156B Week 5

Overview of Status of Analysis, Design, Fabrication, Tests, etc.

• Status of Analysis: 

  • Exploring all the FEA tests that can performed on Fusion 360, SolidWorks, Ansys that may help us get closer to structural strength

    • Point - impact tests

      • Cutting tests

    • Planning out usability tests one 3D printed model is shipped to us

  • Status of Design:

    • We have a working prototype for the outer shell of our box.

    • Currently generating ideas for the looping mechanism and assessing design trade-offs

    • Reverse engineered locking mechanism from MasterLock reference lock to assemble it into our prototype

  • Status of Fabrication:

    • We have set up a meeting with Chris Cassidy for getting our working prototype 3D printed

    • Our sponsors have contacted a manufacturer in Tijuana to fabricate the prototype for us. We will be having a meeting with them sometime within the next week or two.

Accomplishments from Previous Week

• • Closed on the outer design of the working prototype. Re-assessed timeline and increased internal meeting frequency to at least one meeting a day.

  • Conducted meeting with Tom Chalfant and Steve Mersack for insights on developing looping mechanism

  • Conduced meeting with Chris Cassidy to get 3D printed parts

Goals for Next Week (list names after each item). Use specific and measurable objectives.

• • Friday meeting with Chris Cassidy: Get our design 3D printed and shipped out to Bryan. - All team

  • Implement the MasterLock locking assembly in our 3D printed design and ship it to the sponsor. - Bryan

  • Receive sponsor feedback and make immediate changes to our shell design. - All team

  • Finalize locking and looping mechanisms. - All team + sponsor

  • Talk to Prof. Delson and other knowledgeable folks to figure out different simulation tests that would be useful and applicable. - Hrish

Sponsor Comments from Last Meeting and Actions Taken to Address these Comments (indicate date of comments and if via email or in person)

• • 28 April: Sponsor seems generally satisfied with the outer shell of the lockbox. Sponsor realized that the 156B team is running out of time and needs to move faster. As a consequence, internal meeting frequency was increased to reduce iteration time.

    • Sponsor is awaiting a satisfying solution to the looping and locking mechanism. Sponsor communicated some ideas for looping mechanism which were later determined to be difficult to implement in a meeting with Tom Chalfant and Steve Mersack.

    • Meanwhile, sponsor clarified the details of the Tijuana manufacturing firm, suggesting that the turnaround time would be approximately a week after receiving the final design.

  • Next sponsor meeting set for Sunday, 3 May 2020

Instructor Comments from Last Meeting and Actions Taken to Address these Comments  (indicate date of comments and if via email or in person)

• • Two of the teammates could not attend the instructor meeting so it was pushed to Monday, 4 May 2020.

Comments from Other Students in the Class (indicate date of comments and if via email or in person)

• • General tone of comments presented from presentation were as follow:

    • "Good presentation and graphics"

    • "Needs more analysis for outer shell and design"

    • "Team has made progress but needs to make more progress"

Risks and Areas of Concern

• • Locking mechanism has highly precise parts that may not be able to be machined or mass-produced 

  • Current looping mechanisms being developed after conversation with Tom and Steve have usability trade-offs that the sponsor may not approve of

  • (same as last week) Exposure of spaces near the hinge are could make the lock more prone to be broken into and hence we need tighter tolerances.

  • (same as last week) Making the handle adjustable might be not feasible and could have a limited life cycle.

Resources or Information Required but not Available

• • How to make SolidWorks, Fusion 360 etc. simulation choices?

Schedule

• • Describe upcoming milestone:

    • Looping mechanism figured out and approved by sponsor

  • Update Gantt chart.

Budget (list amount spent and amount remaining)

• • Allocated: $2000

  • Spent: $100

  • Left: $1900 

Progress on Report and Webpage

• • Webpage updated with design

  • Report writing commenced. First draft of report due this weekend.