technical Analysis (Guitar):Guitar FEM Stress Contour Plot:


Technical Analysis Summary (Guitar):

The stress values from both surfaces of the plate elements were averaged in this analysis.

The pressure load from the clamping mechanism of the EZ Tabber produced a max principal stress of 377 psi.

The compressive yield strength of the material is 3.12 ksi.

M.S. =[(3120 psi / 377 psi) - 1 ] = +7.28.

Selected design approved by means of analysis.23Team 2 - Product Readiness Review

Verification Testing

Testing was conducted on October 28 and November 9

Product assembly and testing lasted a total of approximately 6 hours plus 2 additional hours donated by the customer.

Verification tests are considered successful, as the team was able to demonstrate that the EZ Tabber is mechanically able to record frequency readings from each string.




Frequency Reading

Harmonics



Frequency Reading

Final Cost AnalysisEZ Tabber Cost Analysis

Cost Description Retail Cost Actual Cost

Machining $207.00 $0.00

Assembly (2 hrs, $15/hr) $30.00 $0.00

LED Lights $14.50 $0.00

Motion Detectors $22.74 $0.00

Product Testing $20.00 $0.00

Test Guitar $200.00 $0.00

Engineering Consultant $1,000.00 $0.00

Engineering Labor $1,000.00 $0.00

Total $2,494.24 $0.00


Cost Analysis Support

LED lights:

• http://www.plasmaled.com/5mm8mmled.htm

Motion Detectors:

• http://www. silonex.com

Rapid Prototype Machining:

• www.redeyeondemand.com

Engineering Consultant:

• $100/hr, approximately 10 hours.

Engineering Labor:

• $25/hr, approximately 40 hours


http://www.plasmaled.com/5mm8mmled.htm

http://www.seeedstudio.com/depot/tiny-pir-motion-sensor-module-p-277.html

http://www.silonex.com/datasheets/specs/images/pdf/101987.pdf

http://www.silonex.com/datasheets/specs/images/pdf/101987.pdf

Manufacturing Methods

Product is made using rapid prototype machine

Diodes are bonded in place

Electronics are bonded in place

UAH machine shop is fabricating the product with the assistance of Steve Collins

Assembly completed in CAO laboratory


Assembly/Installation Product assembly was a group effort

Team spent approximately 3 hours to assemble the product

During assembly, Sam Hobbs and Chris Kirchner aided Ben Fowler in part assembly.o Diode-Detector assembly

o Diode-Detector housing placement

o Foam core placement

Jared Nelson, with help from Sam Hobbs and Chris Kirchner, completed all wire soldering.o Soldering positive and negative wires to the light diodes and motion

detectors

Sam Hobbs was in charge of pictorially documenting this work


Assembly/Installation




GO VOLS!!!!

Problems and Solutions

Too many wires exiting the EZ Tabber

• Consolidate to 1 wire exiting the wire housing

Soldered wires not withstanding the stress

• Apply liquid soldering flux which makes soldering quicker and stronger

Incorrect piece manufactured

• Steve Collins agreed to rebuild the piece at no cost to Team 2


Lessons Learned

Build, build, build

• It is very helpful to build as many prototypes as possible, getting as many potential ideas as possible

Measurement Precision

• If more care had been taken with the original measurements, Team 2 may have avoided the necessity of building a 2nd prototype

Motion detectors are very sensitive to ambient light

• Future plans involve infrared lighting

• LED lighting was necessary for prototype, giving the designers the ability to see the direction of the lights


Customer Response During verification testing, Mr. Blackwell

informed Team 2 that he was pleased with and excited about the product designed and manufactured by the team

Mr. Blackwell believes we have designed a very good product which fulfills the agreed upon technical and mechanical requirements


Summary Customer is satisfied and informed the team

that it fulfilled the agreed upon requirements

The team stayed within Mr. Blackwell’s budget, due to part and manufacturing donations

EZ Tabber has experimentally been successful in measuring the frequency of each string


Acknowledgements

Team 2 would like to thank Mr. Tim Blackwell for his knowledge and assistance in product assembly and verification testing

Team 2 would like to thank Mr. Steve Collins and the MAE machine shop for their help in producing both EZ Tabber prototypes

The team would like to thank Dr. Carmen for her assistance in this presentation and past documents that have played a vital role in the success of this project


Product

Demonstration


Low E String


D String


product readiness review...technical analysis (ogp): the selected design for the ez tabber was...

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